车床的数控化改造设计
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摘要
GE5-1000S西班牙生产的管子车床主要用于加工油管螺纹及对原有油管螺纹进行修复。由于该机床在控制方面的设计与国内同类型机床有很大差异，造成操作者在实际操作时不习惯，导致在安装调试后的几年内，不能投入使用。为解决问题，同时提高加工的自动化程度，我们提出对该车床进行数控改造。
本文介绍了用NUM1040T数控系统对管子车床的改造设计方法，重点阐述了机床的电气设计、PLC程序编制与调试以及螺纹重复切削功能实现三方面的问题。
NUM-1040T数控系统是一种开放式的功能强大的数控系统，该系统除具备与其它数控系统相同的基本功能外，还具有“螺纹重复切削”功能，可对工件原有螺纹进行修复并且不出现乱扣现象。针对该机床的结构特点，为它配备了NUM1040T数控系统及性能良好的BPH系列伺服电动机(X轴：22N·m，Z轴：36N·m)和MDLA系列驱动系统，并在主轴箱内安装了编码器。
主电路设计：主轴变速及正、反转控制采用西门子伺服系统进行驱动；数控刀架正、反转通过改变电路相序来实现；主控电路设计主要完成数控系统、主轴电机、数控刀架以及驱动系统供电及其控制。
利用NUM数控系统提供的PLCTOOL软件开发了该机床的PLC控制程序，实现了PLC输入输出端与机床面板信号联结、PLC输出端与机床强电信号联结、PLC输入端与CNC机床数控装置I/O口的联结及CNC加工代码G、M、T的实现。
文中分析了NUM数控系统中特有的螺纹修复功能原理，通过对G38+、G33编程语句中变量的理解，完成了对损坏较轻的螺纹保证刀具对准原螺纹槽进行的修复车削，有效地提高了油管螺纹的加工效率，同时节省了管材和刀具。在应用G38+功能后，使所加工的螺纹精度达到了API标准。
利用NUM-1040T数控系统对GE5-1000S西班牙管螺纹车床改造后，该机床操作方便，降低了操作者的劳动强度，提高了生产率，经测试各项技术指标均已达到工业标准，系统运行平稳。
The GE5-1000s tube-lather, which was made in Spain, was mainly used for processing the petroleum pipeline thread and fixing the original pipeline thread. Because there are quite difference of the same kind of machine tool in the design of control system between that of the overseas and of the local, the operator feel not better to use the machine tool at actual operation. As a result the machine tool could not work after the machine tool was install and adjust in several years. To solve this problem, and at the time to improve the automatic degree, we put forward to use the numerical control system alter the machine tool.
The altering design of the tube-lather of using the NUM1040T, the number controls system, was introduced in this text. Three point problems, altering of machine tool electric, PLC control and implement of the function of resumption of thread cutting, were expatiated.
NUM-1040T numerical control system is an open and powerful numerical system. Besides the basic functions of the others numerical control system, it has the continuously function of resumption thread cutting, which is cutting the thread continue the originally thread and without the phenomenon of different thread. According to the characteristics of the machine' s structure, the machine has been configured the NUM1040T numerical controls system and NUMDRIVE numerical servo. The BPH electromotor has been installed in two enter coordinates respectively (X:22N·m, Z:36N·m). And we have installed the coder in the headstock.
The designs of the main circuit: the shift gears of the spindle and control of positive or reversal implemented drive by SIMENS servo system; To implement of the positive or reversal of the numerical control knife rest, we should change the phrase order of the circuit. The main tasks of the design work about the main circuit are as follows: the numerical control system; principal axis electric machinery; numerical control knife rest and control circuit of the drive system.
Using the PLCTOOL software, which provide by the NUM numerical control system, we have write the programs of PLC control; have realized the signal join between the I/O of PLC and the control panel; the joint between the PLC export and the power electric signal of the machine tool; the joint between the PLC input and I/O of the numerical control installation of CNC machine tool and the implement of the CNC process code and G, M, T.
The distinctive function and theory of resumption of thread cutting of the NUM system were analyzed in this paper. Under the comprehension of the G38+, G33+ program' s variable, Cutting tool aim at the old thread, we have finished the resumption of thread cutting of the old thread, which was lightly destroyed. It has greatly improved the efficiency of producing tube thread, at the same time; it has save the tube materials and cutting tools. After applied the G38+ functiongs, the precision of the artifact thread has reached to the API standard.
