Article(id=1245407864458687453, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156262727438951343, articleNumber=null, orderNo=null, doi=10.12404/j.issn.1671-1815.2307547, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1695571200000, receivedDateStr=2023-09-25, revisedDate=1720454400000, revisedDateStr=2024-07-09, acceptedDate=null, acceptedDateStr=null, onlineDate=1774857973446, onlineDateStr=2026-03-30, pubDate=1741363200000, pubDateStr=2025-03-08, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1774857973446, onlineIssueDateStr=2026-03-30, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1774857973446, creator=13701087609, updateTime=1774857973446, updator=13701087609, issue=Issue{id=1156262727438951343, tenantId=1146029695717560320, journalId=1146123166801305609, year='2025', volume='25', issue='7', pageStart='2193', pageEnd='3077', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1753604116544, creator=13701087609, updateTime=1753771263994, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1156963794699248405, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156262727438951343, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1156963794699248406, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156262727438951343, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=2784, endPage=2791, ext={EN=ArticleExt(id=1245407865918304351, articleId=1245407864458687453, tenantId=1146029695717560320, journalId=1146123166801305609, language=EN, title=Online Recognition of Single Crystal Diamond Tool Grinding Direction Based on PSO-BP and Multi-information Fusion, columnId=1156262729003422020, journalTitle=Science Technology and Engineering, columnName=Papers·Petroleum and Natural Gas Industry, runingTitle=null, highlight=null, articleAbstract=

In order to improve the online recognition accuracy of the grinding direction of single crystal diamond tools and address the limitation of acquiring limited information from a single sensor in grinding monitoring, this study a method for online recognition of the grinding direction of single crystal diamond tools based on multi-information fusion and particle swarm optimization (PSO) algorithm for optimizing the BP(back propagation) neural network was proposed. Vibration signals and acoustic emission (AE) signals were collected during the grinding process. The wavelet packet decomposition method was applied to analyze the vibration signals of the tool and identify the characteristic frequency bands strongly correlated with the grinding direction. The parameter analysis method was used to analyze the AE signals and extract the characteristic parameters. The energy values of the characteristic frequency bands in the vibration signals and the characteristic parameters of the AE signals were taken as the feature parameters for identifying the grinding direction of the tool. These feature parameters were then used as inputs to the BP neural network model for fusion and online recognition of the grinding direction. To overcome the disadvantage of the BP neural network easily getting stuck in local minima, the PSO algorithm was utilized to optimize the weights and thresholds of the neural network, effectively solving the problem of local minima. The experimental results show that the accuracy of online identification of the grinding direction of single crystal diamond tools is effectively improved by PSO-BP and multi-information fusion, reaching an accuracy of 85%, providing a new method for online identification of the grinding direction of single crystal diamond tools.

, correspAuthors=Hai-tao MA, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Xue-wen FENG, Bin ZHAO, Hai-tao MA, Jia-yu WU, Jirigalantu), CN=ArticleExt(id=1245407872897626670, articleId=1245407864458687453, tenantId=1146029695717560320, journalId=1146123166801305609, language=CN, title=基于PSO-BP单晶金刚石刀具刃磨方向多信息融合在线识别, columnId=1156262729603207500, journalTitle=科学技术与工程, columnName=论文·石油、天然气工业, runingTitle=null, highlight=null, articleAbstract=

为了提高单晶金刚石刀具刃磨方向在线识别精度,以及解决刃磨监测中单一传感器采集信息有限的问题,提出一种基于多信息融合与粒子群优化(particle swarm optimization,PSO)算法优化反向传播(back propagation,BP)神经网络的单晶金刚石刀具刃磨方向在线识别方法。通过采集刃磨过程中的振动信号和声发射(acoustic emission,AE)信号,采用小波包分解法分析刀具振动信号,得出与刀具刃磨方向强相关的特征频段,采用参数分析法来分析声发射信号,得出特征参数。将振动信号特征频段能量值和声发射信号特征参数作为识别刀具刃磨方向的特征参量。将特征参量作为BP神经网络模型输入进行融合,在线识别刀具刃磨方向。针对BP神经网络的容易陷入局部最小值的缺点,利用PSO算法优化神经网络权值和阈值,有效解决陷入局部最小值的问题。实验结果表明,经PSO-BP与多信息融合对单晶金刚石刀具刃磨方向在线识别准确率得到了有效提高,达到85%的准确率,为单晶金刚石刀具刃磨方向在线识别提供了一种新方法。

