数控钢筋矫直切断机的数控系统研究与在线检测
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摘要
GTK6/12数控冷轧带肋钢筋矫直切断机是燕山大学的一项科研成果，在国内首次采用数控技术进行钢筋自动定尺切断，可以自动设定加工根数、计算重量、显示故障和待料停机，实现了高性能柔性制造。但是切断钢筋时常存在超差现象，严重影响该机型的实用化，为此立项提高剪切精度问题。本课题从分析剪切误差原因着手，采用理论计算和科学测试相结合的方法进行研究。
论文首先运用电气知识，阐述了该机型所使用的数控元件工作原理，计算出执行系统各组成部分的动作时间。
其次，运用动力学基本理论对数控剪切机构系统运动周期进行了计算分析，得出数控剪切系统的理论周期；推导出曲柄滑块剪切机构的剪切时间和钢筋运行速度的关系式；推导出剪切钢筋的长度误差方程。
为了测试产生误差各环节所占的比例，本文提出单片机在线检测方法，对数控系统进行全面测试，主要针对光电编码器、电磁换向阀、接近开关的输出脉冲定时计数。本课题采用AC4162集成的可编程计数定时器实现在线检测，同时在定时器精度方面进行深入的研究，解决了高速信号实时检测难题。
最后结合理论计算分析和测试结果确定出误差原因，提出了有效的改进方案，获得良好的成效，GTK6/12数控冷轧带肋钢筋矫直切断机将投入批量生产，具备很好的市场前景。
GTK6/12 numerical control cold-rolled ribbed bars straightening and cutting machine is a scientific research production of YanShan University. For the first time in China, numerical control technology is imported on this kind of device to achieve high-powered flexible manufacture. Automatic length-fixing and cutting can be realized. Machining quantity, weight calculation, display failure and material waiting can be automatically set up. Whereas, error exists frequently when bars are cutted and badly affected putting the product into practice. Therefore the aim of this dissertation is to minish the error. We begin with what causes the error. Theory calculation and scientific inspection are used to do the research.
Firstly, numerical control components are explained with electric knowledge. The working time of every part of executive system is calculated.
Secondly, utilizing the basis theory of dynamics, the system periods is analyzed and theoretic periods is obtained. The cutting time of crank-block outfit and the relation formula are deduced. Error equation is acquired.
To test the proportion between each factor of reason for error, the method of SCM(single chip micyoco) inspection online is put forward creatively. The numerical control system is tested comprehensively, mainly aiming at the output pulse count of photoelectric coder, electromagnetism valve and contacting switch. In this work we adopt AC4162 integrated programmable count timer. Meanwhile further research is made on timer precision. This difficult problem is solved effectively.
At last, on the basis of theory calculation and inspection result, the reason for error is confirmed. A optimization theme is designed and take good effect.The GTK6/12 numerical control cold-rolled ribbed bars straightening
and cutting machine will be manufactured and has excellent market prospect.
论文首先运用电气知识，阐述了该机型所使用的数控元件工作原理，计算出执行系统各组成部分的动作时间。
其次，运用动力学基本理论对数控剪切机构系统运动周期进行了计算分析，得出数控剪切系统的理论周期；推导出曲柄滑块剪切机构的剪切时间和钢筋运行速度的关系式；推导出剪切钢筋的长度误差方程。
为了测试产生误差各环节所占的比例，本文提出单片机在线检测方法，对数控系统进行全面测试，主要针对光电编码器、电磁换向阀、接近开关的输出脉冲定时计数。本课题采用AC4162集成的可编程计数定时器实现在线检测，同时在定时器精度方面进行深入的研究，解决了高速信号实时检测难题。
最后结合理论计算分析和测试结果确定出误差原因，提出了有效的改进方案，获得良好的成效，GTK6/12数控冷轧带肋钢筋矫直切断机将投入批量生产，具备很好的市场前景。
GTK6/12 numerical control cold-rolled ribbed bars straightening and cutting machine is a scientific research production of YanShan University. For the first time in China, numerical control technology is imported on this kind of device to achieve high-powered flexible manufacture. Automatic length-fixing and cutting can be realized. Machining quantity, weight calculation, display failure and material waiting can be automatically set up. Whereas, error exists frequently when bars are cutted and badly affected putting the product into practice. Therefore the aim of this dissertation is to minish the error. We begin with what causes the error. Theory calculation and scientific inspection are used to do the research.
