基于PLC及伺服技术的钢轨精磨机摇摆系统设计
摘要
随着中国乃至世界开始迈向“高铁时代”,人们更多的开始关注高铁技术的发展。铁轨作为列车运行的平台,其基础作用是不言而喻的。当前发展的无缝线路是由单根标准长度为25m或者12.5m的钢轨焊接而成的,焊接产生的焊接瘤则成为影响钢轨平直度的主要因素,因此,研制相关的打磨设备是必要的。目前主流的打磨设备是数控钢轨精磨机,本文设计的摇摆系统作为钢轨精磨机仿形打磨的重要组成部分,其研究是有很强的现实意义的。
本文首先针对数控钢轨精磨机打磨箱的一般工作特点,提出了机械系统的整体设计方案,通过对传动装置的设计和电机的计算选型,保证了负载各项运作要求能够实现。其次,通过对钢轨断面的特征分析,设计一种算法使钢轨接头外形尺寸在磨头打磨后能够得到保证。即：假定两个打磨点是相邻的,那么两点之间的焊接瘤是不需要打磨的,也就是说这两点之间焊接瘤的高度是低于或等于最大允许偏差值的,在这个条件的基础上再结合几何关系就能计算出两打磨点之间磨头的转动角度。然后进行控制系统设计,包括总体设计、硬件设计和软件设计。本文选用三菱FX2N系列PLC、定位模块、MR-J3系列驱动器、HF-SP系列伺服电机以及接近开关组成闭环和半闭环系统保证了定位控制的精度。选用三菱GOT-A900系列触摸屏作为人机界面,方便了工人的操作。由GX Developer软件编写出的梯形图控制程序与控制硬件的结合使磨头的精确定位控制得到了实现。本系统的设计为今后钢轨精磨机的进一步研究奠定了基础,也可为其他定位控制提供借鉴。
As China and even the world began to move towards "high-speed rail era", the more and more people begin to pay attention to high-speed rail technology. The tracks as a train platform, its fundamental role is self-evident. The current CWR rail is welded together by single standard rail with25m or12.5m length, Welding tumor have become major factors affecting steel rail straightness, Therefore, development of polishing equipment is necessary. At present, the mainstream is the NC rail grinding machine, An important part of the system as a swing grinding rail refining mill profile, its research is a very strong practical significance.
Firstly,the NC rail refining mill grinding box generally work, puts forward the overall design scheme of mechanical system, Through the calculation and selection of design and motor for driving device, ensure the operation load requirements to achieve. Secondly, through analysis of the characteristics of the rail profile, provides a guarantee grinding track rail joint dimension algorithm. Namely:suppose two grinding is adjacent, then welding tumor between two points is not need grinding, That is highly welding tumor is less than or equal to the maximum allowable deviation value between these two points, At the basis of this condition combined with the geometric relationship between the two can be calculated between the grinding head rotation angle. Then the control system design, such as the overall design, hardware design and software design. This paper selects the Mitsubishi FX2N series PLC, positioning module, MR-J3series, HF-SP series servo motor drive and proximity switch to form a closed loop and half closed loop control system to ensure the positioning precision. The Mitsubishi GOT-A900series touch screen as man-machine interface, convenient for the operation of workers. Combined with the control ladder diagram program and control hardware is written by GX Developer software to make precise positioning head control is realized. The design of the system has laid the foundation for the further study in the future rail refining mill, also can provide reference for other positioning.
本文首先针对数控钢轨精磨机打磨箱的一般工作特点,提出了机械系统的整体设计方案,通过对传动装置的设计和电机的计算选型,保证了负载各项运作要求能够实现。其次,通过对钢轨断面的特征分析,设计一种算法使钢轨接头外形尺寸在磨头打磨后能够得到保证。即：假定两个打磨点是相邻的,那么两点之间的焊接瘤是不需要打磨的,也就是说这两点之间焊接瘤的高度是低于或等于最大允许偏差值的,在这个条件的基础上再结合几何关系就能计算出两打磨点之间磨头的转动角度。然后进行控制系统设计,包括总体设计、硬件设计和软件设计。本文选用三菱FX2N系列PLC、定位模块、MR-J3系列驱动器、HF-SP系列伺服电机以及接近开关组成闭环和半闭环系统保证了定位控制的精度。选用三菱GOT-A900系列触摸屏作为人机界面,方便了工人的操作。由GX Developer软件编写出的梯形图控制程序与控制硬件的结合使磨头的精确定位控制得到了实现。本系统的设计为今后钢轨精磨机的进一步研究奠定了基础,也可为其他定位控制提供借鉴。
As China and even the world began to move towards "high-speed rail era", the more and more people begin to pay attention to high-speed rail technology. The tracks as a train platform, its fundamental role is self-evident. The current CWR rail is welded together by single standard rail with25m or12.5m length, Welding tumor have become major factors affecting steel rail straightness, Therefore, development of polishing equipment is necessary. At present, the mainstream is the NC rail grinding machine, An important part of the system as a swing grinding rail refining mill profile, its research is a very strong practical significance.