, correspAuthors=马海涛, authorNote=null, correspAuthorsNote=
* 马海涛(1977—),女,汉族,吉林德惠人,博士,副教授。研究方向:智能仪器与智能控制。E-mail:
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冯雪雯(1997—),女,汉族,山东枣庄人,硕士研究生。研究方向:信息检测与智能控制技术。E-mail:

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冯雪雯(1997—),女,汉族,山东枣庄人,硕士研究生。研究方向:信息检测与智能控制技术。E-mail:

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figureFileSmall=FQQ0ADTGn56GEnQZARYdqQ==, figureFileBig=aY/kaT4N/qCBlhmTzPJlxg==, tableContent=null), ArticleFig(id=1245407879700787339, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1245407864458687453, language=CN, label=图11, caption=不同的算法模型对刀具刃磨方向的识别精度, figureFileSmall=FQQ0ADTGn56GEnQZARYdqQ==, figureFileBig=aY/kaT4N/qCBlhmTzPJlxg==, tableContent=null), ArticleFig(id=1245407879830810768, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1245407864458687453, language=EN, label=Table 1, caption=

The correlation between tool grinding efficiency and grinding direction

, figureFileSmall=null, figureFileBig=null, tableContent=
对应方向 1 2 3
刃磨率k/
10-5[μm3·(N·m·s-1)-1]
0~2 2~4 4~6
), ArticleFig(id=1245407879952445590, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1245407864458687453, language=CN, label=表1, caption=

刀具刃磨效率与研磨方向对应关系

, figureFileSmall=null, figureFileBig=null, tableContent=
对应方向 1 2 3
刃磨率k/
10-5[μm3·(N·m·s-1)-1]
0~2 2~4 4~6
), ArticleFig(id=1245407880074080411, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1245407864458687453, language=EN, label=Table 2, caption=

Tool grinding direction label

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刃磨方向分类 刃磨率k/
10-5[μm3·(N·m·s-1)-1]
标签
方向1 0~2 [100]
方向2 2~4 [010]
方向3 4~6 [001]
), ArticleFig(id=1245407880191520928, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1245407864458687453, language=CN, label=表2, caption=

刀具刃磨方向标签

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刃磨方向分类 刃磨率k/
10-5[μm3·(N·m·s-1)-1]
标签
方向1 0~2 [100]
方向2 2~4 [010]
方向3 4~6 [001]
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基于PSO-BP单晶金刚石刀具刃磨方向多信息融合在线识别
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冯雪雯 1 , 赵彬 1 , 马海涛 1, * , 吴佳玉 1 , 吉日嘎兰图 2
科学技术与工程 | 论文·石油、天然气工业 2025,25(7): 2784-2791
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科学技术与工程 | 论文·石油、天然气工业 2025, 25(7): 2784-2791
基于PSO-BP单晶金刚石刀具刃磨方向多信息融合在线识别
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冯雪雯1 , 赵彬1, 马海涛1, * , 吴佳玉1, 吉日嘎兰图2
作者信息
  • 1 长春工业大学电气与电子工程学院, 长春 130012
  • 2 中国科学院长春光学精密机械与物理研究所, 长春 130033
  • 冯雪雯(1997—),女,汉族,山东枣庄人,硕士研究生。研究方向:信息检测与智能控制技术。E-mail:

通讯作者:

* 马海涛(1977—),女,汉族,吉林德惠人,博士,副教授。研究方向:智能仪器与智能控制。E-mail:
Online Recognition of Single Crystal Diamond Tool Grinding Direction Based on PSO-BP and Multi-information Fusion
Xue-wen FENG1 , Bin ZHAO1, Hai-tao MA1, * , Jia-yu WU1, Jirigalantu2
Affiliations
  • 1 School of Electrical &Electronic Engineering, Changchun University of Technology, Changchun 130012, China
  • 2 Changchun Institute of Optics, Fine Mechanics and Physics, Chinese Academy of Sciences, Changchun 130033, China
出版时间: 2025-03-08 doi: 10.12404/j.issn.1671-1815.2307547
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为了提高单晶金刚石刀具刃磨方向在线识别精度,以及解决刃磨监测中单一传感器采集信息有限的问题,提出一种基于多信息融合与粒子群优化(particle swarm optimization,PSO)算法优化反向传播(back propagation,BP)神经网络的单晶金刚石刀具刃磨方向在线识别方法。通过采集刃磨过程中的振动信号和声发射(acoustic emission,AE)信号,采用小波包分解法分析刀具振动信号,得出与刀具刃磨方向强相关的特征频段,采用参数分析法来分析声发射信号,得出特征参数。将振动信号特征频段能量值和声发射信号特征参数作为识别刀具刃磨方向的特征参量。将特征参量作为BP神经网络模型输入进行融合,在线识别刀具刃磨方向。针对BP神经网络的容易陷入局部最小值的缺点,利用PSO算法优化神经网络权值和阈值,有效解决陷入局部最小值的问题。实验结果表明,经PSO-BP与多信息融合对单晶金刚石刀具刃磨方向在线识别准确率得到了有效提高,达到85%的准确率,为单晶金刚石刀具刃磨方向在线识别提供了一种新方法。

