数控车床转塔刀架可靠性试验台的研制
摘要
数控机床是国家的战略制造装备,其制造和技术水平直接反映了一个国家的工业现代化水平。转塔刀架是数控车床的关键功能部件,其可靠性水平直接影响到整机的可靠性水平,转塔刀架可靠性的深入研究对整机可靠性的提高有着重要的意义。目前国内一些相关企业里的转塔刀架可靠性试验台的研制仅是从功能角度出发,只能进行一些转位试验,由于转塔刀架在工作时会受到动态切削力的作用,所以单独的转位试验对刀架实际工况模拟并不好,试验效果也不理想。
本文结合国家科技重大专项-高速精密数控机床可靠性设计与性能试验技术(课题编号：2009ZX04014-011),以转塔刀架的实际工况为出发点,将动态加载环节融入试验流程,研制了数控车床转塔刀架可靠性试验台,能够对转塔刀架进行加速试验,提高试验效率,为转塔刀架可靠性研究提供依据,主要研究内容包括：
(1)根据转塔刀架的工作原理和实际工作时的受力状况,参照转塔刀架国家标准,提出了转位试验和动态加载试验的转塔刀架试验方法。进行了试验台的功能需求分析和试验台的总体设计,试验台分成试验台架、电液伺服加载系统、下层PLC控制系统和上位机监控系统4部分。
(2)根据试验要求,对试验台架进行结构设计和制造,实现了对转塔刀架的多角度变换加载。运用ANSYS对台架进行了有限元分析,找出了台架的刚度薄弱环节,对薄弱环节进行了改进。对电液伺服加载系统进行了设计,并对液压系统关键元件进行了参数计算与选型。
(3)采用OMRON PLC作为下层控制系统的核心,根据试验台的控制要求,进行了PLC的选型、I/0地址编辑及下层控制系统控制流程分析,最后完成了控制程序的编制,实现了对转塔刀架及相关电器的控制。
(4)上位机监控系统开发软件选用Visual Basic,对人机界面进行了编制,基于MSComm控件的通信功能完成了与PLC的通信程序,并完成了整个试验台总体控制程序的编制,最后进行了Access试验数据库的开发,建立了试验信息和故障信息数据库。
试验台调试完成后经过一段时间的试验检测,试验结果表明：试验台功能达标,运行稳定,验收合格,同时获得了一部分试验数据,也发现了转塔刀架的些故障,并对故障进行了分析与排除。数控车床转塔刀架可靠性试验台的研制对数控车床关键功能部件转塔刀架的可靠性深入研究有着重要的理论意义和实用价值。
CNC machine tools are the strategic manufacturing equipment of the country, its manufacture technology reflects a country's industry modernization level directly. The turret tool is the essential functional component of CNC lathe, its quality makes a important effect on the reliability of the integrate machine, so the improvement of the reliability for the turret tool has a important significance on the enhancing the reliability of the integrate machine. At present, although some related domestic enterprises have some simple test-bed about turret tool, they can only make some function experiments, that is revolving test. But when a turret tool is working, it must stand a dynamic cutting force, so the revolving test can't imitate the real manufacturing environment, and the results from the test are also not satisfied.
Combined with the national science and technology project-reliability design and performance test of high speed and high precision CNC machine tools (Project number:2009ZX04014-011),based on the turret tool's real working environment, this paper has designed and realized the reliability test-bed for CNC lathe turret tool. Through the acceleration test, the hidden failure of the turret tool can be exposed in short time and it can provide the basis for the reliability research of the turret tool.
The main researching work is as follows:
(1) The working principle and loading condition of turret tool are analyzed, and according to the turret tool GB,the revolving test and dynamic loading test are proposed. With the proposing of the test methods, the function demands of test-bed are analyzed. Based on the function demands of test-bed, the overall design of the test-bed is confirmed. The test-bed is made up by four parts, the bed gantry, electrohydraulic servo loading system, lower PLC control system and upper computer monitor control system.
(2) According to the test's function demands, the structure of the test-bed is designed and manufactured. Based on this test-bed, the turret tool can be loaded on different degrees. The Finite Element Analysis of the test-bed's structure is also complete through ANSYS, according to the analysis results, the weak points of the structure is improved. After that,the electrohydraulic servo loading system is also designed, the function and principle of electrohydraulic servo loading system are analyzed, the performance parameter of important parts in the system are calculated。
(3) OMRON PLC is chose as the core of the lower control system, much work is done, for example, analyzing the working principle of the servo control box, choosing the type of PLC, defining the address of the I/O, analyzing the control process of the system and so on, at last the program are achieved and the control function of the PLC is realized.
(4) Visual Basic is chose as the development software of the upper computer monitor control system. The user Interface is programmed. Based on the communicating functions of Visual Basic MSComm component, the communication between computer and PLC is completed perfectly and all control of the lower control system is completed. At last, Access database is developed in order to save the test date and failure data of the turret tool.
After the adjustment of the test-bed, the test is carried on for many days. The result indicates:The function of the test-bed is up to standard and the performance is steady. The test-bed meets the test requirements. The test also provides some dada and some failure of turret tool is exposed. Certainly, the failure is analyzed and resolved. The reliability test-bed of CNC lathe turret tool makes a significance and reality worth for the deeply reliability research of CNC Lathe Turret tool.