Firstly,the NC rail refining mill grinding box generally work, puts forward the overall design scheme of mechanical system, Through the calculation and selection of design and motor for driving device, ensure the operation load requirements to achieve. Secondly, through analysis of the characteristics of the rail profile, provides a guarantee grinding track rail joint dimension algorithm. Namely:suppose two grinding is adjacent, then welding tumor between two points is not need grinding, That is highly welding tumor is less than or equal to the maximum allowable deviation value between these two points, At the basis of this condition combined with the geometric relationship between the two can be calculated between the grinding head rotation angle. Then the control system design, such as the overall design, hardware design and software design. This paper selects the Mitsubishi FX2N series PLC, positioning module, MR-J3series, HF-SP series servo motor drive and proximity switch to form a closed loop and half closed loop control system to ensure the positioning precision. The Mitsubishi GOT-A900series touch screen as man-machine interface, convenient for the operation of workers. Combined with the control ladder diagram program and control hardware is written by GX Developer software to make precise positioning head control is realized. The design of the system has laid the foundation for the further study in the future rail refining mill, also can provide reference for other positioning.
引文
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[3]靳玉保.探秘铁路无缝钢轨[J].现代物理知识,2010
[4]罗林高速铁路的轨道平顺性问题[J].铁道建筑,1991(增刊)
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[7]殷继友.秦沈客运专线跨区间无缝线路铺设综合技术研究.中南大学,硕士论文,2007
[8]黎宏飞.基于VERICUT的数控钢轨精磨机加工仿真.西南交通大学,硕士论文,2009
[9]张春宜.减速器设计实例精解[M].机械工业出版社,2010
[10]侯会喜.液压与气动技术[M].北京理工大学出版社,2010
[11]黄玉美.机械制造装备设计[M].高等教育出版社,2008
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[18]O'Connor, Roy. Factory automation's forceful performer[J].Design News.3/23/98, Vol. 54 Issue 6,78
[19]Alber Brian. PLC Open Association[M]. The IEC 1131-3 standard,2004.62
[20]A. Remriez-Serrano,S. C. Zhu, S. K. H. Chan. teal. A hybrid PC or PLC architecture for manufacturing system control-theory and implementation[J]. Journal of Intelligent Manufacturing.2002(4):251～272
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[22]潘新民,王燕芳.微型计算机控制技术实用教程[M].电子工业出版社,2006
[23]吕金波,张治洪.可编程控制器在流量积算仪校准中的应用[J].工业计量,2008
[24]王玉梅.数控机床电气控制[M].中国电力出版社,2012
[25]文兴怀.数控铣床设计[M].化学工业出版社,2005
[26]路士涛.钢轨数控精磨机整体方案及测控系统设计.西南交通大学,硕士论文,2011
[27]赵韩,黄康,陈科.机械系统设计[M].高等教育出版社,2005
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[31]周春晖.过程控制工程手册[M].化学工业出版社,1993
[32]王阿根.电气可编程控制原理与应用[M].清华大学出版社,2007
[33]顾德英,罗长杰.现代电器控制技术[M].北京邮电大学出版社,2006
[34]常健生.检测与转换技术[M].机械工业出版社,2001
[35]FX2N系列微型可编程控制器使用手册[M].三菱公司
[36]通用交流伺服放大器技术资料集[M].三菱公司
[37]屈伟平.电容式触摸屏将引领市场潮流[J].电子工业专用设备,2010
[38]张培彦等.浅谈在数控机床设计中伺服电机的选择[J].中国科技信息,2008
[39]俞国亮.PLC原理与应用[M].清华大学出版社,2005
