基于PLC控制技术的渐开线齿轮加工系统设计研究
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摘要
本文针对渐开线齿轮加工特点,设计出一种新型的具有较高精度、较高效率和较高经济性的渐开线齿轮加工系统,能够用来加工较多模数的渐开线齿轮。本系统采用了以可编程逻控制器(PLC)为核心的数字控制技术,对渐开线齿轮加工时圆周进给和径向进给进行了精确的数字控制。采用控制面板上的按钮可以对渐开线齿轮加工机床进行调整,加工时,通过设计的人机界面来输入加工数据,给出渐开线齿轮加工的各种操作命令。渐开线齿轮加工机床控制上采用可编程控制器,使系统的动力驱动比普通机床得到很大的简化,减少了齿轮加工系统的传动链误差,提高了系统的可靠性和有效的降低了加工成本,特别适合目前许多渐开线齿轮加工现场加工要求。
本文在齿轮的啮合原理和包络原理的基础上对渐开线齿轮的加工原理进行了分析,运用包络法对渐开线齿轮齿廓进行数学建模,求出了渐开线齿轮齿廓加工参数方程,为渐开线齿轮加工控制系统设计编程提供了数据计算的依据。对渐开线齿轮加工系统的运动进行了分析,紧紧围绕渐开线齿轮加工的发展趋势,设计了适合渐开线齿轮加工的基于可编程控制器(PLC)的数字控制系统,并对数控系统的硬件和软件系统做了详细的设计。根据渐开线齿轮的加工特点,对渐开线齿轮加工系统的加工工艺进行了深入的探讨。结合机床加工生产实际,探讨了PLC控制系统抗干扰性,对PLC控制系统的硬、软件系统进行了抗干扰设计,采取多种途径提高系统抗干扰性,确保设备的正常运转。对系统调试和故障诊断技术进行了详细的分析,给出了PLC控制系统调试和故障诊断的应对策略。
The paper developed a novel system to process the involute gears with high efficiency, high precision and high economy in allusion to the character of involute gears processing. The system was available to process the involute gears in different modulus. Using the numeric control technique with the programmable logic controller (PLC) as the core of the technique, we could achieve the precise numeric control of the rotary feed and the radial feed of the involute gears machine tool. We could adjust the machine tool using the buttons on the control panel. In the processing, we used the human-computer interface to input the processing data and send the operating commands. Using PLC in numeric control system of the involute gears machine tool can reduce the errors from the drive chains of the machine tool. PLC improved the reliability and reduced the cost the processing. It especially fit the demands from the involute gears processing fieldwork.
In this paper, we analyzed the processing principle of the involute gears based on mesh principle and the enveloping principle. We developed the mathematical modeling of the tooth shape of the involute gears and proposed the parameter equation of the tooth processing of the involute gears. The analyzed and the equation gave us the data calculation rule in compiling the program of the control system for the involute gears processing system. We analyzed the movement of the involute gears processing system, designed the mechanical construction of the numerical controlled system suitable on processing the involute gears firmly enclosed the involute gears processing tendency. And then we designed the detail hardware and software system of the numerical control system. We deeply discussed the processing techniques of the involute gears processing system on the basis of the characteristic of the involute gear processing. According the working condition of the machine tool, we developed the anti-interference technique and designed the hardware and software anti-interference system of the PLC control system, all these works assured the normal operation of the involute gear process system.At last, we analyzed the details of the technology of debugging and fault diagnosis and gave out the debugging and fault diagnosis strategy of the PLC control system.