单晶金刚石刀具  /  刃磨方向  /  多信息融合  /  在线识别  /  PSO-BP

In order to improve the online recognition accuracy of the grinding direction of single crystal diamond tools and address the limitation of acquiring limited information from a single sensor in grinding monitoring, this study a method for online recognition of the grinding direction of single crystal diamond tools based on multi-information fusion and particle swarm optimization (PSO) algorithm for optimizing the BP(back propagation) neural network was proposed. Vibration signals and acoustic emission (AE) signals were collected during the grinding process. The wavelet packet decomposition method was applied to analyze the vibration signals of the tool and identify the characteristic frequency bands strongly correlated with the grinding direction. The parameter analysis method was used to analyze the AE signals and extract the characteristic parameters. The energy values of the characteristic frequency bands in the vibration signals and the characteristic parameters of the AE signals were taken as the feature parameters for identifying the grinding direction of the tool. These feature parameters were then used as inputs to the BP neural network model for fusion and online recognition of the grinding direction. To overcome the disadvantage of the BP neural network easily getting stuck in local minima, the PSO algorithm was utilized to optimize the weights and thresholds of the neural network, effectively solving the problem of local minima. The experimental results show that the accuracy of online identification of the grinding direction of single crystal diamond tools is effectively improved by PSO-BP and multi-information fusion, reaching an accuracy of 85%, providing a new method for online identification of the grinding direction of single crystal diamond tools.

