Analysis of transformation of numerical control machine tool
In order to survival and development of enterprises, improve the rate of CNC machine tools is necessary. Transformation of the equipment needed for NC machine tools in general, including traditional and recently introduced from abroad, due to a problem can not be put into the machine tool equipment and production lines.
First, transform the contents of the NC
CNC machine tools and production line transformation of the main contents are: (1) restoration of the original function, machine tools, production lines there is some fault diagnosis and recovery; (2) NC-based, in the general machine tools addend remarkable device or add numerical control system; ( 3) The renovation, to improve accuracy, efficiency and degree of automation, mechanical, electrical parts of the renovation, the mechanical part of the re-assembly process, to restore the original precision; can not meet the production requirements of its CNC system be updated with the latest CNC; (4) technology updates or technical innovation, in order to improve performance or grade, or for the use of new technology, new technology, based on the original large-scale technology updates or technical innovation.
Second, the development trend of CNC system
l. To open, the sixth generation of PC-based direction
The openness of the PC-based, low-cost, high reliability, rich in natural resources such as hardware and software features, and more CNC system manufacturer will be to go down this path. At least with PC, as its front-end machines, to deal with man-machine interface, programming, networking and communications issues, the original system to take over some tasks PC CNC machines has the friendly interface, will reach all of the CNC system. The remote communication, remote diagnostics and maintenance of applications will be more common.
2. To the development of high-speed and high precision.
3. To the intelligent direction
(1) The application of adaptive control technology. Numerical control system can detect the process of important information and automatically adjust system parameters, improving the system operation status.
2) the introduction of expert systems to guide processing. Will be skilled workers and expertise, processing and general laws and special laws into the system to process parameter database support, establish an artificial intelligence expert system.
(3) the introduction of fault diagnosis expert system
(4) intelligent digital servo drives. Can automatically identify the load and automatically adjust the parameters of the drive system to get the best state of operation.
Third, the choice of numerical control system
1. Open-loop system
The system's servo-driven device is a stepper motor, power stepper motors, electro-hydraulic pulse motors. This system does not require position and velocity feedback, displacement accuracy depends mainly on the angular displacement precision stepper motor and gear drive components such as precision screw, so displacement of low accuracy. But the system is simple, debugging easy maintenance, reliable, low cost, easily converted successfully.
2. Closed-loop system
The system consists of grating, sensor position detection device synchronization, etc. The actual measured position signal fed back to the computer, compared with a given value, the difference between the two amplification and transformation, driving the implementing agencies in order to eliminate bias. The system complexity, high cost and strict temperature requirements on the environment. But the system of high precision, speed and big power. According to technological requirements and decide whether to adopt.
3. Semi-closed-loop system
Semi-closed-loop system detects components installed in the middle of transmission parts, the indirect measurement of the location of the implementation of parts. It can only compensate for part of the components within the system loop error, and therefore its more accurate than the accuracy of closed-loop system is low, but its structure and debugging as compared with the closed-loop system is simple.
Current production numerical control system are more companies and manufacturers, foreign companies such as Siemens of Germany, Japan, Fanuc, Inc.; domestic Everest companies such as China, the Beijing Aerospace CNC System Corporation, Huazhong CNC CNC high-grade corporate and Shenyang National Engineering Research Center. Select CNC systems are mainly based on numerical control after transformation to be achieved in a variety of precision machine tools, drive motor power and the user's requirements to determine.
Fourth, the main steps CNC transformation
1. Determination of rehabilitation programs
(1) Mechanical and Electrical Repair transformation combined. Generally speaking, in need of transformation of electrical machines, are in need of mechanical repair. To determine repair requirements, scope and content; have to ascertain the electrical modification of the mechanical structure in need of transformation requirements and content; but also determine the transformation of electrical and mechanical repair, reconstruction staggered between the time requirements. Mechanical properties of intact are electrical transformation success.
(2) the easier issues first, after the first partial overall. Determine the transformation step, the whole electrical part of the transformation should be divided into several sub-systems, the basic shape of various systems to be connected after the completion of the whole system work. In each subsystem, we should do first the less technical, workload the larger work, and then do a technical high, requiring fine work, can focus people's attention to key areas.
(3) selection system under conditions of use. For the transformation of the object to determine its environment and conditions, which the selection of electrical system protection, anti-jamming, self-cooling and air filtering performance can provide the correct basis. Electrical system options must also be considered mature products, their performance should be reasonable and practical, there are spare parts to provide maintenance support, features a number of years to meet the current and future development requirements.
