大型封头冲压设备自动上下料辅机的设计与研究
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摘要
随着现代制造技术的发展,冲压生产技术也向高速化、自动化、柔性化方向发展。冲压生产过程中的手动操作、人工上下料等传统生产方式已无法满足高速发展的工业要求。在冲压生产中采用自动化生产单元或组成柔性自动化生产线,是进行高速、高效、高质量冲压生产的一种有效方法,也是现代冲压生产技术的重要发展方向之一。
大型封头零件冲压设备作为一种特种专用冲压设备,其成本高、数量少,一直以来采用人工上下料。人工上下料困难、安全性差、工作效率低下,严重制约了大型封头冲压设备的利用率,影响了国内企业在国际市场上的竞争力。
本文从国内外冲压上下料辅机的发展状况着手,研制了一种专为大型封头零件冲压设备提供自动上下料服务的辅机,它能高效率地完成上下料、对中定心、喷涂润滑液等工作。本文的具体工作如下:
研究了大型封头零件的冲压生产工艺,分析了大型封头零件冲压主机的工作方式、结构特点、对上下料工作的要求,确定了上下料辅机的工作原理,设计了自动上下料辅机的系统方案。
从系统方案入手,依照模块化设计方法,对坯料小车、上料小车、下料小车和喷涂旋转及升降机构等关键部件进行了分析、设计与计算。
对辅机中采用的液压系统与气动真空系统进行了研究。对真空吸盘的上升下降运动、旋转机构的升降运动、对中机构的运动特点进行了分析,拟定了液压系统的工作原理,并对关键元器件进行了设计计算;分析了气动真空系统的工作特点,确定了工作原理图,并对真空吸盘、真空发生器等关键元器件进行了计算选择。
对辅机的控制系统进行了研究设计。分析了控制对象的特点,根据控制系统的特点,选择了PLC为控制核心的控制系统,确定了硬件连接,编制了软件程序。
最后,对全文进行了总结与展望。
With the development of modern manufacture engineering, punching manufacturing technology becomes more automatic and more flexible and its speed becomes higher. Traditional ways such as manual operation, manual feed and manual transfer in the process of punching can not meet the requirements of the fast developing industry. The automatization of manufacturing cell or the makeup of flexible automatic production lines in the process of punching production is an efficient way to carry out the production in high speed, high efficiency and high quality. It is one of the most important directions of modern punching manufacturing technology.
As special and specific punching equipment, large punching machines for heads are few and their costs are very expensive. Furthermore, their work efficiency is very slow in our country because its feeding and blanking depend on manual operation, which are difficult and dangerous. These traditional operation ways restrict the utilization ratio of large punching machines for heads seriously and have a side effect on the competitive power of domestic enterprises in international markets.
Following the domestic and international development of auxiliary machines for punching, this thesis has developed an auxiliary machine served for a big punching machine, which can complete feeding, blanking, alignment, and spraying lubricating liquid high effectively. The specific work in this thesis is as following:
Firstly, the punching techniques of production for large head parts are researched. The operation mode, the characters of structures, and the requirement of feeding and blanking are analyzed. The operating principle of the auxiliary machine for feeding and blanking is confirmed. The system blueprint of the automatic auxiliary machine for feeding and blanking is designed.
In detail, according to the design blueprint, following the modular design method, this thesis has analyzed, calculated and designed the billet vehicle, feeding vehicle, blanking vehicle, rotary and lifting mechanism for spray coating.
Secondly, the hydraulic system and the pneumatic system adopted in the auxiliary machine are researched. This thesis has also analyzed the lifting of both the vacuum sucking disk and rotary mechanism, demonstrated the operating principle of the pneumatic system, calculated and designed for key devices, analyzed the operation characters of the pneumatic system, drawn the operating principle chart, and calculated and chosen key devices, such as vacuum sucking disk, vacuum pumps and so on.
Finally, the control system of the auxiliary machine has been designed. According to the characters of both controlled objective and control system, PLC has been selected as the core of the control system; the hardware connection has been ensured; and the software procedures have been coded.