本文在齿轮的啮合原理和包络原理的基础上对渐开线齿轮的加工原理进行了分析,运用包络法对渐开线齿轮齿廓进行数学建模,求出了渐开线齿轮齿廓加工参数方程,为渐开线齿轮加工控制系统设计编程提供了数据计算的依据。对渐开线齿轮加工系统的运动进行了分析,紧紧围绕渐开线齿轮加工的发展趋势,设计了适合渐开线齿轮加工的基于可编程控制器(PLC)的数字控制系统,并对数控系统的硬件和软件系统做了详细的设计。根据渐开线齿轮的加工特点,对渐开线齿轮加工系统的加工工艺进行了深入的探讨。结合机床加工生产实际,探讨了PLC控制系统抗干扰性,对PLC控制系统的硬、软件系统进行了抗干扰设计,采取多种途径提高系统抗干扰性,确保设备的正常运转。对系统调试和故障诊断技术进行了详细的分析,给出了PLC控制系统调试和故障诊断的应对策略。
The paper developed a novel system to process the involute gears with high efficiency, high precision and high economy in allusion to the character of involute gears processing. The system was available to process the involute gears in different modulus. Using the numeric control technique with the programmable logic controller (PLC) as the core of the technique, we could achieve the precise numeric control of the rotary feed and the radial feed of the involute gears machine tool. We could adjust the machine tool using the buttons on the control panel. In the processing, we used the human-computer interface to input the processing data and send the operating commands. Using PLC in numeric control system of the involute gears machine tool can reduce the errors from the drive chains of the machine tool. PLC improved the reliability and reduced the cost the processing. It especially fit the demands from the involute gears processing fieldwork.
In this paper, we analyzed the processing principle of the involute gears based on mesh principle and the enveloping principle. We developed the mathematical modeling of the tooth shape of the involute gears and proposed the parameter equation of the tooth processing of the involute gears. The analyzed and the equation gave us the data calculation rule in compiling the program of the control system for the involute gears processing system. We analyzed the movement of the involute gears processing system, designed the mechanical construction of the numerical controlled system suitable on processing the involute gears firmly enclosed the involute gears processing tendency. And then we designed the detail hardware and software system of the numerical control system. We deeply discussed the processing techniques of the involute gears processing system on the basis of the characteristic of the involute gear processing. According the working condition of the machine tool, we developed the anti-interference technique and designed the hardware and software anti-interference system of the PLC control system, all these works assured the normal operation of the involute gear process system.At last, we analyzed the details of the technology of debugging and fault diagnosis and gave out the debugging and fault diagnosis strategy of the PLC control system.
引文
[1]李树生,机械原理[M],沈阳:东北大学出版社,2000
[2]安子军,机械原理教程[M],北京:机械工业出版社,2003
[3]国家机械工业委员会,初级齿轮工工艺学[M],北京:机械工业出版社,1988
[4]齿轮手册编写委员会,齿轮手册[M],北京:机械工业出版社,1990
[5] John Parker, Mechanical Manufacturing Technology in the 21stCentury, The Proceedings of the First International Conference on Mechanical Engineering, November 2000, China
[6]陈厚军,蒙日曲面共轭原理与环面蜗杆珠轮传动技术的研究[D] ,大连:大连理工大学,2009
[7]刘舸,圆柱蜗杆斜齿轮传动的理论分析及实验研究[D] ,重庆:重庆大学,2004
[8]孙桓,机械原理[M],北京:高等教育出版社,2000
[9] Matsuo T,El-Antably A,Lipo T A,A new control strategy for optimum-efficiency operation of a synchronous reluctance motor[J],Industry Applications,IEEE Transactions on,1997,3(5)1146～1153
[10] Syh-Shiuh Yeh,Pau-Lo Hsu,Analysis and design of integrated control for multi-axis motion systems[J],Control Systems Technology,IEEE Transactions on,2003,11(3):375～382.