(4) The implementation and responsibilities of personnel involved in reconstruction.
(5) The transformation of the determination of the scope and cycle.
2. Transformation of the technical preparation
(1) mechanical parts ready. In line with the transformation of mechanical electrical repairs should be completed in advance. The same time, be demolished and replaced and processing should be part of such advance planning is necessary to properly interface with the entire transformation.
(2) The electrical information on the new system to digest.
(3) The conversion of the old system interface design. According to the scope of each of the different equipment modification required to pre-designed interface, part of the conversion, if the entire transformation should be designed to convert mechanical and electrical interfaces, operation panel control and configuration, the Internet part of the contact, parameter measurement, the maintenance and so on. Require the operation and maintenance easy and reasonable, alignments, fluent, primary and secondary connection point less electrical interference with the strength of the smallest, with an appropriate margin and so on. Local transformation, but also need to consider the performance of the system match the old and new, the voltage polarity and size of change, the installation location, digital-analog conversion, etc., if necessary, need to create their own interfaces.
(4) operation and programming staff technical training. ① training should cover the new control panel configuration, function and meaning of the instructions; ② the scope of the new system features, use, and the difference between the old system; ③ maintenance requirements; ④ programming standards and automated programming and more. Focused understood, grasp operating instructions and programming instructions.
(5) Debugging steps and acceptance criteria for the determination. Debugging should be done by the project leader carried out with the others. Debugging step can be from simple to complex, from small to large, from outside to inside, you can also after the first local situation, the whole system after the first subsystem. The development of acceptance criteria must be realistic, too high or too low a standard will have a negative impact on the transformation.
3. The implementation of reform
(1) The overall maintenance of the machine. The long-term use of the original machine, you need to conduct a comprehensive maintenance. Secondly, the response to machine tools to make a change before the geometric accuracy, dimensional accuracy of measurement, and for the record. In this way pairs of reference to guide the transformation of the role, but also in the transformation of the end for comparison analysis.
(2) to retain the electrical adjustment of some of the best. If the electrical system as part of the transformation, in turn, should retain the parts of the maintenance and optimization adjustments, such as high power part of the spare parts replacement, electrical maintenance, drying transformer insulation, pollution, cleaning, ventilation and cooling equipment cleaning, servo Drive optimization adjustments, update aging wires and cables, connectors and other fastening. Only the electrical part of the reservation and do excellent optimization adjustment, in order to ensure that transformed the machine tool have lower failure rates.
(3) The original systems were dismantled. The removal of the original system must be controlled carefully to the original drawings in time to make mark in the drawings to prevent the omission or been demolished. In the process of demolition will find some of the new system design in the gaps, it is timely to add and correction. Removed the system should be properly safeguarded in case of unsuccessful reconstruction resume use. There is a definite value, and can be used for spare parts.
(4) reasonable arrangements for the location and wiring the new system. Connection must be a clear division of labor, there is one person review the inspection to ensure that the connection process specifications, diameter suitable, correct, reliable and beautiful.
(5) debugging. Debug must be pre-established procedures and requirements. Debugging the first to test the safety protection system sensitivity, personal and equipment to prevent accidents. Debugging the site must be clean; the moving coordinate extension units at the center of the whole trip; be able to load test, the first no-load after load; can simulate the experiment, the first real action after simulated; be manual, first manually and automatically.
4. Acceptance and post-work
(1) The mechanical properties of machine tool acceptance. Machine tool should meet the requirements of the mechanical properties, geometric accuracy should be within the limits prescribed.
(2) The electrical control functions and control accuracy and acceptance. The various functions of electrical control actions must meet the normal, sensitive and reliable. Control precision application system itself functions (such as step size, etc.) and standard measuring apparatus (such as laser interferometer, coordinate measuring machine, etc.) control checks, to reach within a range. Should also be modified before the machine with the functions and accuracy to make comparison, access to quantifiable indicators of difference.
(3) The test piece cutting and acceptance. Can refer to the relevant domestic and international standards for CNC cutting specimens, in a qualified operator, the programmer with the trial under the cut. Specimen cutting machine tools can be acceptance of stiffness, cutting force, noise, motion trajectory, related actions, are generally not suitable for specimen use of a product part.