大型封头零件冲压设备作为一种特种专用冲压设备,其成本高、数量少,一直以来采用人工上下料。人工上下料困难、安全性差、工作效率低下,严重制约了大型封头冲压设备的利用率,影响了国内企业在国际市场上的竞争力。
本文从国内外冲压上下料辅机的发展状况着手,研制了一种专为大型封头零件冲压设备提供自动上下料服务的辅机,它能高效率地完成上下料、对中定心、喷涂润滑液等工作。本文的具体工作如下:
研究了大型封头零件的冲压生产工艺,分析了大型封头零件冲压主机的工作方式、结构特点、对上下料工作的要求,确定了上下料辅机的工作原理,设计了自动上下料辅机的系统方案。
从系统方案入手,依照模块化设计方法,对坯料小车、上料小车、下料小车和喷涂旋转及升降机构等关键部件进行了分析、设计与计算。
对辅机中采用的液压系统与气动真空系统进行了研究。对真空吸盘的上升下降运动、旋转机构的升降运动、对中机构的运动特点进行了分析,拟定了液压系统的工作原理,并对关键元器件进行了设计计算;分析了气动真空系统的工作特点,确定了工作原理图,并对真空吸盘、真空发生器等关键元器件进行了计算选择。
对辅机的控制系统进行了研究设计。分析了控制对象的特点,根据控制系统的特点,选择了PLC为控制核心的控制系统,确定了硬件连接,编制了软件程序。
最后,对全文进行了总结与展望。
With the development of modern manufacture engineering, punching manufacturing technology becomes more automatic and more flexible and its speed becomes higher. Traditional ways such as manual operation, manual feed and manual transfer in the process of punching can not meet the requirements of the fast developing industry. The automatization of manufacturing cell or the makeup of flexible automatic production lines in the process of punching production is an efficient way to carry out the production in high speed, high efficiency and high quality. It is one of the most important directions of modern punching manufacturing technology.
As special and specific punching equipment, large punching machines for heads are few and their costs are very expensive. Furthermore, their work efficiency is very slow in our country because its feeding and blanking depend on manual operation, which are difficult and dangerous. These traditional operation ways restrict the utilization ratio of large punching machines for heads seriously and have a side effect on the competitive power of domestic enterprises in international markets.
Following the domestic and international development of auxiliary machines for punching, this thesis has developed an auxiliary machine served for a big punching machine, which can complete feeding, blanking, alignment, and spraying lubricating liquid high effectively. The specific work in this thesis is as following:
Firstly, the punching techniques of production for large head parts are researched. The operation mode, the characters of structures, and the requirement of feeding and blanking are analyzed. The operating principle of the auxiliary machine for feeding and blanking is confirmed. The system blueprint of the automatic auxiliary machine for feeding and blanking is designed.
In detail, according to the design blueprint, following the modular design method, this thesis has analyzed, calculated and designed the billet vehicle, feeding vehicle, blanking vehicle, rotary and lifting mechanism for spray coating.
Secondly, the hydraulic system and the pneumatic system adopted in the auxiliary machine are researched. This thesis has also analyzed the lifting of both the vacuum sucking disk and rotary mechanism, demonstrated the operating principle of the pneumatic system, calculated and designed for key devices, analyzed the operation characters of the pneumatic system, drawn the operating principle chart, and calculated and chosen key devices, such as vacuum sucking disk, vacuum pumps and so on.
Finally, the control system of the auxiliary machine has been designed. According to the characters of both controlled objective and control system, PLC has been selected as the core of the control system; the hardware connection has been ensured; and the software procedures have been coded.
