One, background
CNC machine tools are the key production equipment for processing lines in various enterprises. If a failure occurs and maintenance cannot be followed in time, its long-term shutdown will bring huge losses to production.
No matter how high the reliability of the CNC machine tool is, its failure is unavoidable. Therefore, what the user is most concerned with is how to diagnose in advance when the equipment has a fault symptom signal and how to perform maintenance in time after the failure.
CNC machine tools are mechanical and electrical integration products that integrate mechanical manufacturing, computer, hydraulic pressure, sensing, information processing, optical and electrical machinery and other technologies. Given the complexity of CNC machine tools and the limited manpower reserves of companies, equipment maintenance must rely on external forces. Sometimes because of some minor problems, it is necessary to let the machine tool manufacturers come to the scene for repairs, resulting in high travel costs and waste of human resources. With the development of network technology, the emergence of network-based fault diagnosis system has solved the above problems.
Second, solve the idea:
The remote fault diagnosis technology of CNC machine tools combines the fault diagnosis technology of CNC machine tools with computer network technology, establishes state monitoring points on the CNC machine tools, collects its operating status data, and establishes an expert diagnostic center on the enterprise LAN and INTERNET. The operating status is analyzed and diagnosed. It can make fault diagnosis more flexible and convenient, and can effectively improve the accuracy of diagnosis and work efficiency, reduce maintenance time.
Third, the system consists of:
The main functional modules of the system are: data acquisition module, data transmission module, network diagnostic service program and condition monitoring and remote diagnostic software.
1. Data acquisition module: Collect the operating data, parameters of the numerical control system and the information code related to the fault.
2. Data transmission module: The collected operating data and parameters are sent to the remote diagnosis center. Here, we propose to use the F2114 industrial communication module based on the GPRS network as the data transmission module. For complex faults, expert diagnoses are also combined with video information.
3. Fault diagnosis module: According to the fault location or fault phenomenon of the current machine tool, through the Web access method, combined with the available machine tool information provided by the machine tool manufacturer, the cause of the fault and the processing method can be queried so as to implement a simple fault query of the numerical control system. And diagnosis.
Four letter industrial grade wireless communication module F2114 provides reliable machine tool equipment wireless networking, data remote transmission function in this system. The communication between the equipment and the remote center is not limited by distance. The patented anti-dropping mechanism enables the device to be online 24 hours a day, ensuring smooth communication. Support unified access of various machine tools and equipments with different brands and communication protocols. Multi-level user rights security management, network management functions to achieve worry-free monitoring, reliable communication links provide reliable protection for remote maintenance of equipment.
V. Economic Analysis:
Thanks to the remote machine diagnosis and service system, for CNC machine users, you can:
1. Effective use of external expert systems to reduce machine downtime and increase production efficiency.
2. Realize predictive maintenance and early detection of hidden troubles.
3. Reasonably predict the life of the machine tool, so that the machine tool can be extended to service under the conditions of guarantee and production.
At the same time, remote machine diagnosis and services can also bring benefits to machine tool manufacturers in many ways:
Service personnel and costs can be reduced;
Conveniently track the quality of machine tool usage, find weak links, and continuously improve the quality of machine tools;
State management of equipment to achieve organic integration of post-mortem maintenance, planned maintenance, and predictive maintenance.
Establish long-term and close relationships with users.
