高速电主轴振动测试系统的研究
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摘要
加工中心是在数控机床出现后,为了进一步提高加工效率,减少辅助时间,将更换刀具的动作与数控机床集成而形成的一类自动化程度和生产率更高的新型数控机床。高速电主轴是高速加工中心最关键的部件之一,是机床实现高精度、高效率、高可靠性的关键部件。主轴部件的性能高低直接影响加工中心的品质,电主轴的振动直接影响部件加工精度。在保证电主轴质量分布均匀的情况下,本课题利用LabVIEW软件,针对转速为15000r/min的电主轴设计了一套电主轴振动测试系统,振动测量范围0～±1000μm,振动幅度分辨率0.1μm,可分析的频段到5000HZ的数据采集技术要求。
测试系统主要包括:系统激励,数据采集,数据分析、数据处理与数据保存。其中数据采集和数据分析是本论文的关键,为了缩短采样周期,设计数据采集与数据分析同步工作。该测试系统是一套基于PC的虚拟仪器测试系统,包括硬件和软件两部分。测试系统软件是实现各测试性能的功能程序;测试系统硬件是由传感器,数据采集卡PCI-6220与计算机组成。本文具体内容包括:
1.通过对电主轴测试技术指标的分析,选择满足测试技术指标的传感器,设计出具有高精度,高分辨率的数据采集系统,保证准确、快速的采集到电主轴的振动信号,完成了数据采集程序的虚拟设计,并对采集数据进行存储。
2.提出对电主轴振动信号的处理和分析方法,分别在时域和频域内对电主轴动态振动信号进行分析和处理,绘制主轴振动频谱图,主轴振动波形,轴心轨迹图来显示主轴振动的动态性能。以信号采样原理为数据设置理论依据,通过重置数据采集系统每个模块的相关参数,评价系统每个模块对整个系统的影响与可靠性,为对系统进行改进提供理论依据。完成了数据采集和数据分析同步工作的程序设计。
CNC machining center is a new type of CNC machine tools, in order to further improve processing efficiency, reduce the auxiliary time, replace the action and function of the tool and CNC machine tools to form a class of integrated automation and higher productivity. High-speed machining center spindle is the most critical components of the CNC machining center; is one of the critical components of the tools to achieve high precision, high efficiency, high reliability of. Spindle components directly affects the performance of the quality of machining center, the vibration of the spindle affect parts machining accuracy directly. In the case that ensure the spindle quality was distributed uniform. The thesis uses the LabVIEW software designed a spindle dynamic imbalance signal test systems for electric spindle speed 15000r/min, vibration measuring range reaches 0 ~±1000μm, vibration amplitude resolution of 0.1μm, It can Analysis of the band to 5000HZof the data acquisition technology requirements. And the development of a new incentive program to test the reliability and stability of this system.
The test system including: system excitation source, the data collection, data analysis and processing. Data collection and data analysis which is the key to this thesis, while they simultaneously work. The test system is a PC based virtual instrument test systems, including hardware and software of two parts, the test system software is to achieve the performance capabilities of the test procedures, test system hardware is a PCI-6220 data acquisition card and computer components.
1. Measurement system through the analysis of technical indicators, selected to meet the requirements of the sensor, designed with high accuracy, high-resolution data acquisition system, to ensure that the system can acquire the spindle vibration signals accurately and rapidly. And complete the virtual design data collection procedures, and data collection for storage.
2. Made on the spindle vibration signal processing and analysis methods, analys and process the vibration signal of spindle dynamic in the time domain and frequency domain respectively, drawing axis vibration frequency spectrum, the spindle vibration waveform, orbit diagram to show the dynamic performance of the spindle. By resetting the parameters of data acquisition system, from different angles to understand the dynamic balance of the spindle information, program design for synchronous operation. completed the data collection and data analysis,
测试系统主要包括:系统激励,数据采集,数据分析、数据处理与数据保存。其中数据采集和数据分析是本论文的关键,为了缩短采样周期,设计数据采集与数据分析同步工作。该测试系统是一套基于PC的虚拟仪器测试系统,包括硬件和软件两部分。测试系统软件是实现各测试性能的功能程序;测试系统硬件是由传感器,数据采集卡PCI-6220与计算机组成。本文具体内容包括:
1.通过对电主轴测试技术指标的分析,选择满足测试技术指标的传感器,设计出具有高精度,高分辨率的数据采集系统,保证准确、快速的采集到电主轴的振动信号,完成了数据采集程序的虚拟设计,并对采集数据进行存储。
2.提出对电主轴振动信号的处理和分析方法,分别在时域和频域内对电主轴动态振动信号进行分析和处理,绘制主轴振动频谱图,主轴振动波形,轴心轨迹图来显示主轴振动的动态性能。以信号采样原理为数据设置理论依据,通过重置数据采集系统每个模块的相关参数,评价系统每个模块对整个系统的影响与可靠性,为对系统进行改进提供理论依据。完成了数据采集和数据分析同步工作的程序设计。
CNC machining center is a new type of CNC machine tools, in order to further improve processing efficiency, reduce the auxiliary time, replace the action and function of the tool and CNC machine tools to form a class of integrated automation and higher productivity. High-speed machining center spindle is the most critical components of the CNC machining center; is one of the critical components of the tools to achieve high precision, high efficiency, high reliability of. Spindle components directly affects the performance of the quality of machining center, the vibration of the spindle affect parts machining accuracy directly. In the case that ensure the spindle quality was distributed uniform. The thesis uses the LabVIEW software designed a spindle dynamic imbalance signal test systems for electric spindle speed 15000r/min, vibration measuring range reaches 0 ~±1000μm, vibration amplitude resolution of 0.1μm, It can Analysis of the band to 5000HZof the data acquisition technology requirements. And the development of a new incentive program to test the reliability and stability of this system.