[40]王永华.现代电气控制及PLC应用技术[M].北京航空航天大学出版社,2004
[41]刘金能.计算机与的通讯格式和实现方法[J].机床与液压,1999
[42]GX Developer Version 8操作手册[M].三菱公司,2008
[43]龚仲华等.三菱FX/Q系列PLC应用技术[M].人民邮电出版社,2006
[44]王阿根.PLC控制程序精编108例[M].电子工业出版社,2009
[45]张伟林.电气控制与PLC应用[M].人民邮电出版社,2003
[46]洪志育.例说PLC[M].人民邮电出版社,2006
[47]孙平.可编程控制原理及应用[M].高等教育出版社,2003
[48]连建华,张怀广.应用技术[M].国防工业出版社,2009
[49]龚仲华.交流伺服驱动从原理到完全应用[M].人民邮电出版社,2010
[50]祖龙起,田甜,蒋洋等.PLC的伺服定位控制系统在筷子烙印机上的应用[J].大连工业大学学报,2011
[51]宋春宁.交流伺服电机在全自动端子压着机上的应用[J].电机与控制应用,2011
[52]华保祥.数控旧轨整形机总体及控制系统设计.西南交通大学,硕士论文,2009
[53]刘思文.触摸屏界面通用设计原则研究.上海交通大学,硕士论文,2009
[54]阮友德.PLC、变频器、触摸屏综合应用实训[M].中国电力出版社,2009
[55]何超.钢轨精磨机控制系统研究.西南交通大学,硕士论文,2012
[2]刘兴文.铁路轨道[M].西南交通大学出版社,2011
[3]靳玉保.探秘铁路无缝钢轨[J].现代物理知识,2010
[4]罗林高速铁路的轨道平顺性问题[J].铁道建筑,1991(增刊)
[5]卢晶.浅析我国高速铁路的发展进程[J].技术与市场,2011
[6]刘东.高速铁路无缝线路钢轨焊接技术研究[J].中国高新技术企业,2011
[7]殷继友.秦沈客运专线跨区间无缝线路铺设综合技术研究.中南大学,硕士论文,2007
[8]黎宏飞.基于VERICUT的数控钢轨精磨机加工仿真.西南交通大学,硕士论文,2009
[9]张春宜.减速器设计实例精解[M].机械工业出版社,2010
[10]侯会喜.液压与气动技术[M].北京理工大学出版社,2010
[11]黄玉美.机械制造装备设计[M].高等教育出版社,2008
[12]冯辛安.机械制造装备设计[M].机械工业出版社,2006
[13]王敏,于爱兵,张义.机床造型设计方法[J].现代制造工程,2005
[14]李洪.实用机床设计手册[M].辽宁科学技术出版社,1999
[15]雷晓燕.铁路轨道结构数值分析方法[M].中国铁道出版社,1998
[16]中华人民共和国铁道行业标准,2005
[17]Kamm.Design Cost—Efficient Mechanisms.Mcgraw—Hill Inc,1990
[18]O'Connor, Roy. Factory automation's forceful performer[J].Design News.3/23/98, Vol. 54 Issue 6,78
[19]Alber Brian. PLC Open Association[M]. The IEC 1131-3 standard,2004.62
[20]A. Remriez-Serrano,S. C. Zhu, S. K. H. Chan. teal. A hybrid PC or PLC architecture for manufacturing system control-theory and implementation[J]. Journal of Intelligent Manufacturing.2002(4):251～272
[21]尹佑盛,邹昌平,梁锡昌.机械控制学[M].重庆出版社,1997
[22]潘新民,王燕芳.微型计算机控制技术实用教程[M].电子工业出版社,2006
[23]吕金波,张治洪.可编程控制器在流量积算仪校准中的应用[J].工业计量,2008
[24]王玉梅.数控机床电气控制[M].中国电力出版社,2012
[25]文兴怀.数控铣床设计[M].化学工业出版社,2005
[26]路士涛.钢轨数控精磨机整体方案及测控系统设计.西南交通大学,硕士论文,2011
[27]赵韩,黄康,陈科.机械系统设计[M].高等教育出版社,2005
[28]李群英,龚邦明.钢轨精磨机的研制[J].机械制造与自动化,2008(10)
[29]曲尔光,弓锵.机床电气控制与PLC[M].北京：电子工业出版社,2010
[30]刘武发,张瑞等编.机床电气控制[M].北京：化学工业出版社,2009
[31]周春晖.过程控制工程手册[M].化学工业出版社,1993
[32]王阿根.电气可编程控制原理与应用[M].清华大学出版社,2007
[33]顾德英,罗长杰.现代电器控制技术[M].北京邮电大学出版社,2006
[34]常健生.检测与转换技术[M].机械工业出版社,2001
[35]FX2N系列微型可编程控制器使用手册[M].三菱公司
[36]通用交流伺服放大器技术资料集[M].三菱公司
[37]屈伟平.电容式触摸屏将引领市场潮流[J].电子工业专用设备,2010
[38]张培彦等.浅谈在数控机床设计中伺服电机的选择[J].中国科技信息,2008
[39]俞国亮.PLC原理与应用[M].清华大学出版社,2005
[40]王永华.现代电气控制及PLC应用技术[M].北京航空航天大学出版社,2004
[41]刘金能.计算机与的通讯格式和实现方法[J].机床与液压,1999
[42]GX Developer Version 8操作手册[M].三菱公司,2008
[43]龚仲华等.三菱FX/Q系列PLC应用技术[M].人民邮电出版社,2006
[44]王阿根.PLC控制程序精编108例[M].电子工业出版社,2009
[45]张伟林.电气控制与PLC应用[M].人民邮电出版社,2003
[46]洪志育.例说PLC[M].人民邮电出版社,2006
[47]孙平.可编程控制原理及应用[M].高等教育出版社,2003
[48]连建华,张怀广.应用技术[M].国防工业出版社,2009
[49]龚仲华.交流伺服驱动从原理到完全应用[M].人民邮电出版社,2010
[50]祖龙起,田甜,蒋洋等.PLC的伺服定位控制系统在筷子烙印机上的应用[J].大连工业大学学报,2011
[51]宋春宁.交流伺服电机在全自动端子压着机上的应用[J].电机与控制应用,2011
[52]华保祥.数控旧轨整形机总体及控制系统设计.西南交通大学,硕士论文,2009
[53]刘思文.触摸屏界面通用设计原则研究.上海交通大学,硕士论文,2009
[54]阮友德.PLC、变频器、触摸屏综合应用实训[M].中国电力出版社,2009
[55]何超.钢轨精磨机控制系统研究.西南交通大学,硕士论文,2012