single crystal diamond tool  /  grinding direction  /  multi-information fusion  /  online identification  /  PSO-BP
冯雪雯, 赵彬, 马海涛, 吴佳玉, 吉日嘎兰图. 基于PSO-BP单晶金刚石刀具刃磨方向多信息融合在线识别. 科学技术与工程, 2025 , 25 (7) : 2784 -2791 . DOI: 10.12404/j.issn.1671-1815.2307547
Xue-wen FENG, Bin ZHAO, Hai-tao MA, Jia-yu WU, Jirigalantu. Online Recognition of Single Crystal Diamond Tool Grinding Direction Based on PSO-BP and Multi-information Fusion[J]. Science Technology and Engineering, 2025 , 25 (7) : 2784 -2791 . DOI: 10.12404/j.issn.1671-1815.2307547
单晶金刚石具有极高的硬度、良好的耐磨性以及最优良的物理、化学、光学和材料性能,能满足精密及超精密加工对刀具材料的大多数要求[1],近年来在光学晶体材料、陶瓷材料的精密加工中发挥出不可替代的重要作用。但极高的硬度和耐磨性也意味着金刚石表层材料难以去除,给单晶金刚石刀具的刃磨制备带来了困难[2]。为提高刃磨速率和质量,现研究单晶金刚石刃磨过程中寻找易磨方向的方法。单晶金刚石在刃磨时会产生振动、声发射和力等信号,这些信号带有金刚石刀具刃磨的一些信息,可以反映刀具的刃磨状态、磨损程度等。
对于监测技术在金刚石刀具刃磨过程中的应用,大多是采用单一信号。例如,Huang等[3]使用声发射传感器检测电镀金刚石磨削刀具磨损状态。倪留强[4]将光栅刻划刃磨过程中的刀具振动信号作为故障诊断的特征信号,采用小波包分析确定能够表征刃磨振动的故障阈值,以识别刀具刃磨过程的状态。Bouchama等[5]采用功率谱密度(power spectral density,PSD)和重力加速度的平均平方值的平方根(gravitational RMS acceleration,GRMS)分析振动信号,对硬质合金刀片车削不锈钢工件过程中的刀具磨损和表面粗糙度进行监测。Wu等[6]提出了一种用于超精密金刚石切削刀具磨损状态预测的混合深度学习模型,识别精度在85%以上。但是单一传感器所获取的刀具信息比较片面,无法完全可靠地反映刀具的状态。为了提高刀具监测系统的可靠性和精度。本文中采用振动和声发射两种信号进行联合监测,以此辅助刃磨过程调控并提高单晶金刚石刀具刃磨方向在线识别效率。
与刀具的使用过程不同,刀具的制备要求刃磨刀具的前后刀面形成完整锋利的刀具刃口,为确保制备效率和刃口质量,需要借助于振动和声发射信号监测、实时判断并寻找刀具刃磨面上最易磨的方向。本文中对刀具刃磨声发射信号着重进行参数分析,重点关注声发射信号的特征参数。且对刀具刃磨振动信号进行小波包分解,找到与易磨方向相关性最大的特征频段。通过粒子群优化(particle swarm optimization,PSO)优化反向传播(back propagation,BP)神经网络进行特征融合,讨论信号特征与金刚石刀具研磨面易磨方向的映射规律。并通过与单信号输入PSO-BP、多信号输入传统BP识别结果进行对比分析,证明本文所提出方法对刃磨方向的识别更准确与可靠。
金刚石晶体具有明显的各向异性,即不同晶面的磨削率不同,在同一晶面上不同方向的磨削率也有较大差异。如图1所示[7],金刚石晶体的3个晶面在沿不同的研磨方向进行研磨时,其磨削率随之发生变化。根据磨削率大小,将研磨方向大致分为易磨方向、难磨方向和介于易磨和难磨之间的方向。如果研磨方向偏离所磨晶面的易磨方向,将使磨削效率显著降低。而当遇到难磨方向时,则会发生打滑、振动、噪声和磨不动等情况,研磨出的锋锐度和轮廓度将不会很理想。因而金刚石晶体在研磨时一般选择易磨方向作为研磨方向。
金刚石的各向异性还表现在不同晶面的物理力学性能差异较大。所以刃磨面选择不同的晶面可获得具有不同性能的金刚石刀具。综合考虑刃磨的质量和效率,采用{100}晶面作为刀具的前后刀面,容易刃磨出高质量的刀具刃口,微观强度高,不易出现微观崩刃现象。因此,本文中以金刚石{100}晶面为代表进行试验研究和分析。
按{100}晶面研磨时研磨方向与磨削率的关系,可将刀具刃磨效率与研磨方向进行对应,分为如表1所示情况。方向1代表难磨方向,方向2代表介于易磨和难磨之间的方向,方向3代表易磨方向。