Using the special functions of repairing thread of the NUM system, correct using the programs dictate of G38+, we can repair the original threads, which light destroy thread by ensuring the knife aim at the original thread.
本文介绍了用NUM1040T数控系统对管子车床的改造设计方法，重点阐述了机床的电气设计、PLC程序编制与调试以及螺纹重复切削功能实现三方面的问题。
NUM-1040T数控系统是一种开放式的功能强大的数控系统，该系统除具备与其它数控系统相同的基本功能外，还具有“螺纹重复切削”功能，可对工件原有螺纹进行修复并且不出现乱扣现象。针对该机床的结构特点，为它配备了NUM1040T数控系统及性能良好的BPH系列伺服电动机(X轴：22N·m，Z轴：36N·m)和MDLA系列驱动系统，并在主轴箱内安装了编码器。
主电路设计：主轴变速及正、反转控制采用西门子伺服系统进行驱动；数控刀架正、反转通过改变电路相序来实现；主控电路设计主要完成数控系统、主轴电机、数控刀架以及驱动系统供电及其控制。
利用NUM数控系统提供的PLCTOOL软件开发了该机床的PLC控制程序，实现了PLC输入输出端与机床面板信号联结、PLC输出端与机床强电信号联结、PLC输入端与CNC机床数控装置I/O口的联结及CNC加工代码G、M、T的实现。
文中分析了NUM数控系统中特有的螺纹修复功能原理，通过对G38+、G33编程语句中变量的理解，完成了对损坏较轻的螺纹保证刀具对准原螺纹槽进行的修复车削，有效地提高了油管螺纹的加工效率，同时节省了管材和刀具。在应用G38+功能后，使所加工的螺纹精度达到了API标准。
利用NUM-1040T数控系统对GE5-1000S西班牙管螺纹车床改造后，该机床操作方便，降低了操作者的劳动强度，提高了生产率，经测试各项技术指标均已达到工业标准，系统运行平稳。
The GE5-1000s tube-lather, which was made in Spain, was mainly used for processing the petroleum pipeline thread and fixing the original pipeline thread. Because there are quite difference of the same kind of machine tool in the design of control system between that of the overseas and of the local, the operator feel not better to use the machine tool at actual operation. As a result the machine tool could not work after the machine tool was install and adjust in several years. To solve this problem, and at the time to improve the automatic degree, we put forward to use the numerical control system alter the machine tool.
The altering design of the tube-lather of using the NUM1040T, the number controls system, was introduced in this text. Three point problems, altering of machine tool electric, PLC control and implement of the function of resumption of thread cutting, were expatiated.
NUM-1040T numerical control system is an open and powerful numerical system. Besides the basic functions of the others numerical control system, it has the continuously function of resumption thread cutting, which is cutting the thread continue the originally thread and without the phenomenon of different thread. According to the characteristics of the machine' s structure, the machine has been configured the NUM1040T numerical controls system and NUMDRIVE numerical servo. The BPH electromotor has been installed in two enter coordinates respectively (X:22N·m, Z:36N·m). And we have installed the coder in the headstock.
The designs of the main circuit: the shift gears of the spindle and control of positive or reversal implemented drive by SIMENS servo system; To implement of the positive or reversal of the numerical control knife rest, we should change the phrase order of the circuit. The main tasks of the design work about the main circuit are as follows: the numerical control system; principal axis electric machinery; numerical control knife rest and control circuit of the drive system.
Using the PLCTOOL software, which provide by the NUM numerical control system, we have write the programs of PLC control; have realized the signal join between the I/O of PLC and the control panel; the joint between the PLC export and the power electric signal of the machine tool; the joint between the PLC input and I/O of the numerical control installation of CNC machine tool and the implement of the CNC process code and G, M, T.
The distinctive function and theory of resumption of thread cutting of the NUM system were analyzed in this paper. Under the comprehension of the G38+, G33+ program' s variable, Cutting tool aim at the old thread, we have finished the resumption of thread cutting of the old thread, which was lightly destroyed. It has greatly improved the efficiency of producing tube thread, at the same time; it has save the tube materials and cutting tools. After applied the G38+ functiongs, the precision of the artifact thread has reached to the API standard.
Using the special functions of repairing thread of the NUM system, correct using the programs dictate of G38+, we can repair the original threads, which light destroy thread by ensuring the knife aim at the original thread.