(4), drawings, information and acceptance. Machine transformation finished, should be promptly drawings, data, transform the file summary, collate, transfer into the file. This is the future and stable operation of the equipment is very important.
(5) Summary and improve.
5, numerical examples of reconstruction
1. Milling machine with the Siemens 810M transformation X53
In 1998, the company invested 200,000 yuan, with Germany's Siemens 810M CNC system, 611A AC servo drive system on the company's X53 model of a milling machine to X, Y, Z three-axis numerical control transformation. Retained the original spindle system and cooling system. -Axis transformation of a ball screw used in the machinery and gear transmission mechanism. The transformation of work includes mechanical design, electrical design, PLC program preparation and debugging, machine tool repair, machine installation and debugging. After transformation, milling, processing and effective travel X, Y, Z axis respectively, 880mm, 270mm, 280mm; maximum speed of X, Y, Z axis respectively, 5 000mm/min, 1 500mm/min, 800mm/min; point moving speed of X, Y, Z axis respectively 3 000mm/min, 1 000mm/min, 500 mm / min; machining accuracy of ± 0.001 mm. Machine tools, coordinate linkage to be completed by a variety of complex curve or surface processing.
2. GSK980T and stepper drive system with the transformation of C6140 lathe
In 1999, the company invested 8 million yuan, with Guangzhou CNC Equipment Factory production GSK980T numerical control system, DY3 hybrid stepper drive unit on the company's a longer C6140 lathe X, Z 2-axis transform. Retained the original spindle system and cooling system. Transformation of two-axis ball screw in the machinery used, and synchronous transmission. The transformation of work includes mechanical design, electrical design, machine overhaul and machine installation and debugging. Lathe After the transformation, processing and effective stroke X, Z axis respectively, 390mm, 1400mm; maximum speed X, Z axis respectively, 1 200mm/min, 3 000mm/min; jog speed 400mm/min; point moving fast X, Z-axis respectively, 1 200mm/min, 3 000mm/min; machine smallest mobile unit 0.001mm.
6, numerical transformation of the issues and recommendations
1. Transformation problems in NC