Firstly, numerical control components are explained with electric knowledge. The working time of every part of executive system is calculated.
Secondly, utilizing the basis theory of dynamics, the system periods is analyzed and theoretic periods is obtained. The cutting time of crank-block outfit and the relation formula are deduced. Error equation is acquired.
To test the proportion between each factor of reason for error, the method of SCM(single chip micyoco) inspection online is put forward creatively. The numerical control system is tested comprehensively, mainly aiming at the output pulse count of photoelectric coder, electromagnetism valve and contacting switch. In this work we adopt AC4162 integrated programmable count timer. Meanwhile further research is made on timer precision. This difficult problem is solved effectively.
At last, on the basis of theory calculation and inspection result, the reason for error is confirmed. A optimization theme is designed and take good effect.The GTK6/12 numerical control cold-rolled ribbed bars straightening
and cutting machine will be manufactured and has excellent market prospect.
引文
1. 金贺荣.数控冷轧带肋钢筋矫直切断机的系统研究及设计.[燕山大学工学硕士论文].2001:52-91
2. 孟进礼,卫青珍.对钢筋切断机发展的几点看法.建筑机械,2000, (2):14-15
3. 李英波,邓莉辉,冯正进.高速自动校直切断机控制系统设计.机电工程,2000，17(2):33-35
4. 胡正隆.高精度板材管材矫直机.机床与液压,2001, (1):67
5. 秀平.板材生产用新型矫直机.钢铁,2000, (9):26
6. 周红,杨宵.矫直机辊缝自动调整计算机集成控制系统设计.冶金自动化,2000, (4):18
7. 王平,张强.钢筋调直切断机剪切机构的分析与研究.建筑机械,1999, (12):56
8. 焦振学.微机数控技术.北京:北京理工大学出版社,2000:9-29
9. 王爱玲.现代数控原理及控制系统.北京:国防工业出版社,2002:1-9
10. 白恩远.现代数控机床伺服及检测技术.北京: 国防工业出版社,2002:5-20
11. Warren S.seanes.Computer Numberical Control.Delmar Publishing Inc.1986:20-34
12. Yoram Koren.Computer Control of Manufacturing System.NewYork.McGraw-Hill.1983:
12-46
13. 任玉田,焦振学,王宏甫.机床计算机数控技术.北京:北京理工大学出版社,1996:1-10
14. 邵俊鹏,董玉红.机床数控技术.哈尔滨:哈尔滨工业大学出版社,1996:4-36
15. G.E.Thyer.Computer Numerical Control of Machine Tools.Industrical Press Inc.1998:2-23
16. 16 TK. KUNRA,PN. RAO,N. K. TEWARI.Numerical Control and Computer Aided Manufacturing.Tata McTraw-Hill Publishing Company Limited.1985:1-20
17. Joseph Pusztai.Computer Numerical Control Programming.Prentice Hall Inc.1990:1-15
18. 弭洪涛.可编程序控制器(PLC)原理及应用.北京:中国水利水电出版社,1999:1-51
19. 徐德.可编程序控制器(PLC)应用技术.济南:山东科学技术出版社,2000:178-260
20. 周军.电气控制及PLC.北京:机械工业出版社,2001:90-100
21. 胡学林,宋宏.电气控制与PLC.北京:冶金工业出版社,1997:115-136
22. 彭利标.可编程控制器原理及应用.西安:西安电子科技大学出版社,1999:1-20
23. 齐蓉.最新可编程控制器教程.西安:西北工业大学出版社,2000:1-7
24. 钟肇新,彭侃.可编程控制器原理及应用(第二版).广州:华南理工大学出版社,1999:10-42
25 陈立定,吴玉香.电气控制与可编程控制器.广州:华南理工大学出版社,2001:151-167
26 刘敏.可编程控制器技术.北京:机械工业出版社,2001: 1-265