The test system including: system excitation source, the data collection, data analysis and processing. Data collection and data analysis which is the key to this thesis, while they simultaneously work. The test system is a PC based virtual instrument test systems, including hardware and software of two parts, the test system software is to achieve the performance capabilities of the test procedures, test system hardware is a PCI-6220 data acquisition card and computer components.
1. Measurement system through the analysis of technical indicators, selected to meet the requirements of the sensor, designed with high accuracy, high-resolution data acquisition system, to ensure that the system can acquire the spindle vibration signals accurately and rapidly. And complete the virtual design data collection procedures, and data collection for storage.
2. Made on the spindle vibration signal processing and analysis methods, analys and process the vibration signal of spindle dynamic in the time domain and frequency domain respectively, drawing axis vibration frequency spectrum, the spindle vibration waveform, orbit diagram to show the dynamic performance of the spindle. By resetting the parameters of data acquisition system, from different angles to understand the dynamic balance of the spindle information, program design for synchronous operation. completed the data collection and data analysis,
引文
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[2]刘春时,孙伟,李小彭,张义民.数控机床整机振动测试方法研究[J].中国工程机械学报,2009(3):20-23
[3]弈景美,黄红武.超高速电主轴结构综述[J].精密制造及自动化,2004(3):1-2
[4] H. Schulz. High-speed machining[M]. Annals of the CIRP 41 (2) (1992)
[5]王金平,邓艾东,曹浩.嵌入式旋转机械状态监测系统的设计与研究[J].汽轮机技术,2007(7):10-12
[6]陈燕林,段志善,熊万里.高速电主轴技术的研究现状与发展[J].机械研究与应用,2004(8):72-75
[7] Development of the built-in motor high-speed spindle[J].NSC85-2622-E194-001R, 1998 (in Chinese).J.-S. Chen, K.-W. Chen / International Journal of Machine Tools & Manufacture 45 (2005) 1487–1493 1493.
[8]叶能安,余汝生.动平衡原理与动平衡机[M].武汉:华中工学院出社,1985:15-60
[9]周大帅,伍良生.机床主轴在线动平衡技术综述[J].现代制造工程,2008(7):121-123
[10]王俊元,蒋红琰,杜文华.复合式电主轴在线动平衡装置的开发[J].自然科学版,2007(10):2-5
[11] M. Weck, A. Koch. Spindle-bearing systems for high-speed applications in machine tools[M].Annals of the CIRP 42 (1) (1993).
[12] V.J.Vande. Balancing of flexible rotors during operation[J].Journal of Mechanical Engineering Science 23 (5) (1981) 257–261.
[13] Z. Gosiewski. Automatic balancing of flexible rotors[J]. Part II: Synthesis of system, Journal of Sound and Vibration 114 (1) (1987)103–119.
[14]王越科,叶湘滨等.现代动态测试技术[M].北京:国防工业出版社,2003:130-145
[15]刘习军,贾启芬编著.工程振动与测试技术[M].天津:天津大学出版社,1999:30-80
[16]张思主.振动测试与分析技术[M].北京:清华大学出版社出版,1992:10-97
[17]张曙光主编.检测技术[M].北京:中国水利水电出版社,2002:3-90
[18]常见生编.检测与转换技术[M].北京:机械工业出版社,1992:20-40
[19]肖红,肖丽.一种虚拟振动测试信号分析系统的设计[J].机电产品开发与创新,2005,18(1):114-115
[20]段红.基于虚拟仪器的动平衡仪设计和测试方法研究[J].传感器学报,2005,18(7):2-4
[21]李光伟,张送等.基于虚拟仪器的电主轴振动检测[J].制造业信息化,2009(2):93-94
[22]杨乐平,李海涛,杨磊等. LabVIEW程序设计与应用(第2版)[M].北京:电子工业出版社,2005:20-25
[23]薛金林.虚拟仪器技术及其在农用车辆性能测试中的应用[J].农机化研究,2005(5):250-252
[24]刘颖峰.旋转机械状态监测系统的研究与开发[D].浙江大学:机械与能源工程学院,2003:35-47
[25]陈文勇,王秋晓,王世耕.一种动平衡测试系统测试方法的研究[J].机械研究与应用,2003(2):2-6
[26]唐志宏,刘景能.基于labview的便携式动平衡测试系统的研究[J].手工工业设备,2007(4):4-8
[27]于印民,刘文波.基于USB数据采集卡的高速电主轴轴向热伸长及径向振动数据采集系统的设计[J].组合机床与自动化加工技术,2009,54(4):2-6
[28]杜浣飞,王贤成等.基于LabVIEW的机床主轴回转误差测试系统[J].机床与液压,2009,37(12):168-169
[29]罗开玉,李伯全,王小飞等.基于虚拟仪器的机械转子轴心轨迹分析[J]江苏大学学报,2008,29(6):475-476
[30]孙巩长.如何进行电主轴的振动分析[J].装备制造技术,2008(10):82-83
[31]陈长江,郭丽娟,萧汝峰.数控机床高速电主轴振动原因分析[J].机械传动,2005(10):40-41
[32]魏中主.电子测量与仪器[M].北京:化学工业出版社,2003:20-89
[33]须鼎兴.电子测量仪器原理及应用技术[M].上海:同济大学出版社,2002:11-13
[34]王化祥,张淑英.传感器原理及应用[M].天津:天津大学出版社,1998:10-80
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