引文
[1] 邱继红,李伟成.冲压自动化机器人成套设备.锻压技术,2001,2:44~46
[2] Larson,M.Web hole-punching system delivers precision.Converting Magazine, 2001,4:p66~67
[3] 董长双,杨楚民,宾鸿赞.高速全自动数控冲床研制.机床与液压,1999,6:25~27
[4] 杨家军,张卫国,机械设计基础.武汉:华中科技大学出版社,2002
[5] 马正元,韩启.冲压工艺与模具设计.北京:机械工业出版社,1998
[6] 肖景容,姜奎华.冲压工艺学.北京:机械工业出版社,1990
[7] Mansur,M.A.Punching shear strength of simply supported fibrocement slabs. Journal of Materials in Civil Engineering. 2001, November /December: p 418~426
[8] 檀润华.创新设计.北京:机械工业出版社.2002
[9] 林文坡.气动传动及控制.西安:西安交通大学出版社, 1992
[10] Younis,Mohammed Bani.Formalization of PLC programs to sustain reliability. Automation and Mechatronics. 2004,P613~618
[11] Hardy,Stephen.PLC technology arrayed for wider application.Lightwave,July, 2004,P37~41
[12] 傅祥志,张策.机械原理.武汉:华中科技大学出版社,2001
[13] 刘政华.机械电子学.长沙:国防科技大学出版社,1999
[14] 刘玉魁.真空系统设计原理.北京:新时代出版社,1988.3
[15] 三菱电机株式会社.变频器原理与应用教程.北京:国防工业出版社,1998
[16] 朱孝录.中国机械设计第四卷—机械传动设计.南昌:西科学技术出版社.2002
[17] (美)兰姆贝克,R.P.著.吴忠仁译.液压泵和液压马达选择与应用.北京:机械工业出版社,1989
[18] 何存兴、张铁华.液压传动与气压传动.武汉:华中科技大学出版社,2003
[19] 李玉琳.液压元件与系统设计.北京:北京航空航天大学出版社,1989
[20] Dransfield , Peter . Hydraulic control systems--design and analysis of their dynamics.New York:Springer-Verlag.1981,P121~130
[21] 傀金文,王慧.液压传动.沈阳市:东北大学出版社,2003
[22] 张利平.液压站的设计与使用.北京:海洋出版社,2004,7-18
[23] 明仁雄,万会雄.液压与气压传动.北京:国防工业出版社,2005,251~265
[24] Walters , R . B .( Ronald B. ) . Hydraulic and electric-hydraulic control systems.Dordrecht .Boston:Kluwer Academic Publishers,2000
[25] 官忠范,李笑,杨敢.液压系统设计调节失误实例分析.北京:机械工业出版社,1995
[26] Festo Didactic.Hydraulic course for vocatioal training text book.Festo Didactic, 1978
[27] H.J.Leskiewicz, M.Zaremba.Pneumatic and hydraulic components and instruments in automatic control.proceedings of the IFAC Symposium, Warsaw.Poland.May 1980
[28] Fawcett,J. R.Pneumatic circuits & low cost automation.England:Trade & Technical press,1968
[29] 陆鑫盛,周洪.气动自动化系统的优化设计.上海:上海科学技术文献出版社, 2000,216~271
[30] R.H.Warring Pneumatic handbook.Houston, Tex:Gulf Pub. Co.1982
[31] SMC(中国)有限公司.SMC 培训教材-现代实用气动技术.北京:机械工业出版社,2004,406~433
[32] SMC(中国)有限公司.SMC 气动元件产品样本.2004
[33] 王孝华, 陆鑫盛.气动元件.北京:机械工业出版社,1991
[34] 李建兴.可编程序控制器应用技术.北京:机械工业出版社,2004
[35] 刘瑞已.可编程序控制器(PLC)在数控机床(CNC)中的应用.组合机床与自动化加工技术,2002,12:61～62
[36] 三菱电机株式会社. FX 2n系列微型可编程控制器使用手册
[37] D. M. Auslander, J.R, Ridgely, J.D.Ringgenberg.Design and Implementation of Real Time Software for Control of Mechanical Systems.2002
[38] 朱浩波.PLC在机电设备故障诊断中的应用.哈尔滨理工大学学报,2001,4:35~38
[39] 张世琪,李迎,孙宇.现代制造引论.北京:科学出版社,2003
[40] Karl J.Astrom Bjorm Wittenmark.Computer-Controlled Systems Theory and Design.2001.
