数控火焰切割机改造研究
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摘要
船厂目前所用的设备为两轴切割机，它是上世纪九十年代产品，设备老化，维修困难，加工零件精度低，加工范围小，功能已很难适应新的工艺及船用工件，所以改造时主要从以上几方面考虑。经过与工厂协商，在改造中主要解决改单边驱动为双边驱动，同步检测；改开环为半闭环反馈，加装自动调高系统，改装割炬升降装置，进而适应船用各类新型坡口的加工；整个的数控系统要重新更换，旧的数控系统已很难适应新的加工要求，它是主要的更换部件。
改造后应达到通用性好，可进行直线及任意曲线的切割，可配置任何形式的割炬。精度高，改造后的数控火焰切割机运行精度、定位精度及转角处精度均要得到保证。切割质量好，切割机运行平稳，定位精度高。自动化程度高，切割全过程自动控制。数控系统功能齐全。
本论文的工作重点是数控火焰切割机机械本体和控制系统的改造，通过对机械本体的不合理地方重新设计和计算机数字控制技术应用，完成了数控火焰切割机的改造，并且在实际中进行了运行和调试。本论文的工作及贡献主要有下面几个方面：
1．进行了机械方案设计、计算与分析，其主要内容包括机械本体，传动系统及加装的自动调高，和割炬升降装置改装等。
2．进行了电气控制部分改造。主要是更新数控系统，伺服驱动装置，以及控制算法的设计。
3．对监控系统进行了软件方案设计，设计出了良好的人机界面。
4．对改造后的数控火焰切割机进行了调试和运行，参数设置，诊断分析以及精度检测。
Currently the two axles cutting machine which is applied in the shipyard is mostly the 1990's products, the equipment is aging, difficult to maintenance, low processing precision and processing small scope, it is hard to adapt to new technics and ship's workpiece. So the reconstruct must considerate the above aspects. After consultations with the factory, the main reconstruction is changing the unilateral actuation to the bilateral actuation, and synchronous detection; change the Open-Loop to the half Closed-Loop control, installs the automatic accent highth system, reconstruct the cutting torch elevating device, let it adapts to each kind of new bevel which is used in the ship; The numerical control system must be rechanged, the old numerical control system is difficult to adapt to new processing reqirement. It is the main part to be replaced.
After the reconstruction, the versatility must be good. It can cut both straight lines and any form of curves. High accuracy, the reconstruction of the digital flame cutting machine should meet the operation precision, positioning accuracy and corner offices. Good quality, operated steadily, and high-precision positioning. A high degree of automation. The numerical control systems fully functional.
The main work of the these is to reconstruct the mechine and the control system of the numerical control flame cutter. Through the redesign the unreasonable part of mechanical body and the CNC technology application, completed the numerical control flame cutter reconstruction, and in actual has carried on the movement and the debugging. The present paper work and the contribution mainly has following several aspects:
1. the mechanical plan design, computation and analysis are performed, its main content including the mechanical body, transmission system and adding automating elevating highth system and the cutting torch elevating gear requipment and so on.
2. the electricity control reconstruction is implemented. Mainly the numerical control system, the servo drive system, and the control algorithm design are replenished.
3. the modelling to the numerical control equipment is made, a good man-machine surface is achived.
4. debugging and running on the reconstruct machine are made, let it meet the design precision request.
改造后应达到通用性好，可进行直线及任意曲线的切割，可配置任何形式的割炬。精度高，改造后的数控火焰切割机运行精度、定位精度及转角处精度均要得到保证。切割质量好，切割机运行平稳，定位精度高。自动化程度高，切割全过程自动控制。数控系统功能齐全。
本论文的工作重点是数控火焰切割机机械本体和控制系统的改造，通过对机械本体的不合理地方重新设计和计算机数字控制技术应用，完成了数控火焰切割机的改造，并且在实际中进行了运行和调试。本论文的工作及贡献主要有下面几个方面：
1．进行了机械方案设计、计算与分析，其主要内容包括机械本体，传动系统及加装的自动调高，和割炬升降装置改装等。
2．进行了电气控制部分改造。主要是更新数控系统，伺服驱动装置，以及控制算法的设计。
3．对监控系统进行了软件方案设计，设计出了良好的人机界面。
4．对改造后的数控火焰切割机进行了调试和运行，参数设置，诊断分析以及精度检测。
Currently the two axles cutting machine which is applied in the shipyard is mostly the 1990's products, the equipment is aging, difficult to maintenance, low processing precision and processing small scope, it is hard to adapt to new technics and ship's workpiece. So the reconstruct must considerate the above aspects. After consultations with the factory, the main reconstruction is changing the unilateral actuation to the bilateral actuation, and synchronous detection; change the Open-Loop to the half Closed-Loop control, installs the automatic accent highth system, reconstruct the cutting torch elevating device, let it adapts to each kind of new bevel which is used in the ship; The numerical control system must be rechanged, the old numerical control system is difficult to adapt to new processing reqirement. It is the main part to be replaced.
After the reconstruction, the versatility must be good. It can cut both straight lines and any form of curves. High accuracy, the reconstruction of the digital flame cutting machine should meet the operation precision, positioning accuracy and corner offices. Good quality, operated steadily, and high-precision positioning. A high degree of automation. The numerical control systems fully functional.