引文
[1] 卢晓平．数控机床加工与编程．电子科技大学出版社，1999．5
[2] 李峻勤等．数控机床及其使用与维修．国防工业出版社，1999
[3] 周济，周艳红．数控加工技术．北京：国防工业出版社，2000．1
[4] 北京发那科机电有限公司．数控系统的发展．制造技术与机床，2001．8：48～49
[5] 齐晓芬．数控车床的升级改造．机床电器，2001．5：13～16
[6] 肖爱萍，吴安生，郭攀成．基于普通车床的数控化改造设计．机床与液压，2000．2：74～75
[7] 杨波．浅谈机床数控改造．www.e-works.net.cn/ewkarticles/article7884.htm
[8] NUM数控系列．www.hcty.com.cn/new_page_l.htm
[9] 王玉琪．FhNUC CNC系统与机床的连接与调整．制造技术与机床，2002．1：46～47
[10] 邹方．NUM 1050数控系统在三坐标龙门铣床中的应用．2001．3：52～54
[11] 孙建业．NUM数控系统在SSY-201数控管子车丝机上的应用．制造技术与机床，2001：8：51
[12] 贺平，贺刚，夏秀红．机床数控系统内部总线的连接方法与数据传输．机械科学与技术，2000．1：106～110
[13] 王计文，景顺，志强，浅析普通车床的数控改造．机床与液压，1999．3：82～83
[14] 王文全，王德海，鲍长彬．和用NUM 1040T双轴组功能改造车轮车床一例．制造技术与机床，2002．1：49～50
[15] 王忠．用华中Ⅰ型数控系统对旧车床进行数控改造—推进我国数控产业化的进程．企业技术开发，2000．8：9～11
[16] 苟琪．可编程控制器((PLC)在CNC机床中的应用．机械工业自动化，1998．8：57～59
[17] 刘瑞己．可编程控制器(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
[18] 董景新，李雯，蔡旭帆．利用通用可编程控制器改造旧式数控机床．机械工业自动化，1997．6：52～54
[19] 卢虹霞．用PLC控制电动刀架．机床电器，2001．5：29～30
[20] 陈志新．PLC编程的几个误区．组合机床与自动化加工技术，2002．4：51～52
[21] 贾传圣，杨永娟．经济型数控车床自动换刀原理与维修．机床电器，．2001．4：18～19
[22] 许永华，李钢．数控机床中光电编码器计数电路设计．制造技术与机床，2000．1：14～15
[23] 陈劲松．螺纹的重复切削．制造技术与机床，2001．10：43
[24] 左毅，罗明顺，孙晓艳．MJ系列数控车床的电气模块化设计方法．机床电器，2002．3：25～ 26
[25] 周永麟．采用可转位刀具的螺纹数控加工．机械工艺师，1999．11：14～15
[26] 楼锡银．螺纹加工的编程方法．机电一体化，2001．3：45～47
[27] 畅元江．用经济型CNC车床加工石油油管螺纹．机械工程师，2000．8：27～28
[28] 王可，唐宗军等，管螺纹数控加工中的几个技术问题．石油机械，1998．3：42～43
[29] 乐光学．经济型数控螺纹加工软件设计及应用．机械工艺师，1999．12：10～11
[30] 张剑英．螺纹插补算法的改进．兵工自动化，200U．3：34～36
[31] 唐红权 在经济型数控车床上进行导程螺纹的加工．机械工人(冷加工)，2007．1 61～62
[32] 王钢 数控机床对控制系统的要求 机械工人(冷加工)，2007．2 17～19
[33] 彭晓燕等．CNC车床螺纹加工的插补方法．机械与电子，1997．2
[34] 史旭明．数控系统刀具半径补偿研究．组合机床与自动化加工技术，Ⅰ998．11
[35] 张柱银．数控加工中对刀问题的处理．组合机床与自动化加工技术，2002．9
[36] 陆军．PLC随机编程在机床上的应用．组合机床与自动化加工技术，1999．9
[37] 李耿轶等．数控机床同步轴归零．组合机床与自动化加工技术，2000．5
[38] 赵小林．数控车编程中应注意的几个问题．机床与液压，2002．2
[39] 张柏森．数控车建立工件坐标系的方法．机床与液压，2002．2
[40] 陈光明．数控车对刀原理与对刀方法．机床与液压，2002．3
[41] NUM 1020／1040／10607编程手册．ch-938820／1 NUM GROUPE SCHNEIDER
[42] NUM 1020／1040／10607操作手册．ch-938821／0 NUM GROUPE SCHNEIDER
[43] NUM自动控制功能编程手册梯形图语言．0101938846／7 NUM GROUPS SCHNEIDER
[44] NUM 1020/1040 INSTALLATION AND COMMISSIONING MANUAL en-938938/1 NUM GROUPS SCHNEIDER
