A system for intelligent monitoring of computer numerical control (CNC) processing based on an Industrial Internet of Things (IoT), wherein the system comprises a user platform, a service platform, an industrial IoT management platform, a sensor network platform, and a perception control platform, wherein the industrial IoT management platform includes a production process management sub-platform, a data center, and a device management sub-platform, wherein the industrial IoT management platform is configured to:
- obtain, based on an input device of the perception control platform, information corresponding to a task that will be completed;
- determine a CNC processing parameter and simulated processing data corresponding to the CNC processing parameter by performing a CNC process simulation based on the information, including:
- generating a simulated processing parameter based on the information;
- generating a CNC processing program according to a programming rule based on the simulated processing parameter;
- simulating the CNC processing program and recording the simulated processing data, wherein the simulated processing data includes simulated coordinate positions of tools;
- verifying the simulated processing parameter based on the simulated processing data;
- and
- determining the CNC processing parameter and the simulated processing data corresponding to the CNC processing parameter based on a verification result of the simulated processing parameter, including:
- when the simulated processing parameter does not pass verification, adjusting the simulated processing parameter until an adjusted simulated processing parameter passes the verification, and determining the adjusted simulated processing parameter as the CNC processing parameter, wherein the simulated processing parameter not passing the verification includes that the simulated processing parameter is unreasonable and/or inaccurate, and a unreasonable simulated processing parameter refers to a parameter that results in at least one of:
- there is a collision between a tool and parts that will processed, a processing accuracy of a simulated processing exceeding a processing capability of the tool, and a rotation speed exceeding a processing capability of a CNC processing device;
- and
- when the simulated processing parameter is unreasonable, adjusting a specific parameter that is unreasonable, including:
- when there is the collision between the tool and the parts that will be processed, adjusting a tool route to avoid a portion that is colliding with the parts that will be processed;
- when the rotation speed exceeds the processing capacity of the CNC processing device, reducing the rotation speed of the CNC processing device;
- and
- when the simulated processing parameter is inaccurate, finding out a position where a difference between size information in a simulated processing part and size information in processing drawing information is less than tolerance information, and taking a processing progress before processing the position as a current processing progress to input to an adjustment model to obtain the adjusted simulated processing parameter, wherein the adjustment model is a machine learning model, and
- the CNC processing parameter includes a tool feed step length, a selection of the tools, and the tool route;
- control the CNC processing device of the perception control platform to perform the task based on the determined CNC processing parameter;
- collect actual processing data during a performance of the task according to a monitoring frequency by a monitoring device of the perception control platform, wherein the monitoring frequency includes a monitoring frequency of a sub-route of the tool route, and to determine the monitoring frequency, the industrial IoT management platform is further configured to:
- divide the tool route to determine the sub-route;
- determine, based on a CNC processing parameter of the sub-route, an estimated deviation value corresponding to the sub-route, wherein the estimated deviation value is an estimated maximum processing deviation value when processing the sub-route;
- and
- determine the monitoring frequency for the sub-route based on the estimated deviation value, wherein the monitoring frequency of the sub-route is negatively correlated with a difference between the estimated deviation value corresponding to the sub-route and tolerance information corresponding to a target processing part, when the estimated deviation value corresponding to the sub-route is not less than the tolerance information, the monitoring frequency of the sub-route is adjusted up to a maximum monitoring frequency value that is achieved by the monitoring device;
- perform a deviation determination on the actual processing data and the simulated processing data, wherein the actual processing data includes actual coordinate positions of the tools, the deviation determination includes a single-point deviation determination and a multi-point deviation determination, and the processing alert instruction includes a first-level alert instruction and a second-level alert instruction;
- wherein
- the single-point deviation determination includes:
- in response to determining that a position deviation of the tool exceeds a first level deviation threshold, determining a position abnormity of the tool and generating the first-level alert instruction, or
- obtaining a pressure data sequence based on a pressure sensor of the perception control platform;
- determining deformation data for the parts that will be processed based on the pressure data sequence;
- determining a comprehensive deviation based on the deformation data and the position deviation;
- and in response to determining that the comprehensive deviation exceeds the first level deviation threshold, determining that a processing deviation is abnormal and generates the first-level alert instruction, the position deviation is a deviation between the actual coordinate position of the tool and the simulated coordinate position of the tool;
- the multi-point deviation determination includes:
- in response to determining that the position deviation is between the first level deviation threshold and a second level deviation threshold, performing a multi-level determination based on a deviation point ratio, wherein the second level deviation threshold is less than the first level deviation threshold, and the multi-level determination includes:
- in response to determining that the deviation point ratio exceeds a first level ratio threshold, determining the position abnormity of the tool and generating the first-level alert instruction;
- in response to determining that the deviation point ratio is lower than the first level ratio threshold and higher than a second ratio threshold, determining the position abnormity of the tool and generating the second-level alert instruction;
- the second ratio threshold is lower than the first level ratio threshold;
- in response to a result of the deviation determination satisfying a preset alert condition,
- generate the processing alert instruction and send the processing alert instruction to an alert device of a user platform, wherein the alert device includes a screen, a loudspeaker, and a terminal device carried by a user that issues an alert, an alarm device issues an alarm based on the processing alert instruction, and the alarm includes a highlighting alerting and a voice alerting;
- and
- control the CNC processing device to adjust the tool feed step length based on the actual processing data, including:
- determining a second position deviation based on the actual processing data;
- and
- adjusting the tool feed step length based on the position deviation.