数控机床远程监控系统的研究

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摘要

随着计算机技术、通信技术和网络技术的飞速发展，数控机床集成化、网络

化、智能化的远程监控系统已经成为数控加工领域的发展方向。远程监控系统可

以对数控机床的工作状况和健康状态进行实时监测，有效地保证数控机床处于良

好的工作状态，缩短故障停机的时间，有效提高加工效率。因此实现数控机床远

程监控对于现代制造业意义重大。

现有的数控机床远程监控系统监测功能往往单一，无法实现对数控机床加工

状态的全方位监测；基于无线技术的远程监测系统功率有限、抗干扰能力弱、可

靠性差。针对这些问题，本文基于 FPGA 技术的高性能 cRIO 嵌入式硬件平台，

开发了多测点、多参数的全方位数控机床远程监测系统。该系统采用光纤通信，

基于 NI 网络化硬件测控平台和 LabVIEW 软件平台，确保了远程监控系统的实时

性，可靠性。论文的主要研究工作和成果如下：

(1) 研究了数控机床远程监控系统的总体结构，设计了监控系统的硬件结构，

实现了远程监控数控机床的振动、温度、切削力等状态参数和工作状态的视频监

控。

(2) 设计了采集终端程序、远程通讯程序、监控中心程序等，完成了数控机床

远程监控系统的软件设计。

(3) 以Festo 公司的无杆气缸为研究对象，对其进行了气动位置伺服的远程控

制，验证了本文所设计系统的可行性与实时性。对数控铣床的振动信号进行了远

程监控，进一步验证了本文的研究成果。

关键词：数控机床远程监控 FPGA 技术嵌入式实时性

ABSTRACT

Along with the rapid development of computer technology, the communication

technology and network technology, the CNC machine tool remote monitoring

system’s integrating, networking and intelligent have become the development

direction of CNC machining area. Remote monitoring system of CNC machine tool

can realize real-time monitoring for the machine’s work condition and health state,

ensuring the CNC machine tools are in good condition and shorten the breakdown

time , improving the machining efficiency. Therefore, realizing the remote monitoring

for CNC machine tool is a great significance to the modern manufacturing.

The function of existing CNC machine tool’s remote monitoring system

monitoring is always single, unable to realize the processing state’s all-directional

monitoring for CNC machine; the remote monitoring system based on wireless

technology has limited power, weak anti-interference ability, and poor reliability. In

view of these problems, based on the high-performance cRIO embedded hardware

platform of FPGA technology, omni-directional CNC machine tool remote monitoring

system has been developed in this paper, which with several points and several

parameters. Based on the NI networking hardware’s measurement & control platform

and LabVIEW software platform, the system ensures real-time and reliability of the

remote monitoring system, by using optical fiber communication. The paper’s main

research work and results are as follows:

(1) The overall structure of the CNC machine tool remote monitoring system is

studied, then the hardware structure of the monitoring system is designed, finally

realized the remote monitoring of vibration, temperature, cutting forces and other state

parameters for CNC machine tool and video monitoring of work status.

(2) The acquisition terminal procedure, the remote communication program and

the monitoring center procedure have been designed. Then the software design for the

CNC machine tool remote monitoring system is completed.

(3) Take the company Festo’s pneumatic rodless cylinders as the research object,

the remote control of pneumatic position servo has been completed, then the feasibility

and real-time of the designed system is proved. The remote monitoring of vibration

signals for CNC milling machine has been implemented, and the results of this paper

have been further verified.

Key Words: CNC, Remote monitoring and control, FPGA Technology,

Embedded system, Real-time

中文摘要

ABSTRACT

第一章绪论 .......................................................................................................... 1

§1.1 课题的研究背景和意义 ...................................................................... 1

§1.1.1 研究背景 ...................................................................................... 1

§1.1.2 研究意义 ...................................................................................... 2

§1.2 远程监控技术概述 .............................................................................. 2

§1.2.1 远程监控系统功能分析 .............................................................. 2

§1.2.2 监控方式的分类及其特点 .......................................................... 3

§1.3 数控机床远程监控技术国内外发展现状 .......................................... 4

§1.3.1 国外发展现状 .............................................................................. 4

§1.3.2 国内的发展现状 .......................................................................... 5

§1.4 本文的研究目的和内容 ...................................................................... 6

第二章数控机床远程监控系统总体结构设计 .................................................. 8

§2.1 数控机床远程状态数据采集方法研究 .............................................. 8

§2.1.1 数控机床系统分析 ...................................................................... 8

§2.1.2 数控机床加工性能参数分析 ...................................................... 9

§2.2 远程监控系统功能分析 .................................................................... 10

§2.2.1 采集终端功能要求 .................................................................... 10

