回轮式车床数控化改造及其数控系统的研究与设计
摘要
回轮车床是在普通卧式车床的基础上发展起来的,它与普通卧式车床最大的区别是有一个可绕水平轴线转位的回轮刀架,刀架沿圆周均匀分布许多个装夹刀具用的装刀孔,加工工件时一次装夹工件就可以依次使用不同刀具完成多种工序,不必再重复地测量工件尺寸和装卸刀具,由此可见回轮车床是一种高效机床,但目前市场上并没有出现数控回轮车床。应淄博汇丰汽车配件有限公司的要求,对该公司的一台闲置的型号为C336-1回轮车床进行数控化改造,不仅可以利用闲置资源,恢复和提高原机床精度,更能提高产品的加工精度和效率,稳定产品质量,给企业带来效益。目前经数控化改造的回轮车床已投入使用。本课题主要研究内容简述如下：
应用成熟的数控理论和数控化改造成功经验,用普通车床的数控系统来改造回轮车床。根据改造方案,进行了机械、电气控制、回轮刀架自动分度和定位措施的研究、试验与改造。根据实际情况选择数控系统和交流伺服电机,推导出电子齿轮比与交流伺服电机步距角的关系。最后通过一种制动泵体的加工试验证明回轮车床数控化改造是成功的。
结合普通车床数控系统的功能特点设计研究了适合回轮车床使用的数控系统。确定了"PC+PCI-1750运动控制卡”的硬件结构、人性化的人机交互界面以及模块化的软件开发思路,充分体现了该数控系统开放性的特点。通过控制步进电机、电磁铁和主轴转动的模拟实验,初步实现了回轮式车床数控改造需要的功能。
根据图形交互自动编程原理设计了一个软件系统代替手工完成数控加工程序的编制。。由在汇丰汽车配件公司进行的制动泵加工实验可知,加工沟槽和倒角时,编制数控程序的方法与在普通数控车床上相差很大,并且计算复杂,用自动编程可省略繁琐的计算工作,快速自动地生成数控程序。
Drum lathe is a type of engine lathe developed on the basis of traditional horizontal lathes. Compared with horizontal lathes, drum lathe has a tool holder which could revolve around the fixed horizontal axis. There are lots of holes for clamping tools distributed evenly along the circumference. When machining, instead of being loaded and measured repeatedly, the work piece could be loaded only once, then a variety of processes could be completed with different tools. So drum lathe is a type of high-efficiency machine tools, but numerical drum lathe doesn't appear on the market at present. At the request of Huifeng Auto Parts Company, we conduct research on numerical reform towards an idle drum lathe. At a result of NC reform, we can not only take full advantage of existing resources, recover and improve accuracy of old machine tools, but also enhance machining precision and efficiency, make the product quality stable and reliable, bring enterprises great economic benefit. Now the numerically controlled drum lathe has already been put into use. The main researched contents are as follows:
Sophisticated CNC technology theory and successful experience are applied in this equipment reconstruction. According to the reconstructing plan, machine reconstruction task is divided into two parts, mechanical and electrical. Solutions of changing tools automatically and positioning accurately are proposed on the basis of the mechanism principle of tool holder of the drum lathe. The relationship between step angle and AC servo motor is deduced from experimental research. At last, the consequences are proved through a programming case of a brake pump.
A general design of the NC system for drum lathe is presented. The hardware structure of "PC+PCI-1750Kinematics Controller", object-oriented programming techniques and modular thinking of the development of NC software are ensured. In addition, a friendly user interface of software is designed in this paper. Then simulated experiments of step motor and principal axis rotating are also presented.
On the basis of interactive graphical programming method of automatic, the thesis develops a NC automatic programming system. It can be seen from the programming example of a brake pump in Huifeng Auto Parts Company, NC codes are different from general CNC lathe. Using auto programming tools instead of manual coding, the complex calculation could be left out, and machining program of the work parts for numerical control machine can be produced automatically.