本文结合国家科技重大专项-高速精密数控机床可靠性设计与性能试验技术(课题编号：2009ZX04014-011),以转塔刀架的实际工况为出发点,将动态加载环节融入试验流程,研制了数控车床转塔刀架可靠性试验台,能够对转塔刀架进行加速试验,提高试验效率,为转塔刀架可靠性研究提供依据,主要研究内容包括：
(1)根据转塔刀架的工作原理和实际工作时的受力状况,参照转塔刀架国家标准,提出了转位试验和动态加载试验的转塔刀架试验方法。进行了试验台的功能需求分析和试验台的总体设计,试验台分成试验台架、电液伺服加载系统、下层PLC控制系统和上位机监控系统4部分。
(2)根据试验要求,对试验台架进行结构设计和制造,实现了对转塔刀架的多角度变换加载。运用ANSYS对台架进行了有限元分析,找出了台架的刚度薄弱环节,对薄弱环节进行了改进。对电液伺服加载系统进行了设计,并对液压系统关键元件进行了参数计算与选型。
(3)采用OMRON PLC作为下层控制系统的核心,根据试验台的控制要求,进行了PLC的选型、I/0地址编辑及下层控制系统控制流程分析,最后完成了控制程序的编制,实现了对转塔刀架及相关电器的控制。
(4)上位机监控系统开发软件选用Visual Basic,对人机界面进行了编制,基于MSComm控件的通信功能完成了与PLC的通信程序,并完成了整个试验台总体控制程序的编制,最后进行了Access试验数据库的开发,建立了试验信息和故障信息数据库。
试验台调试完成后经过一段时间的试验检测,试验结果表明：试验台功能达标,运行稳定,验收合格,同时获得了一部分试验数据,也发现了转塔刀架的些故障,并对故障进行了分析与排除。数控车床转塔刀架可靠性试验台的研制对数控车床关键功能部件转塔刀架的可靠性深入研究有着重要的理论意义和实用价值。
CNC machine tools are the strategic manufacturing equipment of the country, its manufacture technology reflects a country's industry modernization level directly. The turret tool is the essential functional component of CNC lathe, its quality makes a important effect on the reliability of the integrate machine, so the improvement of the reliability for the turret tool has a important significance on the enhancing the reliability of the integrate machine. At present, although some related domestic enterprises have some simple test-bed about turret tool, they can only make some function experiments, that is revolving test. But when a turret tool is working, it must stand a dynamic cutting force, so the revolving test can't imitate the real manufacturing environment, and the results from the test are also not satisfied.
Combined with the national science and technology project-reliability design and performance test of high speed and high precision CNC machine tools (Project number:2009ZX04014-011),based on the turret tool's real working environment, this paper has designed and realized the reliability test-bed for CNC lathe turret tool. Through the acceleration test, the hidden failure of the turret tool can be exposed in short time and it can provide the basis for the reliability research of the turret tool.
The main researching work is as follows:
(1) The working principle and loading condition of turret tool are analyzed, and according to the turret tool GB,the revolving test and dynamic loading test are proposed. With the proposing of the test methods, the function demands of test-bed are analyzed. Based on the function demands of test-bed, the overall design of the test-bed is confirmed. The test-bed is made up by four parts, the bed gantry, electrohydraulic servo loading system, lower PLC control system and upper computer monitor control system.
(2) According to the test's function demands, the structure of the test-bed is designed and manufactured. Based on this test-bed, the turret tool can be loaded on different degrees. The Finite Element Analysis of the test-bed's structure is also complete through ANSYS, according to the analysis results, the weak points of the structure is improved. After that,the electrohydraulic servo loading system is also designed, the function and principle of electrohydraulic servo loading system are analyzed, the performance parameter of important parts in the system are calculated。
(3) OMRON PLC is chose as the core of the lower control system, much work is done, for example, analyzing the working principle of the servo control box, choosing the type of PLC, defining the address of the I/O, analyzing the control process of the system and so on, at last the program are achieved and the control function of the PLC is realized.
(4) Visual Basic is chose as the development software of the upper computer monitor control system. The user Interface is programmed. Based on the communicating functions of Visual Basic MSComm component, the communication between computer and PLC is completed perfectly and all control of the lower control system is completed. At last, Access database is developed in order to save the test date and failure data of the turret tool.
After the adjustment of the test-bed, the test is carried on for many days. The result indicates:The function of the test-bed is up to standard and the performance is steady. The test-bed meets the test requirements. The test also provides some dada and some failure of turret tool is exposed. Certainly, the failure is analyzed and resolved. The reliability test-bed of CNC lathe turret tool makes a significance and reality worth for the deeply reliability research of CNC Lathe Turret tool.
引文
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[3]毛丽清,孙淼森.我国数控机床功能部件发展初探[J].机械工程师,2006,7：20-21.
[4]杨丽敏.国内外重型数控机床的技术对比与发展[J].金属加工(冷加工),2010,7：17-19.
[5]张增照.以可靠性为中心的质量设计、分析和控制[M].北京：电子工业出版社,2010.7.
[6]赵东元,攀虎,任志久.可靠性工程与应用[M].北京：国防工业出版社,2009.6
[7]Chirkov A.L, Makarov N.V, Gavryushin A.I, Plekhanova V.M. Enhancing the reliability of NC machines and FMS by running them in at the manufacturers works [J]. Soviet Engineering Research,1989,9(3):114-115.
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[10]余仲裕.数控机床维修.北京：机械工业出版社.2001.
[11]Yash P.Gupta, Toni M.Somers. Avaliability of CNC Machines Multiple-Input Transfer-Function Modeling [J]. IEEE Transaction on Reliability,1989, No3: 30-38.
[12]Rudi H.P.M.Arts, Anuj Saxena, Gerald M.Knapp. Estimation of distribution parameters of mixed failure mode data. Journal of quality in maintenance engineering.1997 3(2).
[13]Me Goldrick P.F, Kulluk H. Machine Tool Reliability—A Critical Factor in Manufacturing Systems [J]. Reliability Engineering,1986(14):205-221.
[14]Jones J A, Hayes J A. Use of a field failure database for improvement of product reliability [J]. Reliability Engineering and System Safety,1997(55):131-134.
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