振动信号是一种非平稳随机信号,其频率和统计特征会随着时间的变化而变化。传统的频谱分析方法无法对这种非平稳信号的特征进行准确分析。为解决这个问题,引入了小波包分析技术。小波包分析是一种能够对各类非平稳随机信号进行有效处理的现代时频分析和处理方法,可将采集的信号在不同频带、不同时刻进行特征分解。其具有很强的时频局部化分解能力,为各类信号的特征提取和识别奠定了基础,已广泛应用于语言、图像、机械振动等领域[8]。由于金刚石刀具在不同刃磨效率状态下,各频带的能量会发生变化,根据能量的变化,可建立刃磨效率与相关频带能量的映射关系。本文中采用小波包对振动信号数据进行分解,找出表征金刚石刀具易磨方向的特征频段。
金刚石刀具刃磨的振动信号集中在低频段,选取1 Hz ~ 10 kHz的传感器,可确保获取的频段具有较好的全面性。对振动信号在MATLAB自带的小波分析工具箱中选择正则性好的db9小波函数进行三层小波包分解。设小波包分解后的重构信号t3,j对应的第3层能量为E3,j,则有
E3,j=$\sum _{k=1}^{m}$|xj,k|2, j=0,1,2,…,23-1,k=1,2,…,m
式(1)中:m为信号的离散采样点数;xj,k为小波包重构信号t3,j离散点的幅值。不同刃磨方向上振动信号的能量分布如图2所示,从图2中所示总体分布上来看,随着刃磨方向的变化,P1(1~ 1.25 Hz)、P3(2.5~3.75 kHz)和P8(8.75~10 kHz)频段内的信号能量减小,特征变化较大,并且不同方向之间区分明显。根据分析选取振动信号的特征为频段P1、P3、P8的能量值。
金刚石刀具所要研磨的前后刀面与砂轮表面接触,砂轮表面的磨粒与刀具研磨面的相互作用激发产生了声发射信号。杜文浩[9]和王宇健[10]的研究结果表明,金刚石刀具刃磨时声发射信号的频率主要在400 kHz以内,其峰值都在100 kHz以下。为研究金刚石刀具刃磨方向与声发射信号的关系,采用参数分析法,探究声发射信号的特征参数在刃磨过程中的变化规律,建立特征参数与刃磨方向之间的映射关系。经实验发现,与刃磨方向相关的声发射信号特征参数有幅值均值T1、均方根值T2和能量均值E,其公式分别表示为
T1=$\frac{\sum _{i-1}^{N}{x}_{t}\left(i\right)}{N}$
T2=$\sqrt{\frac{\sum _{i-1}^{N}{x}_{t}^{2}\left(i\right)}{N}}$
E=$\sum _{i-1}^{N}{x}_{t}^{2}$(i)
在刃磨机上对金刚石{100}晶面进行24组研磨实验,每组实验的研磨方向角度相差15°,其余实验条件和参数均设置相同。实验结果如图3~图5所示。随着研磨方向的变化,声发射信号的幅值均值、幅值均方根值和能量均值拟合曲线变化趋势大致相似,而能量均值略有不同。图3~图5中的曲线都有4个相邻间隔90°的波峰,它们的起伏状况正好与金刚石{100}晶面的磨削率变化规律相反。这个现象可以解释为,在金刚石{100}晶面的易磨方向上材料容易被磨削去除,则磨削过程中进给量不断变小,磨粒与晶面的接触面积减小,因此声发射信号强度不断下降,导致声发射信号的能量也一同下降[11]。因而,声发射信号特征选择信号的幅值均值、幅值均方根值和能量均值。
刀具刃磨是一个复杂的非线性随机过程,受到多个变量影响。在这个过程中,刀具刃磨方向和被监测信号间也呈现高度非线性关系。为了探究刀具刃磨状态与信号特征向量之间的非线性映射关系,人工神经网络被广泛应用于刀具状态的监测、识别中。通过互联大量处理单元,人工神经网络构成了一个非线性、自适应的信息处理系统,能够模拟并实现类似人脑神经系统的信息处理功能。在处理大量数据和复杂特征的情况下,可以进行高度准确的自动分类。
BP神经网络算法,即反向传播神经网络算法,是一种常用的人工神经网络算法。通过结合具体情况,该算法不断调整网络的权重、偏置和各层的处理单元数,以使网络的输出与期望的输出之间的误差最小化。基本的结构由非线性变化单元组成,具有很强的非线性映射能力。在信号处理与模式识别、智能控制等领域应用广泛。然而,BP神经网络在训练过程中常会陷入局部最小值,即无法达到全局最优解。为了解决这个问题,可以采用PSO算法来优化神经网络的权值和阈值。PSO算法是一种模拟自然界鸟群觅食行为的优化算法,它通过不断调整粒子的位置和速度来搜索全局最优解。在使用PSO算法优化BP神经网络时,每个粒子代表一组权值和阈值,通过不断迭代更新粒子的位置和速度,使得粒子逐渐趋近于全局最优解。优化完成后,会得到最佳的权值和阈值,将其赋值给原始的BP神经网络,从而使BP神经网络的收敛性和泛化能力增强,使得BP神经网络能够更好地逼近全局最优解。
