冲床的数控改造及全自动送料装置的研制
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摘要
冲压成形的冲压件具有重量轻、厚度薄、刚性好和质量稳定等一系列优点，冲压设备被广泛使用。但由于传统的冲床控制采用接触器、继电器控制，手工送料的方式，所以往往存在着效率低、速度慢、精度不能保证、安全存在隐患等方面的一系列问题，虽然购置新的数控设备可以解决这一问题，但往往资金投入较大，小型企业难以承受，若能在保留原有机床的基本功能基础上，对其进行适当的改造与改进，不失为一种好的方法。一方面可以节约资金，另一方面也不会使原来的机床闲置浪费，基于此种思想，我们对长治科达工贸公司生产餐盒的冲床进行了全面改造，本文对设计的详细过程进行了全面的论述。
设计主要包含了两方面内容：即原有控制系统的改造与自动送料装置的研制。设计思想是：利用接近开关检测冲头的位置，采集的信息经处理后馈送到PLC控制器，PLC控制器通过程序控制放料电机、喂料步进电机带动机械传动装置与吹风阀协调工作，从而完成“放料——喂料——冲模——吹风”这一系列动作，并借助于触摸屏完成相应参数的显示与选择，运动的启动、停止等控制操作，最后把相关信息再馈送到中央控制室，借助于PC机完成系统的监控。
本论文在内容安排上首先介绍了题目的来源与意义及其相关的背景；系统方案的确定、总体的组成、设计思想与理论依据等；随后对系统进行了详细设计，包括：张力控制设计、电气控制主电路与辅助电路设计、PLC控制器的资源分配、电气连接、软件程序代码的编写、触摸屏部分的连接方式、控制界面的设计等；最后对通讯接口与上位机程序进行了详细设计，包括PLC—触摸屏—PC机的连接方式、通讯协议、以及详细的通讯代码等。
系统经调试自运行三个月以来，无论是在稳定性、可靠性方面，还是在系统的精度与效率方面都有了很大的提高，同时节约了成本，降低了操作人员的劳动强度与人身危险系数，使系统的自动化、现代化程度大大提高，本论文提出“PLC—触摸屏—PC机”的控制方式在工业自动化控制中有一定的理论研究价值意义，控制过程的具体实施有较高的参考与使用价值，在同行业中有一定的推广与应用的实际意义。
The stamping workpiece has a series of advantages with light weight, thin thickness,good rigidity and stable quality and so on. The stamping equipment has been widely used.But traditional punch control often adopts the contactor and relay control and the methodof sending material by hand, so problems exit in low efficiency, slow speed ,precision notbeing guaranteed and potential safety. Although purchasing the new equipment ofnumerical control may solve these problems, but the fund to be invested is greater, smallcompany is hard to bear. It will be a good method if we can carry out proper transformationand improvement for the original machine tool wihout changing its basic functions, whichwill not only economize fund but also make good use of original machine tool. Based onthis thought, overall transformation of the punch producing the meal box in CHANG ZHIKe Da trade company has been carried out.This paper will elaborate the process of designin detail.
The design contains two main sections: the transformation of the original controlsystem and the development of automatically sending material installation. Our designthought is to detect the location of the head of punch by using near switch, handle and feedback the collected information to PLC controler, control put material motor and feedmaterial stepping motor driving the mechanical device to work with blow valvecoordinative by PLC controler, thus complete "put material—feeds material—die—blows" movement. Then we complete corresponding parameter show and selection,movement starting and stoping and other control opration by means of the touch-screenand finally feed related information back to the central control room and monitor systemby means of personal computer.
This paper first introduces the background related to it and the meaning and source ofthis title, the definition of systematic scheme, overall composition and design thoughtand theoretical basis; then it carries out detailed design which includes tension controldesign, electrical control main circuit and supplementary circuit design, the resourceallocation of PLC controler, electrical connection, software program code, theconnected way of touch-screen, the design of control interface and etc; finally as forcommunication interface and last position machine it carries out detailed design thatincluds the connected way of "PLC—touch-screen—personal computer",communication agreement as well as detailed communication code.
Running for three months, the debugged system has got great raising not only instability and reliability but also in system's precision and efficiency, at the same time ithas economized cost, reduced the personal risk factor and labour intensity and largelyraised automatization and modernization of the system. The control way "PLC—touch-screen—personal computer" put forward in this paper has the certain theoreticalresearch value in industry and the control process has higher reference and use significanceand has certain popularization and the actual meaning of application in the field ofindustry.
