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Research on Monitoring System for Electrical Discharge Machining Machine Tools Based on Configuration Monitoring Technology

2026-04-06 05:46:11 · · #1
I. Introduction Currently, most machine tool monitoring systems in China are dedicated systems with poor openness, failing to meet the development needs of today's manufacturing industry and constituting typical "automation silos" within factories. However, the development of computer software technology and industrial control network technology has made the interconnection of factory automation equipment possible. Configuration software, as a bridge and link for the "horizontal" and "vertical" integration of automation systems, has been widely applied in various fields of industrial automation. Configuration monitoring technology provides a basic platform for implementing data acquisition, process monitoring, and production control. Together with detection and control components, it forms a complex application system, playing a core role in energy saving, improving measurement accuracy, enhancing product quality, and facilitating the precise transmission of production information between departments. This helps enterprises eliminate information silos, reduce operating costs, improve production efficiency, and accelerate market response. II. Monitoring System of Electrical Discharge Texturing Machine Tool Electro-discharge texturing (EDT) process uses the roll as the workpiece electrode and copper or graphite as the tool electrode. The roll and the tool electrode are immersed in the insulating working fluid. The electrical discharge machining forms pits and protrusions on the surface of the roll. With the uniform rotation of the roll and the axial reciprocating linear motion, the spiral lines of the pits and protrusions on the surface of the roll intersect and overlap to form a texturing morphology composed of random and disordered pits and protrusions (as shown in Figure 1). The texturing steel plate cold rolled by the EDT roll is widely used in the automotive, home appliance and other industries because of its good stamping and coating properties. The monitoring system of the EDT machine tool adopts the upper and lower computer structure to realize the functions of information management and process monitoring. The lower computer adopts a programmable controller that is good at sequential logic control and switch quantity information processing. It is responsible for the coordinated work of roll rotation and axial movement, electrode servo movement, pulse power supply voltage and current output and working fluid circulation filtration[2]. The host computer uses an industrial control computer and Windows 2000 as the hardware and software platform. It utilizes ForceControl version 2.6 monitoring configuration software to develop a local monitoring program for EDM texturing and a workshop production management system. Remote monitoring stations and IE browsing stations are also established via Ethernet. The host computer communicates with the lower-level PLC via the FX2N-232-BD functional expansion board, using the RS232C serial communication protocol and the I/O device drivers provided in the configuration software. Figure 2 shows a schematic diagram of the EDT machine tool monitoring system. III. Local Monitoring of EDM Texturing Local monitoring of EDM texturing, i.e., the host computer system for EDM texturing machine tools, includes: 1. Real-time monitoring of the roll processing process of the test machine tool, presented in an animated format. 2. Real-time monitoring of the working fluid circulation system of the test machine tool, dynamically reflecting the working status of the working fluid system throughout the entire roll processing process. 3. 4. Allows selection of pre-set roll processing parameters and working fluid circulation system control parameters. Manual settings and modifications are also possible. It can communicate with third-party software Excel via DDE to save modified parameters. 5. Accepts work tasks from the workshop-level management system and allows selection of specific tasks for execution. 6. Provides real-time alarm information. When a system fault occurs, an alarm window automatically pops up, providing an optional audible alarm, and historical alarm information can be queried. 7. Real-time reflection of the changing trends of certain pre-set variables, with historical trends queried. 8. Historical report function, allowing querying of the values ​​of pre-set variables at several points in time within a historical period. 9. Variable overview function, allowing viewing of the current values ​​of variables in all areas and units of the system. 10. Manages operators, with functions for user login, logout, and password modification. Additionally, the event log allows querying operator login and operation status. The lower-level computer is primarily responsible for fault diagnosis and status monitoring of the machine tools, transmitting this information to the upper-level computer to await commands, and controlling the roll processing subsystem and the working fluid circulation subsystem. The upper-level computer is responsible for receiving information from the lower-level computer, reflecting the machine tool's working status and alarm information in real time, setting the process parameters for roll processing and the control parameters for the working fluid circulation system, and receiving work tasks from the workshop-level management system. Furthermore, through the standard DDE interface provided by the configuration software, the monitoring system establishes a connection with the third-party software Microsoft Excel, utilizing Excel's reporting functions to modify and save process and control parameters. IV. Roll Texturing Processing Workshop Production Management System Traditional manufacturing concepts are no longer suitable for the current demands of productivity development; information-based management of factories is imperative. The factory's production management department must promptly, accurately, and