[45] Modular drive MDLA2 INSTALLATION AND MAINTENANCE MANUAL WITH TERMINAL MDLT100. NUM GROUPS SCHNEIDER, ED. 04/96 738E008/C
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[53] Meeting the need for speed. Tooling Production, 1996(6)
[2] 李峻勤等．数控机床及其使用与维修．国防工业出版社，1999
[3] 周济，周艳红．数控加工技术．北京：国防工业出版社，2000．1
[4] 北京发那科机电有限公司．数控系统的发展．制造技术与机床，2001．8：48～49
[5] 齐晓芬．数控车床的升级改造．机床电器，2001．5：13～16
[6] 肖爱萍，吴安生，郭攀成．基于普通车床的数控化改造设计．机床与液压，2000．2：74～75
[7] 杨波．浅谈机床数控改造．www.e-works.net.cn/ewkarticles/article7884.htm
[8] NUM数控系列．www.hcty.com.cn/new_page_l.htm
[9] 王玉琪．FhNUC CNC系统与机床的连接与调整．制造技术与机床，2002．1：46～47
[10] 邹方．NUM 1050数控系统在三坐标龙门铣床中的应用．2001．3：52～54
[11] 孙建业．NUM数控系统在SSY-201数控管子车丝机上的应用．制造技术与机床，2001：8：51
[12] 贺平，贺刚，夏秀红．机床数控系统内部总线的连接方法与数据传输．机械科学与技术，2000．1：106～110
[13] 王计文，景顺，志强，浅析普通车床的数控改造．机床与液压，1999．3：82～83
[14] 王文全，王德海，鲍长彬．和用NUM 1040T双轴组功能改造车轮车床一例．制造技术与机床，2002．1：49～50
[15] 王忠．用华中Ⅰ型数控系统对旧车床进行数控改造—推进我国数控产业化的进程．企业技术开发，2000．8：9～11
[16] 苟琪．可编程控制器((PLC)在CNC机床中的应用．机械工业自动化，1998．8：57～59
[17] 刘瑞己．可编程控制器(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
[18] 董景新，李雯，蔡旭帆．利用通用可编程控制器改造旧式数控机床．机械工业自动化，1997．6：52～54
[19] 卢虹霞．用PLC控制电动刀架．机床电器，2001．5：29～30
[20] 陈志新．PLC编程的几个误区．组合机床与自动化加工技术，2002．4：51～52
[21] 贾传圣，杨永娟．经济型数控车床自动换刀原理与维修．机床电器，．2001．4：18～19
[22] 许永华，李钢．数控机床中光电编码器计数电路设计．制造技术与机床，2000．1：14～15
[23] 陈劲松．螺纹的重复切削．制造技术与机床，2001．10：43
[24] 左毅，罗明顺，孙晓艳．MJ系列数控车床的电气模块化设计方法．机床电器，2002．3：25～ 26
[25] 周永麟．采用可转位刀具的螺纹数控加工．机械工艺师，1999．11：14～15
[26] 楼锡银．螺纹加工的编程方法．机电一体化，2001．3：45～47
[27] 畅元江．用经济型CNC车床加工石油油管螺纹．机械工程师，2000．8：27～28
[28] 王可，唐宗军等，管螺纹数控加工中的几个技术问题．石油机械，1998．3：42～43
[29] 乐光学．经济型数控螺纹加工软件设计及应用．机械工艺师，1999．12：10～11
[30] 张剑英．螺纹插补算法的改进．兵工自动化，200U．3：34～36
[31] 唐红权 在经济型数控车床上进行导程螺纹的加工．机械工人(冷加工)，2007．1 61～62
[32] 王钢 数控机床对控制系统的要求 机械工人(冷加工)，2007．2 17～19
[33] 彭晓燕等．CNC车床螺纹加工的插补方法．机械与电子，1997．2
[34] 史旭明．数控系统刀具半径补偿研究．组合机床与自动化加工技术，Ⅰ998．11
[35] 张柱银．数控加工中对刀问题的处理．组合机床与自动化加工技术，2002．9
[36] 陆军．PLC随机编程在机床上的应用．组合机床与自动化加工技术，1999．9
[37] 李耿轶等．数控机床同步轴归零．组合机床与自动化加工技术，2000．5
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[39] 张柏森．数控车建立工件坐标系的方法．机床与液压，2002．2
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