[11] Chiu George T-C,Tomizuka Masayoshi,Coordinated position control of multi-axis mechanical systems[J],Journal of Dynamic Systems Measurement&Control,1998,120(3):389～393
[12]王君明,基于PLC的数控齿条插齿机的研究[D],武汉:华中科技大学,2004
[13]吴晓玲,袁丽娟,徐万里,中国齿轮传动的历史与进展[J],机械传动,2004,(5):62~64
[14]李洪友,周锦进,庞桂兵,齿轮光整加工工艺及其新进展[J],起重运输机械, 2003,(3):1~3
[15]商向东,齿轮加工精度[M],北京:机械工业出版社,2000
[16]江甫炎,近代齿轮制造工艺[M],北京:航空工业出版社,1994
[17]陈伯时,电气控制技术及其发展展望[M],电气传动,1987,(1):1～6
[18]孟庆金,常景荣,PLC在齿轮淬火机中的应用[J],山东冶金,1997,(5):25~27
[19]黄群辉,朱志红,李作清,YKS5120插齿机数控系统技术的研究[J],机械与电子,1998,(3):35～37
[20]郑胜利,傅素芳,PLC在齿轮加工机床电气控制方面的应用[J],平原大学学报,2004,(3):42~43
[21]冯清秀,贾品瑜,汤漾平等,基于PLC的开式齿轮润滑控制系统[J],机电一体化,2004,(1):57~59
[22]陈伟卓,PLC在齿轮专用机床改造中的运用[J],机械工程师,2009,(8):11~12
[23]鲁远栋,PLC机电控制系统应用设计技术[J],北京:电子工业出版社,2006
[24]齐从谦,王士兰,PLC技术及应用[M],北京:机械工业出版社,2000
[25]李建成,浅析科技型中小企业的信息化[J],CAD/CAM与制造业信息化,2005,(6)
[26]袁哲俊,金属切削刀具(第二版)[M],上海:上海科学技术出版社,1993
[27]张展,渐开线内啮合圆柱齿轮传动[M],北京:国防工业出版社,1991
[28]朱景梓,渐开线外啮合圆柱齿轮传动[M],北京:国防工业出版社,1990
[29]李华敏,韩元莹,王知行编著,渐开线齿轮的几何原理与计算[M],北京:机械工业出版社,1986
[30] Parey, A; Tandon, N. Impact velocity modelling and signal processing of spur gear vibration for the estimation of defect size. Mechanical System and signal processing, 2007, 21(1): 234~243
[31] Karpuschewski, B; Knoche, HJ; Hipke, M. Gear finishing by abrasive processes, Cirp Annals-Manufacturing Technology, 2008, 57(2): 621-640
[32] Eastwick, CN; Johnson, G. Gear windage: A review. Journal of Mechanical Design, 2008, 130(3): 34~40
[33]王明侗,渐开线齿轮精度[M],北京:机械工业出版社,1983
[34] Chen C-K,Yang S-C.Geometric Modelling for Cylindrical and Helical Gear Pumpswith Circular Arc Teeth.Journal of Mechanical Engineering Science, 2000, 214(4):599-607
[35] Chen Chien-Fa,Tsay Chung-Biau.Computerized tooth profile generation and analysis of characteristics of elliptical gears with circular-arc teeth. Journal of Materials Processing Technology, 2004,148(2):226-234
[36]潘存云,温喜森,渐开线环形齿球齿轮传动原理与运动分析,机械工程学报,2005,(5):65~67
[37] Li G X. Computer simulation on quasi-ellpsoidal gear transmission .Journal of Harbin Institute of Technology, 1995, 2(4):42-45
[38]冯显英,王清,艾兴,齿轮加工成形的运动学分析[J],山东工业大学学报,2000,(2):101~106
[39]李海京,齿轮加工的图形学仿真[D] ,西安:西北工业大学,2003
[40]王永华,现代电气控制及PLC应用技术[M],北京:北京航空航天大学出版社,2008