设计主要包含了两方面内容：即原有控制系统的改造与自动送料装置的研制。设计思想是：利用接近开关检测冲头的位置，采集的信息经处理后馈送到PLC控制器，PLC控制器通过程序控制放料电机、喂料步进电机带动机械传动装置与吹风阀协调工作，从而完成“放料——喂料——冲模——吹风”这一系列动作，并借助于触摸屏完成相应参数的显示与选择，运动的启动、停止等控制操作，最后把相关信息再馈送到中央控制室，借助于PC机完成系统的监控。
本论文在内容安排上首先介绍了题目的来源与意义及其相关的背景；系统方案的确定、总体的组成、设计思想与理论依据等；随后对系统进行了详细设计，包括：张力控制设计、电气控制主电路与辅助电路设计、PLC控制器的资源分配、电气连接、软件程序代码的编写、触摸屏部分的连接方式、控制界面的设计等；最后对通讯接口与上位机程序进行了详细设计，包括PLC—触摸屏—PC机的连接方式、通讯协议、以及详细的通讯代码等。
系统经调试自运行三个月以来，无论是在稳定性、可靠性方面，还是在系统的精度与效率方面都有了很大的提高，同时节约了成本，降低了操作人员的劳动强度与人身危险系数，使系统的自动化、现代化程度大大提高，本论文提出“PLC—触摸屏—PC机”的控制方式在工业自动化控制中有一定的理论研究价值意义，控制过程的具体实施有较高的参考与使用价值，在同行业中有一定的推广与应用的实际意义。
The stamping workpiece has a series of advantages with light weight, thin thickness,good rigidity and stable quality and so on. The stamping equipment has been widely used.But traditional punch control often adopts the contactor and relay control and the methodof sending material by hand, so problems exit in low efficiency, slow speed ,precision notbeing guaranteed and potential safety. Although purchasing the new equipment ofnumerical control may solve these problems, but the fund to be invested is greater, smallcompany is hard to bear. It will be a good method if we can carry out proper transformationand improvement for the original machine tool wihout changing its basic functions, whichwill not only economize fund but also make good use of original machine tool. Based onthis thought, overall transformation of the punch producing the meal box in CHANG ZHIKe Da trade company has been carried out.This paper will elaborate the process of designin detail.
The design contains two main sections: the transformation of the original controlsystem and the development of automatically sending material installation. Our designthought is to detect the location of the head of punch by using near switch, handle and feedback the collected information to PLC controler, control put material motor and feedmaterial stepping motor driving the mechanical device to work with blow valvecoordinative by PLC controler, thus complete "put material—feeds material—die—blows" movement. Then we complete corresponding parameter show and selection,movement starting and stoping and other control opration by means of the touch-screenand finally feed related information back to the central control room and monitor systemby means of personal computer.
This paper first introduces the background related to it and the meaning and source ofthis title, the definition of systematic scheme, overall composition and design thoughtand theoretical basis; then it carries out detailed design which includes tension controldesign, electrical control main circuit and supplementary circuit design, the resourceallocation of PLC controler, electrical connection, software program code, theconnected way of touch-screen, the design of control interface and etc; finally as forcommunication interface and last position machine it carries out detailed design thatincluds the connected way of "PLC—touch-screen—personal computer",communication agreement as well as detailed communication code.
Running for three months, the debugged system has got great raising not only instability and reliability but also in system's precision and efficiency, at the same time ithas economized cost, reduced the personal risk factor and labour intensity and largelyraised automatization and modernization of the system. The control way "PLC—touch-screen—personal computer" put forward in this paper has the certain theoreticalresearch value in industry and the control process has higher reference and use significanceand has certain popularization and the actual meaning of application in the field ofindustry.