因此,本文中采用PSO优化BP神经网络算法对金刚石刀具刃磨方向进行在线识别。
神经网络的输入需要选择与金刚石刀具刃磨方向相关性最高的特征参数。通过实验结果分析可知,振动信号P1、P3和P8频段的能量值以及AE信号的幅值均值、幅值均方根值和能量均值这6个特征参数比较合适。即神经网络的输入层神经元为6个。神经网络的输出为刀具的3种刃磨方向,即神经网络的输出层神经元为3个。
隐含层的层数和节点数都是重要参数,它们决定了神经网络的复杂度和性能。根据Kolmogorov定理,一个3层的BP神经网络可实现任意n维到m维的非线性映射,因此隐含层数选择一层。隐含层的节点数少,神经网络可能不足以捕捉到输入数据中的复杂模式和关联性,导致网络的性能下降。而节点数多则可能会导致网络过拟合,使得网络在训练集上表现良好,但在未见过的数据上的泛化能力较差。隐含层节点数的经验公式为
l=$\sqrt{n+m}$+a
式(5)中:l为隐含层节点数;n为输入节点数;m为输出节点数;a为1~10的调节常数。
由式(5)可知,节点的个数在4~13个范围内。采用试探法,通过比较不同个数的网络误差来确定隐含层节点的最优个数。经分析,节点数为10时网络误差最小。因此隐含层节点数定为10个。所以刀具刃磨方向在线识别的3层BP神经网络结构为6~10~3。依据BP神经网络的输出直接判断刀具刃磨方向。
为使神经网络学习到刀具的不同刃磨方向,制作标签如表2所示。采用独热编码(即One-Hot编码)来制作标签,将离散特征转换为向量表示。在任意时刻,只有一个数位是有效的。将特征参数输入到神经网络后,如果输出中的某个数位接近于1,而其他两个数位接近于0,那么对比标签就可以判断当前刀具的刃磨方向。
PSO-BP神经网络的基本流程如图6所示。
(1)准备训练数据,提取振动信号和AE信号的特征向量,将其归一化处理之后作为PSO-BP模型输入数据,刀具刃磨方向作为输出。
(2)初始化粒子群的位置和速度。每个粒子的位置即为BP神经网络的初始权值和阈值,速度用于位置的更新。
(3)每个粒子根据适应度函数来计算适应度值。适应度函数是根据BP神经网络的实际输出值与理想输出值之间的差值来衡量的。
(4)确定每个粒子的个体极值和群体极值。个体极值是粒子自身经历的最佳位置,群体极值是所有粒子中适应度最好的位置。
(5)根据个体极值和群体极值,更新粒子群的速度和位置。速度的更新考虑粒子自身的经验和群体的协作,位置的更新用于更新粒子群的权值和阈值。
(6)判断均方误差是否满足条件,如果满足则输 出最优权值和阈值,否则返回步骤(3)。
(7)找到最优解,即BP神经网络的最优权值和阈值。并赋值给原始的BP神经网络,进行训练评价后,用于对金刚石刀具刃磨方向进行识别。
选用实验室自有刃磨机作为刀具刃磨试验平台,搭建了刀具刃磨方向信息采集系统,结构图如图7所示,系统采集两路信号,分别是刀具刃磨振动信号和刀具刃磨AE信号,振动传感器采用慧石测控有限公司生产的CA3007-100型传感器,声发射传感器采用北京声华公司的SR-800型AE传感器,分别采集刃磨过程刀具振动信号和声发射信号,振动传感器和AE传感器紧贴刀具刀柄处,传感器信号通过放大器和信号调理器处理后,由数据采集卡进行转换后,送入计算机进行分析处理,数据采集卡采用阿尔泰公司生产的USB8812型高精度采集卡,上位机界面采用LABVIEW软件实现,实验平台如图8所示。
用于训练PSO-BP神经网络的刃磨信号特征值有时域、时频域参数,其数据量纲及量纲单位都不同,会影响神经网络的训练结果。因而需要对数据进行归一化处理,让各特征参数的取值统一到同一数量级[0,1]区间里,消除不同特征值之间的量纲差异,使不同特征值具有可比性,避免某些特征对训练的影响过大[12]。数据归一化处理公式为
${x}_{i}^{0}$=1-$\frac{\left|{x}_{i}-\overline{x}\right|}{{x}_{max}-{x}_{min}}$
式(6)中:xmax=max{xi},xmin={xi},$\overline{x}$=$\sum _{i=1}^{n}\frac{{x}_{i}}{n}$
本文中所建立的网络模型为网络结构6→10→3的3层PSO-BP神经网络。BP神经网络设置:隐藏层使用relu激活函数。输出层涉及分类则采用sigmoid激活函数。学习率为0.01,最大训练周期为1 000,训练误差为1×10-8,网络初始权值在(0,1)之间随机选取。粒子群算法参数设置:种群数量N=20,最大迭代次数Tmax=30,学习因子c1=c2=0.5,惯性权重w=0.8,最大速度Vmax=1。从获取的特征值中随机选择30组数据作为训练样本,对网络模型进行训练,训练误差曲线如图9所示,经过39步达到了训练目标精度。