The main work of the these is to reconstruct the mechine and the control system of the numerical control flame cutter. Through the redesign the unreasonable part of mechanical body and the CNC technology application, completed the numerical control flame cutter reconstruction, and in actual has carried on the movement and the debugging. The present paper work and the contribution mainly has following several aspects:
1. the mechanical plan design, computation and analysis are performed, its main content including the mechanical body, transmission system and adding automating elevating highth system and the cutting torch elevating gear requipment and so on.
2. the electricity control reconstruction is implemented. Mainly the numerical control system, the servo drive system, and the control algorithm design are replenished.
3. the modelling to the numerical control equipment is made, a good man-machine surface is achived.
4. debugging and running on the reconstruct machine are made, let it meet the design precision request.
引文
[1] 李亚江等编著．切割技术及应用。北京：化学工业出版社，2004：14-50页
[2] 齐占庆等著．机床电气控制技术．北京：机械工业出版社，1994：5-20页
[3] 樊凤琴 刘龙全等著。现代切割技术及其在工程机械制造中的应用．北京：机械工业出版社，2004：15-17页
[4] 杨克冲等编著．数控机床电气控制．武汉：华中科技大学出版社，2005：12-50页，96-124页
[5] 王永章等编著．数控技术。北京：高等教育出版社，2003：39-44页
[6] 吴祖育等编著．数控机床．上海：上海科学技术出版社，1990：177-180页
[7] Frank M Marlow. Welding Fabrication and Repair: Questions and Answers, New York: Industrial Press Inc, 2002:152-160P
[8] William Galvery Frank M Marlow. Questions and Answers. New York: Industrial Press Inc, 2001: 152-160P
[9] 机械设计手册编委会等编著．机械设计手册 (新版) (第1卷)．北京：机械工业出版社，2005：105-217页
[10] Bejczy, A. K., Robot. Arm. Dynamics. and. Control. TM33-69, JPL, Feb. 1974: 24-26P
[11] Nikravesh. P. E. Computer-aided. analysis, of. mechanicalsystems. [ s. l]: Prentice-Hall Inc., 1988: 61-63P
[12] Kahn. M. E., The Near Minimum Time Control of Open LoadArticulated. Kinematic. Chains. Ph. D. Dissertation, Stanjord University, 1969: 92-95P
[13] Kendall E. Atkinson, An introduction to Numerical Analysis, New York, 1978: 1O2-103P
[14] Hideak Kanoh "Distributed Parameter Models of Flexible Robot Arms". Advanced Robotics, Vol. 5, No. 2, Jun, PP. 177-185, 1990
[15] R. A. C. Slater, Engineering Plasticity, The Macmillan Press LTD, 1997: 27-29P
[16] J. H. Davis&R. M. Hirschorn "Tracking Control of a Flexible Robot Link" IEEE Trans. Autom Contro1, 1988: 238-288P
[17] 高安生等编著．基于工业 PC 机的通用化数控系统研究．北京：高等教育出版社，1997：65-84页
[18] Dorf R C, Bishop R H. Mordern Control System, Ninth Edition. 北京：科学出版社，2002：33-45页
[2] 齐占庆等著．机床电气控制技术．北京：机械工业出版社，1994：5-20页
[3] 樊凤琴 刘龙全等著。现代切割技术及其在工程机械制造中的应用．北京：机械工业出版社，2004：15-17页
[4] 杨克冲等编著．数控机床电气控制．武汉：华中科技大学出版社，2005：12-50页，96-124页
[5] 王永章等编著．数控技术。北京：高等教育出版社，2003：39-44页
[6] 吴祖育等编著．数控机床．上海：上海科学技术出版社，1990：177-180页
[7] Frank M Marlow. Welding Fabrication and Repair: Questions and Answers, New York: Industrial Press Inc, 2002:152-160P
[8] William Galvery Frank M Marlow. Questions and Answers. New York: Industrial Press Inc, 2001: 152-160P
[9] 机械设计手册编委会等编著．机械设计手册 (新版) (第1卷)．北京：机械工业出版社，2005：105-217页
[10] Bejczy, A. K., Robot. Arm. Dynamics. and. Control. TM33-69, JPL, Feb. 1974: 24-26P
[11] Nikravesh. P. E. Computer-aided. analysis, of. mechanicalsystems. [ s. l]: Prentice-Hall Inc., 1988: 61-63P
[12] Kahn. M. E., The Near Minimum Time Control of Open LoadArticulated. Kinematic. Chains. Ph. D. Dissertation, Stanjord University, 1969: 92-95P
[13] Kendall E. Atkinson, An introduction to Numerical Analysis, New York, 1978: 1O2-103P
[14] Hideak Kanoh "Distributed Parameter Models of Flexible Robot Arms". Advanced Robotics, Vol. 5, No. 2, Jun, PP. 177-185, 1990
[15] R. A. C. Slater, Engineering Plasticity, The Macmillan Press LTD, 1997: 27-29P
[16] J. H. Davis&R. M. Hirschorn "Tracking Control of a Flexible Robot Link" IEEE Trans. Autom Contro1, 1988: 238-288P
[17] 高安生等编著．基于工业 PC 机的通用化数控系统研究．北京：高等教育出版社，1997：65-84页
[18] Dorf R C, Bishop R H. Mordern Control System, Ninth Edition. 北京：科学出版社，2002：33-45页