[41]常斗南,可编程序控制器原理?应用?实验[M],北京:机械工业出版社,2008
[42]程周,PLC技术与应用[M],福州:福建科学技术出版社,2004
[43]黄建春,PLC工控系统设计及其在自来水控制中的应用[D],长沙:湖南大学,2005
[44]周万珍,高鸿斌编著,PLC分析与设计应用[M],北京:电子工业出版社,2004
[45]MITSUBISH ELECTRIC CORPORATION,三菱微型可编程控制器MELSEC-F FX2N系列编程手册,三菱公司,2007
[46]Mintchell,Gary A.PLC I/O devices:More options for better machine control,Control Engineering,1998,45(3):127-131
[47]MITSUBISH ELECTRIC CORPORATION,FX2N-10GM和FX2N-20GM硬件/编程手册(B),三菱公司,2007
[48]杨叔子,机械加工工艺师手册(M),北京:机械工业出版社,2002
[49]聂市勇,制造企业SCADA系统研究[D],上海:上海交通大学大学,2005
[50]黄捷,可编程序控制器在生产中应用的探讨[J],四川建材,2008,34(2)
[51]林海燕,周佐良,炼钢厂电磁干扰与抑制措施[J],冶金自动化,2008,32(6)
[52]林剑,王鹏,王中正,浅谈PLC可编程序控制器使用注意事项及故障诊断[J],煤矿现代化,2009,(5)
[53]姚胜蓝,基于数控机床PLC的远程监控与诊断系统研究[D],上海:上海交通大学,2003
[2]安子军,机械原理教程[M],北京:机械工业出版社,2003
[3]国家机械工业委员会,初级齿轮工工艺学[M],北京:机械工业出版社,1988
[4]齿轮手册编写委员会,齿轮手册[M],北京:机械工业出版社,1990
[5] John Parker, Mechanical Manufacturing Technology in the 21stCentury, The Proceedings of the First International Conference on Mechanical Engineering, November 2000, China
[6]陈厚军,蒙日曲面共轭原理与环面蜗杆珠轮传动技术的研究[D] ,大连:大连理工大学,2009
[7]刘舸,圆柱蜗杆斜齿轮传动的理论分析及实验研究[D] ,重庆:重庆大学,2004
[8]孙桓,机械原理[M],北京:高等教育出版社,2000
[9] Matsuo T,El-Antably A,Lipo T A,A new control strategy for optimum-efficiency operation of a synchronous reluctance motor[J],Industry Applications,IEEE Transactions on,1997,3(5)1146～1153
[10] Syh-Shiuh Yeh,Pau-Lo Hsu,Analysis and design of integrated control for multi-axis motion systems[J],Control Systems Technology,IEEE Transactions on,2003,11(3):375～382.
[11] Chiu George T-C,Tomizuka Masayoshi,Coordinated position control of multi-axis mechanical systems[J],Journal of Dynamic Systems Measurement&Control,1998,120(3):389～393
[12]王君明,基于PLC的数控齿条插齿机的研究[D],武汉:华中科技大学,2004
[13]吴晓玲,袁丽娟,徐万里,中国齿轮传动的历史与进展[J],机械传动,2004,(5):62~64
[14]李洪友,周锦进,庞桂兵,齿轮光整加工工艺及其新进展[J],起重运输机械, 2003,(3):1~3
[15]商向东,齿轮加工精度[M],北京:机械工业出版社,2000
[16]江甫炎,近代齿轮制造工艺[M],北京:航空工业出版社,1994
[17]陈伯时,电气控制技术及其发展展望[M],电气传动,1987,(1):1～6
[18]孟庆金,常景荣,PLC在齿轮淬火机中的应用[J],山东冶金,1997,(5):25~27
[19]黄群辉,朱志红,李作清,YKS5120插齿机数控系统技术的研究[J],机械与电子,1998,(3):35～37
[20]郑胜利,傅素芳,PLC在齿轮加工机床电气控制方面的应用[J],平原大学学报,2004,(3):42~43
[21]冯清秀,贾品瑜,汤漾平等,基于PLC的开式齿轮润滑控制系统[J],机电一体化,2004,(1):57~59
[22]陈伟卓,PLC在齿轮专用机床改造中的运用[J],机械工程师,2009,(8):11~12