27 王兆义.可编程控制器教程.北京:机械工业出版社,1993:10-43
28 邱公伟.可编程控制器网络通信及应用.北京:清华大学出版社,2000:223-273
29 SIMATIC S7-200 Application tips.Siemens.1998:1-70
30 SIMATIC STEP7-Micro Programming Reference Manual.Siemens.1999:1-90
31 SIMATIC Components for totally Integrated Automation.Siemens.1999:1-77
32 钟肇新.可编程控制器入门教程(STMATIC S7-200) .广州:华南理工大学出版社,2000:
1-147
33 SMC(中国)有限公司.现代气动实用技术.北京:机械工业出版社,1998
34 何德誉.曲柄压力机.北京:机械工业出版社,1987:10-16
35 李宝忠.加工中心的误差补偿研究.[北京工业大学硕士论文].2000:16-48
36 卢绍青.数控机床通用误差补偿技术研究.[北京工业大学硕士论文].2001:68-80
37 邢统坤. 机械零件三维造型技术及整体设计中的信息集成技术.[北京工业大学硕士论文].2001:20-48
38 马春敏.数控机床主结构设计技术及结构修改技术的研究.[北京工业大学硕士论文].2000:5-12
39 Ni.Jun.CNC machine accuracy enhancement through real-time error compensation.Journal of Manufacturing Science and Engineering,Transactions of the ASME.1997,119(4): 717-725
40 Lee Hyun C,Jeon Gi J. Real-time compensation of two-dimensional contour error in CNC machine tools.IEEE/ASME International Conference on Advanced Intelligent Mechatronics.1999:623-628
41 Hong Maisheng;Su Heng;Li Zijun.Error motion diagnosis of NC machine tools,comment and countermeasure.Chinese Journal of Mechanical Engineering.2002, 38(2):90-94
42 Yun Jintian,Wang Shuxin,Liu Libing.Study on new method of identifying geometric error parameters for NC machine tools.Chinese Journal of Mechanical Engineering (English Edition).2001,14(3):198-202
Qiu Hua,Li Yanbin,Li Yan.A new method and device for motion accuracy measurement of NC machine tools.Part 2:Device error identification and trajectory measurement of
43 general planar motions.International Journal of Machine Tools and Manufacture.2001,41(4):535-554
44 Yuan. Z, Huang. J.Research on cutting error compensation of numerical control pipe-cuttingmachine. Journal of Wuhan University of Technology. 2001:64-66
45 Ahman,Mahbubur,Heikkala,Jouko.Modeling measurement and error compensation of multi-axis machine tools.International Journal of Machine Tools and Manufacture.2000, 40(10):1535-1546
46 Mou J, Liu C.R.Robust error correction method for multi-axis machines.American Society of Mechanical Engineers.1994,55(2):1011-1018
47 Glossinger M.Shedding light on accuracy.Cutting Tool Engineering.2001,53(12):51-53
48 Lin Shen-Wang,Chen Cha'o-Kuang.Study on precision problems of using a ball plate to calibrate coordinate system.Journal of the Chinese Society of Mechanical Engineers.2000,21(2):155-161
49 Mahbubur R Md,Heikkala J,Lappalainen,K.Positioning accuracy improvement in five-axis milling by post processing.International Journal of Machine Tools &Manufacture.1997,37(2):223-236
