基于冲孔缺陷的冲头磨损智能监测方法

Intelligent monitoring method for punch wear based on punching defects

  • 摘要: 针对冲压生产中依赖经验判断冲头磨损所导致的维护不及时或过度维护问题,提出一种基于冲孔缺陷特征与图卷积神经网络(graph convolutional network, GCN)的冲头智能维护方法。首先,通过视觉检测系统采集冲孔图像并进行图像预处理;其次,采用最小二乘圆拟合与凸包拟合等技术,量化提取冲孔的多维几何缺陷特征。为有效利用特征间的复杂关联,基于皮尔逊相关系数构建特征图结构,并借助GCN模型学习缺陷特征之间的深层非线性映射关系。实验结果显示,所提GCN模型在测试集上的诊断准确率达0.991,F1分数达0.987,其性能高于多层感知机(multilayer perceptron, MLP)、支持向量机(support vector machine, SVM)和一维卷积神经网络(1-Dimensional convolutional neural network, 1D-CNN)等基准模型。最后,结合产线实际数据,构建了基于冲孔异常比例的预测性维护策略。现场验证表明,基于冲孔异常比例的预测性维护策略能够减少因提前更换导致的寿命浪费,并降低严重磨损冲头持续生产所引发的批量质量风险,为冲压产线的智能化维护提供了可行的技术途径。

     

    Abstract: To address the issues of untimely or excessive maintenance caused by the reliance on empirical judgment for punch wear in stamping production, this paper proposes an intelligent punch maintenance method based on punching defect features and graph convolutional networks (GCN). Firstly, punching images were acquired via a vision inspection system and underwent image preprocessing. Subsequently, techniques such as least squares circle fitting and convex hull fitting were employed to quantitatively extract multi-dimensional geometric defect features of the punched holes. To effectively utilize the complex correlations among features, a feature graph structure was constructed based on the Pearson correlation coefficient, and a GCN model was utilized to learn the deep non-linear mapping relationships between defect features. Experimental results showed that the proposed GCN model achieved a diagnostic accuracy of 0.991 and an F1-score of 0.987 on the test set, outperforming baseline models such as MLP, SVM, and 1D-CNN. Finally, combining actual production line data, a predictive maintenance strategy based on the proportion of punching anomalies was formulated. Field verification showed that the predictive maintenance strategy based on the proportion of abnormal punched holes could reduce service-life waste caused by premature replacement and lower the batch quality risk associated with continued production using severely worn punches, providing a feasible technical approach for intelligent maintenance of stamping production lines.

     

/

返回文章
返回