CNC machine tools through several transformation and found work, there are also many problems, mainly reflected in: (a) The departments, developers uncertain functions, organizational chaos, a serious impact on progress in the transformation; (2) to develop the work process and plans are mostly developed rule of thumb, less reasonable; (3) the training of relevant personnel is not in place, resulting in machine tool technology officers will not be modified after programming, the operator of the machine operator unskilled and so on.
2. Transformation of the proposed NC
(1) is responsible for transformation of the staff responsibilities of clear penalties and rewards, fully mobilize the enthusiasm of the staff; train a batch of high-quality applications and maintenance personnel, training for selected officers to go out and learn the advanced technologies;
(2) To focus on users, maintenance of CNC system of technical training, the establishment of numerical control technology at home and abroad resource library. The establishment of technical data files, do the work of spare parts.
分析数控机床改造
为了我国民营企业的生存与发展,提高数控机床的速度是必要的。转型所需的设备一般数控机床,包括传统和最近从国外引进的一个问题,由于不能放入机床设备和生产线。
首先,数控机床和生产线改造的主要内容为:(1)恢复原有的功能、机床、生产线有一些故障诊断和恢复;(2),NC-based一般机床设备或添加加数显著数控系统;(3)改造,提高精度、效率和自动化程度,机械,电气部件的改造、机械部分的维护过程中,才能恢复到最初的辨识精度,不能满足生产要求的数控系统被更新到最新的数控;(4)技术更改或技术创新,以提高性能和品位,或使用新技术、新工艺、新技术,基于最初的大型技术更改或技术创新。
第二,数控系统的发展趋势
l.开放、第六代基于pc机的方向
基于pc的开放性、低成本、高可靠性、丰富的自然资源,例如硬件和软件数控系统的特点,并将更多厂商下去这条路。至少,作为它的前端与PC机,处理人机界面,编程,网络和通信问题,将原系统接管一些任务电脑数控机床具有界面友好、将达到所有的数控系统。远程通信、远程诊断和维护程序将会有更多的共同之处。
2.高速的发展,计算精度高。
3.向智能化方向发展
(1)自适应控制技术的应用。数控系统可以检测过程中重要的情报,自动调整系统参数,提高整个系统的运行状况。
(2)引入专家系统来指导加工。将技术工人和专业知识、加工和一般规律和特殊规律进入系统工艺参数数据库支持,建立一个人工智能专家系统。
(3)引入故障诊断专家系统
(4)智能数字伺服驱动器。可以自动识别的热负荷及自动调整参数的驱动系统获得最佳的经营状况。
第三,选择不同的数控系统
1.开环系统
系统的servo-driven装置是一个步进电机、电力,电液步进电机脉冲马达。这个系统并不需要位置与速度反馈、位移精度主要取决于的精密步进电机角位移和齿轮传动部件,如精密螺丝,所以位移精度低。但是系统简单,调试维修方便、可靠、成本低、易于变现的成功。
2.闭环系统
该系统主要由光栅传感器位置检测装置,同步等。现场实测位置信号反馈到计算机,相比之下,给定值之间的差异,这两个放大与转化;推动执行机构为了消除偏见。该系统的复杂性,成本高,对环境温度要求严格。但是系统精度高、速度和强国。根据工艺要求,并决定是否接受。
3.Semi-closed-loop系统
Semi-closed-loop侦测元件安装在系统中,间接测量传动部位的路径实施部分。它只能够弥补内组件的一部分系统回路的误差,因而它更精确的闭环系统的精度低,不过,其结构和调试与闭环系统是简单的。
目前生产的数控系统制造商,越来越多的公司和外国公司,如德国西门子、日本发那科公司;国内埃佛勒斯峰公司如中国、北京航空公司,华中数控系统的数控CNC高档公司和沈阳国家工程研究中心。选择数控系统中主要采用基于数控改造后成就各类精密机床、电机功率和用户的要求来确定的。
第四,数控改造的主要步骤
1.测定的康复程序,
(1)机电维修改造相结合。一般来说,需要转换的电气设备,需要机械维修。点检定修要求、范围和内容,以确定其电气改造机械结构需要转换要求和内容;但也决定转化的电气和机械维修、改造交错的时间之间的要求。完整的力学性能是电气改造的成功。
(2)问题后更容易第一,第一批的整体。确定改造步伐,整个电气部分改造应分为几个子系统的基本形状,不同系统完成后被连接到整个系统的工作。在每个子系统中,我们应该做的第一件事越少、工作量较大的技术工作,然后做一个技术要求高,做工精细,能集中人们的注意力到关键区。