50 Xu H-Y, Tam H-Y, Zhou Z.Variable feedrate CNC interpolation for planar implicit curves. International Journal of Advanced Manufacturing Technology.2001,18(11):794-800
51 刘星.微机原理与接口技术.北京:电子工业出版社,2002:140-148
52 中国机械工业教育协会组.微机原理与接口技术.北京:机械工业出版社,2001:139-148
53 李国伟.微机原理及在机械控制中的应用.哈尔滨:哈尔滨工业大学出版社, 1997:211-220
54 邹逢兴.微型计算机硬件技术及应用基础.北京:国防科技大学出版社,1997:230-235
55 张伟.单片机原理及应用.北京:机械工业出版社,2002:88-110
56 陆延丰,常清璞.三菱3850系列单片机原理和应用.北京:北京航空航天大学出版社,2000:155-202
57 Charlie Calvert etal.Borland C++ Builder 应用开发大全.北京:清华大学出版社,1999:1-106
58 Kent Reisdorph.C++ Builder 4技术内幕.北京:人民邮电出版社,2000:1-152
59 李科杰.新编传感器技术手册.北京:国防工业出版社,2002:784-800
60 杨宝清.现代传感器技术基础.北京:中国铁道出版社,2001:110-111
2. 孟进礼,卫青珍.对钢筋切断机发展的几点看法.建筑机械,2000, (2):14-15
3. 李英波,邓莉辉,冯正进.高速自动校直切断机控制系统设计.机电工程,2000，17(2):33-35
4. 胡正隆.高精度板材管材矫直机.机床与液压,2001, (1):67
5. 秀平.板材生产用新型矫直机.钢铁,2000, (9):26
6. 周红,杨宵.矫直机辊缝自动调整计算机集成控制系统设计.冶金自动化,2000, (4):18
7. 王平,张强.钢筋调直切断机剪切机构的分析与研究.建筑机械,1999, (12):56
8. 焦振学.微机数控技术.北京:北京理工大学出版社,2000:9-29
9. 王爱玲.现代数控原理及控制系统.北京:国防工业出版社,2002:1-9
10. 白恩远.现代数控机床伺服及检测技术.北京: 国防工业出版社,2002:5-20
11. Warren S.seanes.Computer Numberical Control.Delmar Publishing Inc.1986:20-34
12. Yoram Koren.Computer Control of Manufacturing System.NewYork.McGraw-Hill.1983:
12-46
13. 任玉田,焦振学,王宏甫.机床计算机数控技术.北京:北京理工大学出版社,1996:1-10
14. 邵俊鹏,董玉红.机床数控技术.哈尔滨:哈尔滨工业大学出版社,1996:4-36
15. G.E.Thyer.Computer Numerical Control of Machine Tools.Industrical Press Inc.1998:2-23
16. 16 TK. KUNRA,PN. RAO,N. K. TEWARI.Numerical Control and Computer Aided Manufacturing.Tata McTraw-Hill Publishing Company Limited.1985:1-20
17. Joseph Pusztai.Computer Numerical Control Programming.Prentice Hall Inc.1990:1-15
18. 弭洪涛.可编程序控制器(PLC)原理及应用.北京:中国水利水电出版社,1999:1-51
19. 徐德.可编程序控制器(PLC)应用技术.济南:山东科学技术出版社,2000:178-260
20. 周军.电气控制及PLC.北京:机械工业出版社,2001:90-100
21. 胡学林,宋宏.电气控制与PLC.北京:冶金工业出版社,1997:115-136
22. 彭利标.可编程控制器原理及应用.西安:西安电子科技大学出版社,1999:1-20
23. 齐蓉.最新可编程控制器教程.西安:西北工业大学出版社,2000:1-7
24. 钟肇新,彭侃.可编程控制器原理及应用(第二版).广州:华南理工大学出版社,1999:10-42
25 陈立定,吴玉香.电气控制与可编程控制器.广州:华南理工大学出版社,2001:151-167
26 刘敏.可编程控制器技术.北京:机械工业出版社,2001: 1-265
27 王兆义.可编程控制器教程.北京:机械工业出版社,1993:10-43
28 邱公伟.可编程控制器网络通信及应用.北京:清华大学出版社,2000:223-273
29 SIMATIC S7-200 Application tips.Siemens.1998:1-70
30 SIMATIC STEP7-Micro Programming Reference Manual.Siemens.1999:1-90
31 SIMATIC Components for totally Integrated Automation.Siemens.1999:1-77
32 钟肇新.可编程控制器入门教程(STMATIC S7-200) .广州:华南理工大学出版社,2000:
1-147
33 SMC(中国)有限公司.现代气动实用技术.北京:机械工业出版社,1998
34 何德誉.曲柄压力机.北京:机械工业出版社,1987:10-16
35 李宝忠.加工中心的误差补偿研究.[北京工业大学硕士论文].2000:16-48
36 卢绍青.数控机床通用误差补偿技术研究.[北京工业大学硕士论文].2001:68-80
37 邢统坤. 机械零件三维造型技术及整体设计中的信息集成技术.[北京工业大学硕士论文].2001:20-48
38 马春敏.数控机床主结构设计技术及结构修改技术的研究.[北京工业大学硕士论文].2000:5-12