§2.2.2 上位机功能要求 ......................................................................... 11

§2.3 系统总体结构设计 ............................................................................. 11

§2.3.1 RT 技术 ........................................................................................ 11

§2.3.2 FPGA 技术 ................................................................................. 12

§2.3.3 cRIO 嵌入式系统 ....................................................................... 13

§2.3.4 系统总体结构设计 .................................................................... 14

第三章数控机床远程监控系统的硬件实现 .................................................... 16

§3.1 采集终端硬件结构设计 .................................................................... 16

§3.1.1 采集终端嵌入式系统硬件简介 ................................................ 17

§3.2 温度采集模块 .................................................................................... 19

§3.2.1 STT-M A1 温度传感器 .............................................................. 19

§3.2.2 NI-9217 RTD 100ohm 采集卡 ................................................... 20

§3.3 声音振动采集模块 ............................................................................ 21

§3.3.1 EA-LV-141 加速度传感器 ........................................................ 21

§3.3.2 MI 17 声音传感器 ..................................................................... 23

§3.3.3 NI-9234 声音振动采集卡 ......................................................... 24

§3.4 切削力采集模块 ................................................................................ 25

§3.4.1 KISTLER 9257B 测力仪........................................................... 25

§3.4.2 电荷放大器接口电路连接 ........................................................ 26

§3.5 通讯平台硬件设计 ............................................................................ 26

§3.5.1 光端机 ........................................................................................ 27

§3.5.2 光纤收发器 ................................................................................ 27

第四章数控机床远程监控系统的软件设计 .................................................... 29

§4.1 基于 FPGA 技术的 LabVIEW 编程 ................................................. 29

§4.1.1 LabVIEW 虚拟仪器构建 ........................................................... 29

§4.1.2 基于 FPGA 技术的程序功能分配 ........................................... 30

§4.1.3 程序设计流程 ............................................................................ 30

§4.2 采集终端程序实现 ............................................................................ 31

§4.2.1 定时循环技术 ............................................................................ 31

§4.2.2 FPGA 和RT 数据传输技术....................................................... 32

§4.2.3 FXP数据转换 ............................................................................ 34

§4.2.4 振动信号采集程序设计 ............................................................ 36

§4.2.5 温度采集程序实现 .................................................................... 38

§4.3 通讯模块程序设计 ............................................................................ 39

§4.3.1 LabVIEW 网络通信方式分析 ................................................... 40

§4.3.2 网络共享变量 ............................................................................ 40

§4.3.3 Datasocket 编程 .......................................................................... 41

§4.3.4 TCP 编程 .................................................................................... 42

§4.4 监控中心程序设计 ............................................................................ 44

§4.4.1 分析处理程序 ............................................................................ 44

§4.4.2 窗口分屏实现 ............................................................................ 46

§4.4.3 数据存储 .................................................................................... 47

§4.4.4 网络发布 .................................................................................... 48

§4.4.5 TeamViewer 软件实现 ............................................................... 49

第五章远程监控系统应用实例 ........................................................................ 52

§5.1 监控系统的实时控制性试验 ............................................................ 52

§5.1.1 系统测试环境 ............................................................................ 52

§5.1.2 测控原理 .................................................................................... 54

§5.1.3 运行结果及分析 ........................................................................ 56

§5.2 数控机床运行状态的远程实时监测 ................................................ 57

§5.2.1 系统测试环境 ............................................................................ 58

§5.2.2 测试流程 .................................................................................... 59

§5.2.3 测试结果 .................................................................................... 60

§5.2.4 运行结果分析 ............................................................................ 62

第六章总结与展望 ............................................................................................ 63

§6.1 主要工作总结 .................................................................................... 63

§6.2 未来展望 ............................................................................................ 63

参考文献 ................................................................................................................ 65

在读期间公开发表的论文和承担科研项目及取得成果 .................................... 70

致谢 ........................................................................................................................ 71

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摘要：

摘要随着计算机技术、通信技术和网络技术的飞速发展，数控机床集成化、网络化、智能化的远程监控系统已经成为数控加工领域的发展方向。远程监控系统可以对数控机床的工作状况和健康状态进行实时监测，有效地保证数控机床处于良好的工作状态，缩短故障停机的时间，有效提高加工效率。因此实现数控机床远程监控对于现代制造业意义重大。现有的数控机床远程监控系统监测功能往往单一，无法实现对数控机床加工状态的全方位监测；基于无线技术的远程监测系统功率有限、抗干扰能力弱、可靠性差。针对这些问题，本文基于FPGA技术的高性能cRIO嵌入式硬件平台，开发了多测点、多参数的全方位数控机床远程监测系统。该系统采用光纤通信，基于NI网...

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