引文
[1] 徐刚，鲁洁，黄才元．金属板材冲压成形技术与装备的现状与发展．锻压装备与制造技术，2004，(4)：16-22．
[2] 南雷英，戚春晓，孙友松．冲压生产自动送料技术的现状与发展概况．维普资讯http://www.cqvip.com 2006．3文献综述：18-21
[3] 孙发松，张宏超．金属板材加工设备发展新动向——2004上海国际金属板材加工设备展览会．锻压技术，2004，(4)：1-4．
[4] 刘振堂．国外数控冲床的现状和发展趋势．制造技术与机床．2004，(5)：17-19
[5] 李佳特．现代CNC发展趋势．制造技术与机床．2003，(4)：5-8
[6] 江天华，刘颜辉，周英．多工位压力机电子送料技术．锻压机械2002，(3)：3-5．
[7] 宋伯生．可编程序控制器配置、编程、联网．北京：中国劳动出版社，1998．12
[8] 王春香，王永章，贾延林，黄开榜．精密张力控制系统研制中的几个问题．黑龙江自动化技术与应用，1999，(4)：20-22．
[9] 王春香，王永章，付云忠．数控缠绕机精密张力控制系统．自动化仪表，2000，21(6)：36-37．
[10] 张光荣．磁粉离合器和磁粉制动器的结构、性能及选用．机电工程技术．2004年第33卷第10期77-79
[11] 杨娅君，陈德传．传动带成型机的张力控制系统．现代机械，2002(1)：3-4
[12] 许大中．交流电机调速理论．杭州：浙江大学出版社，1991
[13] 陈伯时．电力拖动系统．北京：机械工业出版社，1995
[14] 张健民，杨华勇 交流变频调速技术在液压电梯速度控制中的应用液压与气动 1997，(5)：23-25
[15] 三菱电机株式社编许振茂译变频调速使用手册．北京：兵器工业出版社，1991
[16] 中达电通股份有限公司．VFD-M系列变频器使用手册．2005
[17] 数控网络培训中心天津分中心编．数控原理．北京：机械工业出版社，1997
[18] 严爱珍主编．数控原理与系统．机械工业出版社，1998
[19] 北京斯达特服务中心网站．http://www.sdate.com
[20] 北京斯达特股份有限公司．MS-3H130M步进电机驱动器使用手册．2006
[21] 孙平．可编程控制器原理及应用．北京：高等教育出版社，2002
[22] MITSUBISHI ELECTRIC CORPORATION. FX1S. FX2N Series Programmable ControllersHardware Manual. 1999
[23] 刘敏．可编程控制技术．北京：机械工业出版社，2001
[24] 台方．可编程控制器应用教程．北京：中国水利出版社，2001
[25] MITSUBISHI FXlS可编程控制器使用手册
[26] MITSUBISHI ELECTRIC CORPORATION. FX Series Programmable Controllers Programming Manual. 2000
[27] EasyBui lder500编程使用手册
[28] 朱宁．触摸屏在机床PLC控制系统中的应用．机床电器．2001(6)：17-18
[29] 王立风．触摸屏技术及应用．电子工业专业设备．2005．6．63-65
[30] 赖诚．触摸屏原理及在单片机系统的应用．商业研究．2006年6月总第471期32-33
[31] 衣晓燕，王晓英．触摸屏应用系统的设计与实现．中国当代医学．2004．10 3卷11期43-44
[32] 栾开明．触摸屏在机床控制系统中的应用．哈尔滨轴承．2005年9月．第26卷第3期．37-38
[33] 邢立娟，扬世忠．触摸屏的性能及应用．今日电子．2006．7．71-73
[34] eView MT500系列触摸屏使用手册
[35] EasyManager软件使用手册
[36] 韩志超，桑斌修．PLC与触摸屏通讯的实现和应用．维普资讯http://www.cqvip.com.2006.4 53-55
[37] 邱公伟、杨富文等．可编程序控制器网络通信及运用．北京：清华大学出版社．2000．3
[38] 范逸之．VISUAL BASIC与RS232串行通讯控制．北京：中国青年出版社．2001．7
[39] 李现勇．VISUAL BASIC串口通信技术与工程实践．北京：人民邮电出版社．2002．5
[40] Jan Axelsan-Serial Port Complete Programming and Circuits for RS232 and RS485 Links and Networks. Hardly Publish Company. 2001.5
[41] MITSUBISHI ELECTRIC CORPORATION. Programming Peripheral Support for FX2N, FX2NC, FXIN, FXIS Supplementary Manual. 2001
[42] MITSUBISHI ELECTRIC CORPORATION. FX-485PC-IF RS485 Interface Unit HardwareManual. 1999
[43] MITSUBISHI ELECTRIC CORPORATION. FX1S-232-BD COMMUNICATION BOARDUSER' S GUIDE. 2000
[44] MITSUBISHI ELECTRIC CORPORATION. FX communication (RS-232C, RS485) user's Manual. 2000
[45] Richard C. LeineckerG. 0 Bible. Prentice Hall Publish Company. 2001. 8
[46] 李长林．Visual BASIC串口通讯技术与典型实例．北京：清华大学出版社．2006
[47] 吴昊．工业微机与可编程序控制器的实时通信．电气传动．1997．5．23-25
[48] 李德华等．用VISUAL BASIC语言实现三菱可编程序控制器与计算机的通信．电子技术运用．1996．6．33-34
[49] David Bennete. Visual BASICG. 0. Indurstry Publish Company, 1998.9