comprehensively grasp the operational information of the production site, and adjust production plans in a timely manner based on changes in market demand and workshop production conditions. The production management system for the roll texturing workshop, developed based on ForceControl 2.6 configuration software, realizes centralized monitoring and production task scheduling of machine tools for multiple processes including roll inspection, roll grinding, and roll texturing in the roll texturing workshop. The system includes the following modules: (1) Machine tool centralized monitoring module. This module mainly reflects the operating status, fault alarm status, and work task completion status of the roll inspection machine, roll grinding machine, and roll texturing machine tool; (2) Task management module. This module is responsible for the work task allocation and statistics of the workshop machine tools; (3) Historical data query module. This module realizes historical alarm query, historical trend query, etc.; (4) Personnel management module. Regularly or irregularly manages the work assignment, work permission password authorization, etc. of technical personnel and operators. The implementation principle of the workshop management system issuing work tasks to machine tools is shown in Figure 4. The system interconnects with an Access database via the Open Database Connectivity (ODBC) interface provided by the configuration software. Work task information is read from the database, and then real-time database sharing between the workshop management system and the machine tool monitoring system is achieved through the ForceControl configuration software's network applications NetServer and NetClient. This transmits work tasks to the EDM machine tool and other machine tools. Figure 4 illustrates the principle of work task transmission. V. Remote Monitoring and Web-based Remote Surveillance of EDT Machine Tools. The components of the remote monitoring station for EDT machine tools are identical to those of the local station. The difference is that the remote station itself does not connect to I/O devices. Instead, it accesses the ForceControl real-time database on the local station through a connection established between the ForceControl network application NetClient (based on the TCP/IP protocol) and NetServer. This accesses the local station's variables and uses them to access I/O devices. The remote station shares some variables with the local station, so when local station variables change, the corresponding remote station variables also change, and vice versa. Thus, the remote station achieves the function of remote real-time monitoring of EDT machine tools (as shown in Figure 2). Production managers are no longer satisfied with directly monitoring industrial sites from their offices; web-based remote monitoring is becoming the mainstream method. Utilizing the web publishing function of the force control configuration software, the texturing process of rolls can be easily published to the Internet, providing shared information for professionals in the machine tool industry, as shown in Figure 5. Figure 5: IE browser screen for roll processing. VI. Conclusion Configuration monitoring technology is an important component of automation systems, which will greatly promote the further development of the manufacturing industry and improve the automation level and information integration of the entire manufacturing sector. The EDT machine tool monitoring system, the roll texturing workshop production management system, and the EDT remote monitoring station introduced in this paper have been running stably and reliably on the experimental machine tools, achieving the pre-designed functions well. Using configuration software, a platform tool with good openness, to establish a machine tool monitoring system can effectively realize the interconnection between different automated equipment within the factory, which is undoubtedly a way to establish an integrated network manufacturing system. This article will introduce the monitoring system of EDM texturing machine tool based on ForceControl 2.6 monitoring configuration software (hereinafter referred to as "ForceControl 2.6"). At the same time, ForceControl 2.6 was also used to establish a production management system for roll texturing workshop and a remote monitoring station for EDM texturing machine tool. ForceControl 2.6 has a convenient operating environment, rich graphics processing functions, powerful real-time database and network functions. It is stable and reliable in operation, which can meet the needs of machine tool monitoring system. It also has good openness and low cost. The goal of CIMS is to make the management, production, operation and service of the factory fully automated, scientific and controlled, maximize the role of people, resources and information in the enterprise, improve the efficiency of enterprise operation and market responsiveness, and reduce costs [1]. Automation technology is the foundation of CIMS, but the actual automation systems are scattered on various devices. There is a lack of interconnection between the various automation devices in the enterprise, and data cannot be shared in real time, which fundamentally hinders the implementation of CIMS. In the development of enterprise CIMS, configuration software can serve as the operator station software for DCS; it can facilitate the low-cost and high-efficiency realization of plant-wide informatization; it can solve the interconnection problem of scattered "automation islands," significantly reducing the investment required for CIMS construction. Configuration software has rich I/O drivers, supports fieldbus technology and OPC standards, and has its own network architecture and communication functions. These features will maximize the timely reflection of various production information from the field to higher-level management, enabling management to adjust production plans promptly and adapt to market changes, thereby generating greater economic benefits for the enterprise.
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