数据驱动的磨削过程多尺度目标在线监测及其系统开发

doi:10.12382/bgxb.2022.0187

摘要/Abstract

摘要：

磨削作为国防军工、航空航天、汽车等高附加值行业的关键工艺,实现磨削过程智能采集及监测对提升产品质量水平、确保安全生产具有重要意义。针对现有磨削过程数据采集监测方案目标单一、集成性不够、难以全面获取完整的磨削过程信息等难题,建立磨削过程多尺度目标集成监测体系框架,构建包含质量、效率、状态及绿色的多尺度目标关联监测模型,实现从监测变量到监测目标的表征。提出多传感器采集融合与磨削结果监测特征映射方法,开发磨削过程智能采集监测系统。应用该系统对某高速电主轴轴承磨削过程进行实时数据采集与监测,实测结果表明开发的监测系统可以有效实现零件磨削过程磨削时间、磨削能耗、磨削状态和表面粗糙度的准确预测。

关键词: 多尺度目标, 监测体系框架, 数据驱动, 智能磨削监测系统

Abstract:

Grinding is a key process in high value-added industries, such as national defense and military,aerospace,and automobiles.The realization of intelligent acquisition and monitoring of the grinding process is essentialto improve product quality and ensure safe production.Aiming at the problems in the data collection of the existing grinding process,such as the single target of the monitoring plan,insufficient integration,and difficulty in obtaining complete grinding information,a multi-scale target integrated monitoring system framework is established for the grinding process.A multi-scale target correlation monitoring model including quality,efficiency,status, and a green multi-scale is constructed,which maps monitoring variables and monitoring targets. The multi-sensor acquisition fusion and grinding result monitoring feature mapping method is proposed,and an intelligent acquisition and monitoring system for the grinding process is developed.The system is used for real-time data acquisition and monitoring of a high-speed electric spindle bearing grinding process.The measurement results show that the developed monitoring system can effectively and accurately predict the grinding time,grinding energy consumption,grinding state, and surface roughness during the grinding process.

Key words: multi-scale target, monitoring system framework, data driven, intelligent grinding monitoring system

吕黎曙, 邓朝晖, 刘涛, 滕洪钊, 卓荣锦. 数据驱动的磨削过程多尺度目标在线监测及其系统开发[J]. 兵工学报, 2023, 44(7): 2147-2161.

LÜ Lishu, DENG Zhaohui, LIU Tao, TENG Hongzhao, ZHUO Rongjin. Data-Driven Online Monitoring and System Development of Multi-scale Targets in the Grinding Process[J]. Acta Armamentarii, 2023, 44(7): 2147-2161.

图/表 21

参考文献 29

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序号	砂轮线速度/ (m·s^-1)	工件转速/ (r·min^-1)	磨削深度/ mm	平均磨削功率/ W	粗糙度/μm	平均磨削温度/ ℃	磨削能耗 10^-3/(kW·h)
1	100	90	0.01	2112	0.374	276	77.96
2	100	90	0.02	2655	0.512	412	63.10
3	100	90	0.03	5211	0.605	664.5	58.22
4	100	90	0.04	7556	0.698	848.5	55.58
5	100	90	0.05	8499	0.952	906.5	53.44
6	100	30	0.03	2434	0.346	654	81.88
7	100	60	0.03	2644	0.431	660	63.77
8	100	120	0.03	6756	0.461	676	54.79
9	100	150	0.03	7914	0.544	687	52.78
10	60	90	0.03	3643	0.776	603.3	52.33
				……

序号	砂轮线速度/ (m·s^-1)	工件转速/ (r·min^-1)	磨削深度/ mm	平均磨削功率/ W	粗糙度/μm	平均磨削温度/ ℃	磨削能耗 10^-3/(kW·h)
1	100	90	0.01	2112	0.374	276	77.96
2	100	90	0.02	2655	0.512	412	63.10
3	100	90	0.03	5211	0.605	664.5	58.22
4	100	90	0.04	7556	0.698	848.5	55.58
5	100	90	0.05	8499	0.952	906.5	53.44
6	100	30	0.03	2434	0.346	654	81.88
7	100	60	0.03	2644	0.431	660	63.77
8	100	120	0.03	6756	0.461	676	54.79
9	100	150	0.03	7914	0.544	687	52.78
10	60	90	0.03	3643	0.776	603.3	52.33
				……

变量	特征参数值
变量	1	2	3	4	5	…
VAR01	0.048 7	0.252	0.432	0.389 5	0.571
VAR02	2.678 1	2.706	2.544 2	2.903 4	2.548 4
VAR03	3.359 1	2.898 5	2.702 1	2.845 3	2.651 4
VAR04	4.860 8	4.179 3	3.758 1	4.047 5	3.661 1
VAR05	806.3	969.7	969	888.8	969
VAR06	301	423	690	856	922
VAR07	251	401	639	841	891
VAR08	276	412	664.5	848.5	906.5	…
VAR09	2 212	2 755	5 311	7 656	8 599
VAR10	2 012	2 555	5 111	7 456	8 399
VAR11	2 112	2 655	5 211	7 556	8 499
VAR12	77.96	63.10	58.22	55.58	53.44
VAR13	100	100	100	100	100
VAR14	90	90	90	90	90
VAR15	0.01	0.02	0.03	0.04	0.05

变量	特征参数值
变量	1	2	3	4	5	…
VAR01	0.048 7	0.252	0.432	0.389 5	0.571
VAR02	2.678 1	2.706	2.544 2	2.903 4	2.548 4
VAR03	3.359 1	2.898 5	2.702 1	2.845 3	2.651 4
VAR04	4.860 8	4.179 3	3.758 1	4.047 5	3.661 1
VAR05	806.3	969.7	969	888.8	969
VAR06	301	423	690	856	922
VAR07	251	401	639	841	891
VAR08	276	412	664.5	848.5	906.5	…
VAR09	2 212	2 755	5 311	7 656	8 599
VAR10	2 012	2 555	5 111	7 456	8 399
VAR11	2 112	2 655	5 211	7 556	8 499
VAR12	77.96	63.10	58.22	55.58	53.44
VAR13	100	100	100	100	100
VAR14	90	90	90	90	90
VAR15	0.01	0.02	0.03	0.04	0.05

变量	主成分1	主成分2	主成分3
VAR01	0.796	0.183	-0.164
VAR02	-0.336	0.645	0.422
VAR03	-0.574	0.716	0.001
VAR04	-0.586	0.713	0.006
VAR05	0.328	-0.574	0.443
VAR06	0.893	0.152	0.392
VAR07	0.893	0.152	0.392
VAR08	0.893	0.152	0.392
VAR09	0.910	0.224	-0.290
VAR10	0.910	0.224	-0.290
VAR11	0.910	0.224	-0.290
VAR12	-0.778	0.095	0.168
VAR13	0.068	0.398	-0.552
VAR14	0.448	-0.200	-0.671
VAR15	0.861	0.238	0.397