[50] 张云生．实时控制系统软件设计原理及运用．北京：国防工业出版社．2001．7
[2] 南雷英，戚春晓，孙友松．冲压生产自动送料技术的现状与发展概况．维普资讯http://www.cqvip.com 2006．3文献综述：18-21
[3] 孙发松，张宏超．金属板材加工设备发展新动向——2004上海国际金属板材加工设备展览会．锻压技术，2004，(4)：1-4．
[4] 刘振堂．国外数控冲床的现状和发展趋势．制造技术与机床．2004，(5)：17-19
[5] 李佳特．现代CNC发展趋势．制造技术与机床．2003，(4)：5-8
[6] 江天华，刘颜辉，周英．多工位压力机电子送料技术．锻压机械2002，(3)：3-5．
[7] 宋伯生．可编程序控制器配置、编程、联网．北京：中国劳动出版社，1998．12
[8] 王春香，王永章，贾延林，黄开榜．精密张力控制系统研制中的几个问题．黑龙江自动化技术与应用，1999，(4)：20-22．
[9] 王春香，王永章，付云忠．数控缠绕机精密张力控制系统．自动化仪表，2000，21(6)：36-37．
[10] 张光荣．磁粉离合器和磁粉制动器的结构、性能及选用．机电工程技术．2004年第33卷第10期77-79
[11] 杨娅君，陈德传．传动带成型机的张力控制系统．现代机械，2002(1)：3-4
[12] 许大中．交流电机调速理论．杭州：浙江大学出版社，1991
[13] 陈伯时．电力拖动系统．北京：机械工业出版社，1995
[14] 张健民，杨华勇 交流变频调速技术在液压电梯速度控制中的应用液压与气动 1997，(5)：23-25
[15] 三菱电机株式社编许振茂译变频调速使用手册．北京：兵器工业出版社，1991
[16] 中达电通股份有限公司．VFD-M系列变频器使用手册．2005
[17] 数控网络培训中心天津分中心编．数控原理．北京：机械工业出版社，1997
[18] 严爱珍主编．数控原理与系统．机械工业出版社，1998
[19] 北京斯达特服务中心网站．http://www.sdate.com
[20] 北京斯达特股份有限公司．MS-3H130M步进电机驱动器使用手册．2006
[21] 孙平．可编程控制器原理及应用．北京：高等教育出版社，2002
[22] MITSUBISHI ELECTRIC CORPORATION. FX1S. FX2N Series Programmable ControllersHardware Manual. 1999
[23] 刘敏．可编程控制技术．北京：机械工业出版社，2001
[24] 台方．可编程控制器应用教程．北京：中国水利出版社，2001
[25] MITSUBISHI FXlS可编程控制器使用手册
[26] MITSUBISHI ELECTRIC CORPORATION. FX Series Programmable Controllers Programming Manual. 2000
[27] EasyBui lder500编程使用手册
[28] 朱宁．触摸屏在机床PLC控制系统中的应用．机床电器．2001(6)：17-18
[29] 王立风．触摸屏技术及应用．电子工业专业设备．2005．6．63-65
[30] 赖诚．触摸屏原理及在单片机系统的应用．商业研究．2006年6月总第471期32-33
[31] 衣晓燕，王晓英．触摸屏应用系统的设计与实现．中国当代医学．2004．10 3卷11期43-44
[32] 栾开明．触摸屏在机床控制系统中的应用．哈尔滨轴承．2005年9月．第26卷第3期．37-38
[33] 邢立娟，扬世忠．触摸屏的性能及应用．今日电子．2006．7．71-73
[34] eView MT500系列触摸屏使用手册
[35] EasyManager软件使用手册
[36] 韩志超，桑斌修．PLC与触摸屏通讯的实现和应用．维普资讯http://www.cqvip.com.2006.4 53-55
[37] 邱公伟、杨富文等．可编程序控制器网络通信及运用．北京：清华大学出版社．2000．3
[38] 范逸之．VISUAL BASIC与RS232串行通讯控制．北京：中国青年出版社．2001．7
[39] 李现勇．VISUAL BASIC串口通信技术与工程实践．北京：人民邮电出版社．2002．5
[40] Jan Axelsan-Serial Port Complete Programming and Circuits for RS232 and RS485 Links and Networks. Hardly Publish Company. 2001.5
[41] MITSUBISHI ELECTRIC CORPORATION. Programming Peripheral Support for FX2N, FX2NC, FXIN, FXIS Supplementary Manual. 2001
[42] MITSUBISHI ELECTRIC CORPORATION. FX-485PC-IF RS485 Interface Unit HardwareManual. 1999
[43] MITSUBISHI ELECTRIC CORPORATION. FX1S-232-BD COMMUNICATION BOARDUSER' S GUIDE. 2000
[44] MITSUBISHI ELECTRIC CORPORATION. FX communication (RS-232C, RS485) user's Manual. 2000
[45] Richard C. LeineckerG. 0 Bible. Prentice Hall Publish Company. 2001. 8
[46] 李长林．Visual BASIC串口通讯技术与典型实例．北京：清华大学出版社．2006
[47] 吴昊．工业微机与可编程序控制器的实时通信．电气传动．1997．5．23-25
[48] 李德华等．用VISUAL BASIC语言实现三菱可编程序控制器与计算机的通信．电子技术运用．1996．6．33-34
[49] David Bennete. Visual BASICG. 0. Indurstry Publish Company, 1998.9
[50] 张云生．实时控制系统软件设计原理及运用．北京：国防工业出版社．2001．7