实验中共测得50组数据与其相对应的刀具刃磨方向。将50组数据进行特征提取,并随机挑选出30组作为训练数据,其余20组作为测试数据。金刚石刀具刃磨方向识别结果以机器学习中的混淆矩阵(误差矩阵)来表示识别精度。混淆矩阵以表格形式呈现,行表示实际的类别,列表示模型识别的类别。本文中刀具刃磨方向识别模型得到的混淆矩阵中每一列是识别刀具刃磨方向类别,每一列的数据总数是刃磨方向数据被识别为该类别的数目;每一行是实际刀具刃磨方向类别,每一行的数据总数是该刃磨方向实际的数目;每一列中的数值是实际刀具刃磨方向数据被识别为该类别的数目[13]
在保证PSO-BP神经网络参数及各信号特征值不变的情况下,采用单一信号特征法,将振动信号、声发射信号的特征参量分别输入PSO-BP神经网络进行金刚石刀具刃磨方向识别。识别准确度如图10所示。
图10的识别结果可知,单一的振动信号和声发射信号对刀具刃磨方向的识别准确度分别为70%、75%。相较而言,声发射信号的识别准确度高一点,在金刚石刀具刃磨方向的变化方面,它表现出更高的敏感性。
在保证输入相同多信号特征的情况下,采用PSO-BP神经网络和BP神经网络分别进行金刚石刀具刃磨方向识别。识别准确度如图11所示。
图11所示识别结果可知,BP、PSO-BP神经网络对刀具刃磨方向的识别准确度分别为80%、85%。两个模型的识别结果都比单一信号特征作为输入时的准确度高。无论是采用单一信号特征输入PSO-BP神经网络对金刚石刀具刃磨方向进行识别,还是BP神经网络融合多信号特征进行识别,其识别结果都不理想。而本文所提出的多信息融合和PSO-BP神经网络方法对金刚石刀具刃磨方向在线识别准确度更高。
提出了一种基于多信息融合与PSO-BP神经网络的单晶金刚石刀具刃磨方向在线识别方法。该方法通过多信号特征解决了信息有限问题,再根据刃磨方向特征参数与刀具刃磨方向之间的映射关系建立PSO-BP神经网络。通过编写MATLAB程序对模型进行仿真实验,由实验结果分析可知:
(1)在金刚石刀具刃磨过程中,声发射信号比振动信号对刃磨方向的变化敏感性更高,为金刚石刀具刃磨过程的在线监测提供了可靠的理论支持。
(2)通过对比单信号特征和多信号特征在PSO-BP神经网络下对金刚石刀具刃磨方向的识别精度。结果显示,相比较单一振动信号或声发射信号,多信号特征对刃磨方向的识别准确度分别提高了15%、10%。由此可见,本文所提出的多信息融合和PSO-BP神经网络的刀具刃磨方向识别方法更加准确可靠。
(3)在多信号特征融合情况下,比较分析了BP、PSO-BP神经网络在识别刃磨方向的精确度。结果显示,相比较BP神经网络,PSO-BP神经网络模型的识别精确度提高了5%。研究结果可使金刚石刀具刃磨过程的控制更精良和工艺进一步优化。
综上所述,本文提出的基于多信息融合与PSO-BP神经网络的刀具刃磨方向在线识别方法在提高刀具刃磨精度和效率方面具有重要意义。通过融合多种信号特征和PSO优化BP神经网络算法,准确识别刀具刃磨在线方向,实现对刃磨过程的实时监控和调整,从而提高金刚石刀具的刃磨质量和寿命。
  • 吉林省科技发展计划(20210201104GX)
  • 国家自然科学基金(62075216)
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2025年第25卷第7期
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doi: 10.12404/j.issn.1671-1815.2307547
  • 接收时间:2023-09-25
  • 首发时间:2026-03-30
  • 出版时间:2025-03-08
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  • 收稿日期:2023-09-25
  • 修回日期:2024-07-09
基金
吉林省科技发展计划(20210201104GX)
国家自然科学基金(62075216)
作者信息
    1 长春工业大学电气与电子工程学院, 长春 130012
    2 中国科学院长春光学精密机械与物理研究所, 长春 130033

通讯作者:

* 马海涛(1977—),女,汉族,吉林德惠人,博士,副教授。研究方向:智能仪器与智能控制。E-mail:
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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