(3)选拔制度的条件下使用。改造为对象的确定其环境和条件的选择,电气系统的保护、抗干扰、自扇冷和空气过滤性能可提供正确的基础。电力系统的选择必须考虑成熟的产品,他们的表现应该是合理和实用的,有备件提供维护支持,具有多年来适应当前和未来的发展要求。
(4)实施人员的职责在重建。
(5)的转换范围的确定及周期。
2.改造的技术准备
(1)机械部件准备好了。符合机械电气设备进行维修改造应提前完成。同时,被拆除,取而代之的加工应安排计划的一部分,须妥善界面与整个转型。
(2)在新系统电气信息消化。
(3)转换的旧体制的界面设计。根据每个人的不同范围设备改造需要预先设计好的界面,部分转换,如果整个转型应该设计转换为机械和电气接口、操作面板控制和配置,互联网的部分接触,参数测量、保养等。要求操作和维修简单、合理、队列、流畅,初级和中级连接点电气干扰少的力量,用一个合适的最小保证金等等。当地的转型,而且要考虑系统的性能匹配旧与新、电压极性及大小的变化,安装位置、信号转换,等等,如果必要的话,需要创建自己的接口。
(4)操作和编程人员技术培训。①培训应包括新的控制面板配置、作用和意义的指示范围;②新系统的特点,使用,和旧制度的区别;③;④保养要求编程标准和自动编程和更多。理解、把握重点操作规程,程序指令。
(5)的调试步骤和可接受标准的决心。调试应该由项目领导人进行的人。调试步骤可以由简单到复杂,由小到大,从外到内,你也可以在第一个地方情况,整个系统在第一个子系统。验收标准的发展必须面对现实,过高或过低标准将有负面影响,对转变。
3.摘要改革
(1)整体维护机器。长期使用原机,你需要进行综合维修。其次,对机床的反应来改变之前,空间的几何精度测量精度,为记录。用这种方法对参考引导变革的作用,但也转型的过程中,最后进行比较分析。
(2)保留电动调整的一些最好的。如果电力系统的一部分转化,反过来,应保留部件的维护和优化调整,如高功率的一部分,电气维修备件更换、干燥变压器绝缘、污染、清洁、通风降温设备清洗、伺服驱动优化调整、更新老化的电线电缆、连接器和其他紧固。只有电气部分预定的优秀调整和优化,以确保改造机床故障率较低。
(3)原系统被拆除。取消了原系统必须小心地控制原图纸以让马克在图纸,防止遗漏或被拆除。拆除过程中会发现一些新的制度设计在空白,这是及时补充和修正。移除系统应妥善维护以防不成功的重建恢复使用。有一定的价值,并可用于备件。
(4)合理安排的位置和接线的新系统。连接必须有清楚的分工,有一个人复习检查,以确保连接工艺规范,直径相配,正确、可靠和美丽。
(5)调试。调试必须建立程序和要求。第一个试验调试安全保护系统灵敏度、个人和设备,防止事故发生。调试网站必须干净;延长运动协调单位的中心,整个行程;能够负载试验、第一次在负载后,可以模拟空载实验,第一次真正的行动后,首先模拟;手动手动和自动化水平。
4.接纳和post-work
(1)的力学性能的机床验收。机床应满足要求的力学性能、几何精度应规定的范围内。
(2)电气控制功能和控制精度和接受。各种功能的电气控制行为必须符合正常、灵敏、可靠。控制精度应用系统自身的功能(如一步尺寸等)和标准测量仪器(如激光干涉仪、坐标测量机等),达到控制检查范围内。也应该被修改前的功能和精度机比较,获得可量化指标的差异。
(3)测试片切削和接受。可参阅有关国内、国际标准为数控切削标本,在一个合格的经营者,程序员和审判,在切割。标本切割机工具可以接受刚度、切削力、噪声、运动轨迹,相关的动作,一般都是不适合使用一种产品的样品的部分。
(4)、图纸、信息和接受。机改造完毕后,要及时进行图纸、数据、转换文件总结、整理、转入文件。这样的未来、稳定运行设备是非常重要的。
(5)总结和改进。
五、数值实例的重建
1.铣床西门子810米X53转型
1998年,公司于200000年投资元,与德国西门子810米数控系统、611交流伺服驱动系统在公司的X53模型的铣床,X,Y,Z三轴数控改造。保留了原有的主轴系统和冷却系统。入力轴转型滚珠螺杆用于机械齿轮传动机制。转化的工作包括机械设计、电气设计、PLC程序准备和调试、机床维修、设备安装和调试工作。改造后、铣削、加工、有效旅行X,Y,Z轴分别为270毫米、880毫米、280毫米,最大速度X,Y,Z轴分别5 000毫米/分钟,1 500毫米/分钟,800毫米/分钟;点移动速度X,Y,Z轴分别是000毫米(3分钟,000毫米/分钟,500毫米/分钟;加工精度±0.001毫米。机床坐标联动,要完成各种复杂的曲线、曲面的加工。
2.GSK980T和步进驱动系统的转型C6140车床
1999年,公司于800万年投资元,广州数控设备工厂生产GSK980T数控系统,DY3步进驱动单元混合在公司的长C6140 X、Z两车床改造。保留了原有的主轴系统和冷却系统。two-axis转型滚珠丝杠的机器的使用,和同步传输。转化的工作包括机械设计、电气设计、机器检修和机器的安装和调试。改造后的车床、加工和有效X、Z轴分别中风,390毫米、1400毫米,最大速度X、Z轴分别1 200毫米/分钟,3 000毫米/分钟;慢跑400毫米/分钟;速度点快速的移动,X、Z轴分别1 200毫米/分钟,3 000毫米/分钟;机器最小移动单位0.001毫米。
6、数值变换的问题和建议
1.转化问题的数控
通过几个数控机床改造和找工作,也存在很多问题,主要体现在:(一)有关部门、开发商不确定的功能、组织混乱,严重影响了发展转型;(2)开发工作流程和计划大多数发达的拇指规则,更少的合理的;(3)相关人员的培训不到位,导致机床技术官员将不会进行修改后,程序设计中,机器操作熟练的操作人员等。
2.该数控改造
(1)负责员工的责任转变清晰的惩罚和奖励,充分调动员工的积极性,培养了一批高质量的应用程序和维修人员的培训人员,选择去学习先进的技术;
(2)为重点,为维护数控系统用户的技术培训,建立数控技术在国内外资源的图书馆。建立技术数据文件,做的工作,备件。