39 Ni.Jun.CNC machine accuracy enhancement through real-time error compensation.Journal of Manufacturing Science and Engineering,Transactions of the ASME.1997,119(4): 717-725
40 Lee Hyun C,Jeon Gi J. Real-time compensation of two-dimensional contour error in CNC machine tools.IEEE/ASME International Conference on Advanced Intelligent Mechatronics.1999:623-628
41 Hong Maisheng;Su Heng;Li Zijun.Error motion diagnosis of NC machine tools,comment and countermeasure.Chinese Journal of Mechanical Engineering.2002, 38(2):90-94
42 Yun Jintian,Wang Shuxin,Liu Libing.Study on new method of identifying geometric error parameters for NC machine tools.Chinese Journal of Mechanical Engineering (English Edition).2001,14(3):198-202
Qiu Hua,Li Yanbin,Li Yan.A new method and device for motion accuracy measurement of NC machine tools.Part 2:Device error identification and trajectory measurement of
43 general planar motions.International Journal of Machine Tools and Manufacture.2001,41(4):535-554
44 Yuan. Z, Huang. J.Research on cutting error compensation of numerical control pipe-cuttingmachine. Journal of Wuhan University of Technology. 2001:64-66
45 Ahman,Mahbubur,Heikkala,Jouko.Modeling measurement and error compensation of multi-axis machine tools.International Journal of Machine Tools and Manufacture.2000, 40(10):1535-1546
46 Mou J, Liu C.R.Robust error correction method for multi-axis machines.American Society of Mechanical Engineers.1994,55(2):1011-1018
47 Glossinger M.Shedding light on accuracy.Cutting Tool Engineering.2001,53(12):51-53
48 Lin Shen-Wang,Chen Cha'o-Kuang.Study on precision problems of using a ball plate to calibrate coordinate system.Journal of the Chinese Society of Mechanical Engineers.2000,21(2):155-161
49 Mahbubur R Md,Heikkala J,Lappalainen,K.Positioning accuracy improvement in five-axis milling by post processing.International Journal of Machine Tools &Manufacture.1997,37(2):223-236
50 Xu H-Y, Tam H-Y, Zhou Z.Variable feedrate CNC interpolation for planar implicit curves. International Journal of Advanced Manufacturing Technology.2001,18(11):794-800
51 刘星.微机原理与接口技术.北京:电子工业出版社,2002:140-148
52 中国机械工业教育协会组.微机原理与接口技术.北京:机械工业出版社,2001:139-148
53 李国伟.微机原理及在机械控制中的应用.哈尔滨:哈尔滨工业大学出版社, 1997:211-220
54 邹逢兴.微型计算机硬件技术及应用基础.北京:国防科技大学出版社,1997:230-235
55 张伟.单片机原理及应用.北京:机械工业出版社,2002:88-110
56 陆延丰,常清璞.三菱3850系列单片机原理和应用.北京:北京航空航天大学出版社,2000:155-202
57 Charlie Calvert etal.Borland C++ Builder 应用开发大全.北京:清华大学出版社,1999:1-106
58 Kent Reisdorph.C++ Builder 4技术内幕.北京:人民邮电出版社,2000:1-152
59 李科杰.新编传感器技术手册.北京:国防工业出版社,2002:784-800
60 杨宝清.现代传感器技术基础.北京:中国铁道出版社,2001:110-111