[41] Bennet Stuart.BriefHistory of Servomechanisms.IEEE Control Systems Magazine. 1994,14(2):75~79
[42] Einar A. Endregaard.Paint Robotics-Improving Automotive Painting Performance. Volume: 100, Issue: 5, May, 2002:pp. 8-10,12-13
[43] Vincze,M. Pichler, A. Biegelbauer, G..Detection of classes of features for automated robot programming. Robotics and Automation, 2003. Proceedings. ICRA 03. IEEE International Conference on , Volume: 1 , 14-19 Sept. 2003 vol.1:Pages:151 - 156
[2] Larson,M.Web hole-punching system delivers precision.Converting Magazine, 2001,4:p66~67
[3] 董长双,杨楚民,宾鸿赞.高速全自动数控冲床研制.机床与液压,1999,6:25~27
[4] 杨家军,张卫国,机械设计基础.武汉:华中科技大学出版社,2002
[5] 马正元,韩启.冲压工艺与模具设计.北京:机械工业出版社,1998
[6] 肖景容,姜奎华.冲压工艺学.北京:机械工业出版社,1990
[7] Mansur,M.A.Punching shear strength of simply supported fibrocement slabs. Journal of Materials in Civil Engineering. 2001, November /December: p 418~426
[8] 檀润华.创新设计.北京:机械工业出版社.2002
[9] 林文坡.气动传动及控制.西安:西安交通大学出版社, 1992
[10] Younis,Mohammed Bani.Formalization of PLC programs to sustain reliability. Automation and Mechatronics. 2004,P613~618
[11] Hardy,Stephen.PLC technology arrayed for wider application.Lightwave,July, 2004,P37~41
[12] 傅祥志,张策.机械原理.武汉:华中科技大学出版社,2001
[13] 刘政华.机械电子学.长沙:国防科技大学出版社,1999
[14] 刘玉魁.真空系统设计原理.北京:新时代出版社,1988.3
[15] 三菱电机株式会社.变频器原理与应用教程.北京:国防工业出版社,1998
[16] 朱孝录.中国机械设计第四卷—机械传动设计.南昌:西科学技术出版社.2002
[17] (美)兰姆贝克,R.P.著.吴忠仁译.液压泵和液压马达选择与应用.北京:机械工业出版社,1989
[18] 何存兴、张铁华.液压传动与气压传动.武汉:华中科技大学出版社,2003
[19] 李玉琳.液压元件与系统设计.北京:北京航空航天大学出版社,1989
[20] Dransfield , Peter . Hydraulic control systems--design and analysis of their dynamics.New York:Springer-Verlag.1981,P121~130
[21] 傀金文,王慧.液压传动.沈阳市:东北大学出版社,2003
[22] 张利平.液压站的设计与使用.北京:海洋出版社,2004,7-18
[23] 明仁雄,万会雄.液压与气压传动.北京:国防工业出版社,2005,251~265
[24] Walters , R . B .( Ronald B. ) . Hydraulic and electric-hydraulic control systems.Dordrecht .Boston:Kluwer Academic Publishers,2000
[25] 官忠范,李笑,杨敢.液压系统设计调节失误实例分析.北京:机械工业出版社,1995
[26] Festo Didactic.Hydraulic course for vocatioal training text book.Festo Didactic, 1978
[27] H.J.Leskiewicz, M.Zaremba.Pneumatic and hydraulic components and instruments in automatic control.proceedings of the IFAC Symposium, Warsaw.Poland.May 1980
[28] Fawcett,J. R.Pneumatic circuits & low cost automation.England:Trade & Technical press,1968
[29] 陆鑫盛,周洪.气动自动化系统的优化设计.上海:上海科学技术文献出版社, 2000,216~271
[30] R.H.Warring Pneumatic handbook.Houston, Tex:Gulf Pub. Co.1982
[31] SMC(中国)有限公司.SMC 培训教材-现代实用气动技术.北京:机械工业出版社,2004,406~433
[32] SMC(中国)有限公司.SMC 气动元件产品样本.2004
[33] 王孝华, 陆鑫盛.气动元件.北京:机械工业出版社,1991
[34] 李建兴.可编程序控制器应用技术.北京:机械工业出版社,2004
[35] 刘瑞已.可编程序控制器(PLC)在数控机床(CNC)中的应用.组合机床与自动化加工技术,2002,12:61～62
[36] 三菱电机株式会社. FX 2n系列微型可编程控制器使用手册
[37] D. M. Auslander, J.R, Ridgely, J.D.Ringgenberg.Design and Implementation of Real Time Software for Control of Mechanical Systems.2002
[38] 朱浩波.PLC在机电设备故障诊断中的应用.哈尔滨理工大学学报,2001,4:35~38
[39] 张世琪,李迎,孙宇.现代制造引论.北京:科学出版社,2003
[40] Karl J.Astrom Bjorm Wittenmark.Computer-Controlled Systems Theory and Design.2001.
[41] Bennet Stuart.BriefHistory of Servomechanisms.IEEE Control Systems Magazine. 1994,14(2):75~79
[42] Einar A. Endregaard.Paint Robotics-Improving Automotive Painting Performance. Volume: 100, Issue: 5, May, 2002:pp. 8-10,12-13
[43] Vincze,M. Pichler, A. Biegelbauer, G..Detection of classes of features for automated robot programming. Robotics and Automation, 2003. Proceedings. ICRA 03. IEEE International Conference on , Volume: 1 , 14-19 Sept. 2003 vol.1:Pages:151 - 156