应用成熟的数控理论和数控化改造成功经验,用普通车床的数控系统来改造回轮车床。根据改造方案,进行了机械、电气控制、回轮刀架自动分度和定位措施的研究、试验与改造。根据实际情况选择数控系统和交流伺服电机,推导出电子齿轮比与交流伺服电机步距角的关系。最后通过一种制动泵体的加工试验证明回轮车床数控化改造是成功的。
结合普通车床数控系统的功能特点设计研究了适合回轮车床使用的数控系统。确定了"PC+PCI-1750运动控制卡”的硬件结构、人性化的人机交互界面以及模块化的软件开发思路,充分体现了该数控系统开放性的特点。通过控制步进电机、电磁铁和主轴转动的模拟实验,初步实现了回轮式车床数控改造需要的功能。
根据图形交互自动编程原理设计了一个软件系统代替手工完成数控加工程序的编制。。由在汇丰汽车配件公司进行的制动泵加工实验可知,加工沟槽和倒角时,编制数控程序的方法与在普通数控车床上相差很大,并且计算复杂,用自动编程可省略繁琐的计算工作,快速自动地生成数控程序。
Drum lathe is a type of engine lathe developed on the basis of traditional horizontal lathes. Compared with horizontal lathes, drum lathe has a tool holder which could revolve around the fixed horizontal axis. There are lots of holes for clamping tools distributed evenly along the circumference. When machining, instead of being loaded and measured repeatedly, the work piece could be loaded only once, then a variety of processes could be completed with different tools. So drum lathe is a type of high-efficiency machine tools, but numerical drum lathe doesn't appear on the market at present. At the request of Huifeng Auto Parts Company, we conduct research on numerical reform towards an idle drum lathe. At a result of NC reform, we can not only take full advantage of existing resources, recover and improve accuracy of old machine tools, but also enhance machining precision and efficiency, make the product quality stable and reliable, bring enterprises great economic benefit. Now the numerically controlled drum lathe has already been put into use. The main researched contents are as follows:
Sophisticated CNC technology theory and successful experience are applied in this equipment reconstruction. According to the reconstructing plan, machine reconstruction task is divided into two parts, mechanical and electrical. Solutions of changing tools automatically and positioning accurately are proposed on the basis of the mechanism principle of tool holder of the drum lathe. The relationship between step angle and AC servo motor is deduced from experimental research. At last, the consequences are proved through a programming case of a brake pump.
A general design of the NC system for drum lathe is presented. The hardware structure of "PC+PCI-1750Kinematics Controller", object-oriented programming techniques and modular thinking of the development of NC software are ensured. In addition, a friendly user interface of software is designed in this paper. Then simulated experiments of step motor and principal axis rotating are also presented.
On the basis of interactive graphical programming method of automatic, the thesis develops a NC automatic programming system. It can be seen from the programming example of a brake pump in Huifeng Auto Parts Company, NC codes are different from general CNC lathe. Using auto programming tools instead of manual coding, the complex calculation could be left out, and machining program of the work parts for numerical control machine can be produced automatically.
引文
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[34]王军锋,唐宏.伺服电机选型的原则和注意事项[J].装备制造技术,2009(11)：129-131.
[35]刘肖.基于Windows平台的数控系统的研究与开发[D.张店：山东理工大学,2010.
[36]王爱玲,李梦群,冯裕强.数控加工理论与实用技术[M].北京：机械工业出版社,2009.
[37]周凯.PC数控原理、系统及应用[M].北京：机械工业出版社,2006.
[38]尹家凡,王孙安.基于PC的开放式数控系统的研究[J].机械工程师,2004(8)：6-70.
[39]曹遂军,王会良.国内外开放式数控系统的研究与现状[J].机电工程技术,2003.
[40]Power in Automation PA 8000 NT CNC-Series. Power Automation AG CNC-Automatisierungstechnik[M]. Pleidelsheim.2003.
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[42]张宏.数控系统硬件平台的设计与加工仿真.北京：北京工业大学,2008.
[43]姜培吕,卢军霞,赵庆志.基于PCI-1750数据采集卡的步进电机控制系统设计[J].山东理工大学学报,2010(1).
[44]PCI-1750快速入门手册[Z].
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[46]姚习武,朱志红,田文超Windows数控平台下数控代码解释系统的研究与实践[J].机械与制造工程,1999(5)：24-26.
[47]唐保STAR06T(ZP)数控系统研究与盘装零件数控自动检测机的研制[D].合肥：合肥工业大学,2008.
[48]陆卫忠,刘文亮C++Builder 6程序设计教程[M].北京：科学出版社,2005.
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[50]孙哲.6-UPU型并联机床数控系统研究与设计[D].张店：山东理工大学,2011.
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[2]马雪峰.X5040铣床的数控化改造[D].哈尔滨：哈尔滨工程大学,2007.
[3]周哲波.机床数控技术与应用[M].江苏：中国矿业大学出版社,2009,02.
[4]Randy Black, Mitch Fletcher. Open System Architecture-Both Boon and Bane[R].25th, Digital Avionic System Conference,2006.
[5]Harry H. Cheng, John L, Michaloski, William P. Shackleford. Real-Time Computing in Open Systems for Manufacturing[J] Technology Review,2001,1:94-99.
[6]Boldea, Sayed A Naser. Linear electric actuators and generators. Cambridge University Press,1997.
[7]Technologies Enabling Agile Manufacturing (Team) Intelligent Closed Loop Processing (LCLP) API Working Group. Open Architecture Specification:Part I:General Information. Jan.1996.
[8]Quan Liu, Xinjuan Jin, Yihong Long. A Service-oriented Networked Numerical Control System for Resource Sharing[C]. IEEE International Conference on Industrial Technology. 2008:1076-108.