[23]鲁远栋,PLC机电控制系统应用设计技术[J],北京:电子工业出版社,2006
[24]齐从谦,王士兰,PLC技术及应用[M],北京:机械工业出版社,2000
[25]李建成,浅析科技型中小企业的信息化[J],CAD/CAM与制造业信息化,2005,(6)
[26]袁哲俊,金属切削刀具(第二版)[M],上海:上海科学技术出版社,1993
[27]张展,渐开线内啮合圆柱齿轮传动[M],北京:国防工业出版社,1991
[28]朱景梓,渐开线外啮合圆柱齿轮传动[M],北京:国防工业出版社,1990
[29]李华敏,韩元莹,王知行编著,渐开线齿轮的几何原理与计算[M],北京:机械工业出版社,1986
[30] Parey, A; Tandon, N. Impact velocity modelling and signal processing of spur gear vibration for the estimation of defect size. Mechanical System and signal processing, 2007, 21(1): 234~243
[31] Karpuschewski, B; Knoche, HJ; Hipke, M. Gear finishing by abrasive processes, Cirp Annals-Manufacturing Technology, 2008, 57(2): 621-640
[32] Eastwick, CN; Johnson, G. Gear windage: A review. Journal of Mechanical Design, 2008, 130(3): 34~40
[33]王明侗,渐开线齿轮精度[M],北京:机械工业出版社,1983
[34] Chen C-K,Yang S-C.Geometric Modelling for Cylindrical and Helical Gear Pumpswith Circular Arc Teeth.Journal of Mechanical Engineering Science, 2000, 214(4):599-607
[35] Chen Chien-Fa,Tsay Chung-Biau.Computerized tooth profile generation and analysis of characteristics of elliptical gears with circular-arc teeth. Journal of Materials Processing Technology, 2004,148(2):226-234
[36]潘存云,温喜森,渐开线环形齿球齿轮传动原理与运动分析,机械工程学报,2005,(5):65~67
[37] Li G X. Computer simulation on quasi-ellpsoidal gear transmission .Journal of Harbin Institute of Technology, 1995, 2(4):42-45
[38]冯显英,王清,艾兴,齿轮加工成形的运动学分析[J],山东工业大学学报,2000,(2):101~106
[39]李海京,齿轮加工的图形学仿真[D] ,西安:西北工业大学,2003
[40]王永华,现代电气控制及PLC应用技术[M],北京:北京航空航天大学出版社,2008
[41]常斗南,可编程序控制器原理?应用?实验[M],北京:机械工业出版社,2008
[42]程周,PLC技术与应用[M],福州:福建科学技术出版社,2004
[43]黄建春,PLC工控系统设计及其在自来水控制中的应用[D],长沙:湖南大学,2005
[44]周万珍,高鸿斌编著,PLC分析与设计应用[M],北京:电子工业出版社,2004
[45]MITSUBISH ELECTRIC CORPORATION,三菱微型可编程控制器MELSEC-F FX2N系列编程手册,三菱公司,2007
[46]Mintchell,Gary A.PLC I/O devices:More options for better machine control,Control Engineering,1998,45(3):127-131
[47]MITSUBISH ELECTRIC CORPORATION,FX2N-10GM和FX2N-20GM硬件/编程手册(B),三菱公司,2007
[48]杨叔子,机械加工工艺师手册(M),北京:机械工业出版社,2002
[49]聂市勇,制造企业SCADA系统研究[D],上海:上海交通大学大学,2005
[50]黄捷,可编程序控制器在生产中应用的探讨[J],四川建材,2008,34(2)
[51]林海燕,周佐良,炼钢厂电磁干扰与抑制措施[J],冶金自动化,2008,32(6)
[52]林剑,王鹏,王中正,浅谈PLC可编程序控制器使用注意事项及故障诊断[J],煤矿现代化,2009,(5)
[53]姚胜蓝,基于数控机床PLC的远程监控与诊断系统研究[D],上海:上海交通大学,2003