[9]He Qing, Gui Gui-Sheng. Research on numerical control technology of HSM[c]. Proceedings of the 38th international conference on computers and industrial engineering,2008:2590-2594.
[10]何明晋.基于FANUC系统的普通铣床6M612的数控化改造[D].西安：西安科技大学,2009.
[11]李园.基于西门子SINUMERIK 802S的CA6140的车床数控化改造[D].浙江：浙江工业大学,2007.
[12]马雪峰.X5040铣床的数控化改造[D].哈尔滨：哈尔滨工程大学,2007.
[13]谢勇.我国机床数控化市场浅析[J].自动测量与控制,2008,(12)：81-82.
[14]赵娇.数控特种编程方法研究及编译功能实现[D].上海：上海交通大学,2008.
[15]Amirouche, Farid M L. Principles of computer-aided design and manufacturing. Upper Saddle River, N. J:Pearson Prentice Hall,2004,23:78-82.
[16]Y Zhao, K. Ridgway, AI-Amharic. Integration of CAD and a cutting tools election system. Computers & Industrial Engineering,2002,42:17-34.
[17]刘婷婷.基于VC60的图形自动编程系统的研究[D].北京：中国农业大学,2006.
[18]曾建雄.凸轮轴数控磨削自动编程系统的开发及虚拟磨削技术研究[D].长沙：湖南大学,2009.
[19]肖慧霞.基于PLC的盘式制动器制动泵总成综合性能实验台的研制[D].武汉：武汉理工大学,2009.
[20]鄢细林.CA6132普通乍床数控化改造[D].东营：中国石油大学,2009.
[21]田晓文,赵庆志,孙哲.回轮式车床数控改造中回转刀架的控制研究[J].山东理工大学学报,2012(1)：89-92.
[22]刘春时,宋威,马仕龙.轴向刀架动力模块的传动方案研究[J].机械设计与制造,2010(12)：260-261.
[23]高改芬.CA6140普通车床的数字化设计及实现[D].保定：华北电力大学,2008.
[24]陈胜勇.基于嵌入式Linux与MCX314的数控系统研究[D].成都：成都理工大学,2009.
[25]孙颖.浅谈在数控机床设计中伺服电机的选取[J].民营科技,2010(9)：22.
[26]李春红.超声-磨削设备及工艺试验[D].广州：广东工业大学,2009.
[27]文怀兴,夏田.数控机床设计实践指南[M].北京：化学工业出版社,2008,01.
[28]王光斗,王春福.机床夹具设计手册第三版[M].上海：上海科学技术出版社,2000,11.
[29]K100Ti-D车床数控系统使用手册[Z].
[30]ZD-15交流电机电子制动器使用手册[Z].
[31]谭积明,戴怡,石秀敏.电子齿轮在数控车床伺服系统中的应用[J].创造业自动化,2009(7)：38-40.
[32]高荣.电子齿轮在数控机床中的应用[J].机床与液压,2007(6)：250-251.
[33]刘军锋,万淑芸,周永鹏.交流伺服系统的开放式接口设计[J].机械与电子,2002(5)：31-33.
[34]王军锋,唐宏.伺服电机选型的原则和注意事项[J].装备制造技术,2009(11)：129-131.
[35]刘肖.基于Windows平台的数控系统的研究与开发[D.张店：山东理工大学,2010.
[36]王爱玲,李梦群,冯裕强.数控加工理论与实用技术[M].北京：机械工业出版社,2009.
[37]周凯.PC数控原理、系统及应用[M].北京：机械工业出版社,2006.
[38]尹家凡,王孙安.基于PC的开放式数控系统的研究[J].机械工程师,2004(8)：6-70.
[39]曹遂军,王会良.国内外开放式数控系统的研究与现状[J].机电工程技术,2003.
[40]Power in Automation PA 8000 NT CNC-Series. Power Automation AG CNC-Automatisierungstechnik[M]. Pleidelsheim.2003.
[41]李爱平.NC嵌入PC型开放式数控系统的研究[J].组合机床与自动化加工技术,2001(12).
[42]张宏.数控系统硬件平台的设计与加工仿真.北京：北京工业大学,2008.
[43]姜培吕,卢军霞,赵庆志.基于PCI-1750数据采集卡的步进电机控制系统设计[J].山东理工大学学报,2010(1).
[44]PCI-1750快速入门手册[Z].
[45]夏丰.曲轴综合测量仪[D].陕西：西安理工大学,2002.
[46]姚习武,朱志红,田文超Windows数控平台下数控代码解释系统的研究与实践[J].机械与制造工程,1999(5)：24-26.
[47]唐保STAR06T(ZP)数控系统研究与盘装零件数控自动检测机的研制[D].合肥：合肥工业大学,2008.
[48]陆卫忠,刘文亮C++Builder 6程序设计教程[M].北京：科学出版社,2005.
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