数控旧轨整形机总体与控制系统设计
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摘要
钢轨是铁路设备的基础,钢轨的性能决定了列车运行的安全性与舒适度。钢轨在线上服役一段时间后,由于磨损,影响使用性能,将钢轨拆下通过加工降级成“再用轨”继续使用。旧轨整形机就是对钢轨未磨损面的顶面和侧面进行铣削,以达到延长钢轨的使用寿命的目的。目前,国内使用的旧轨整形设备是进口法国的,设备老旧、维修困难,本课题是设计国产化的旧轨整形机。
本课题采用的是PLC控制系统,以三菱PLC FX3U-128MRTES为核心,触摸屏和变频器协同工作,实现整个机床的各项功能。控制系统包括液压控制系统和电气控制系统,主要设计电气控制系统的硬件部分和软件部分。硬件部分包括主电路和控制电路,而软件部分包含PLC控制程序及触摸屏画面。其中软件部分是本次设计的重点,PLC控制程序包含了变频调速程序、伺服定位程序、进给夹具程序和铣削主夹具程序,触摸屏画面包含了欢迎画面、主界面、参数设置画面、自动运行画面、手动调节画面和报警画面等。所设计的控制程序合理,设计的人机画面友好,变频器和触摸屏选择的都是三菱的产品,这样可以与PLC协同进行联合仿真,调试PLC程序和触摸屏画面的正确性。
通过对旧轨整形机的总体和控制系统设计,能够实现机床的基本动作与性能,如伺服定位准确、液压夹紧可靠、电机转速精准,人机交互直观方便、操作简单,工人可以通过操作台和触摸屏来控制机床动作,从而实现高效率、高自动化、高可靠性的铣削,从真正意义上实现旧轨整形机的国产化。
The rail is the basis of railway equipment, and the performance of rail determines the safety and comfort of the train operation. The rail services online after a period of time, due to wear, which affects the performance, and it can be removed and processed to degrade into a "re-use rail" to continue to use. The shaping machine of the old rail is using to milling the unworn top surface and side of the rail, in order to achieve the purpose of extending the service life of the rail. At present, the shaping equipment of the old rail used in our country is imported in France, which is becoming old and difficult to maintenance, and this thesis is designed the localization shaping machine of the old rail.
This thesis uses a PLC control system, which is with Mitsubishi PLC FX3U-128MRTES as the core, and touch screen and inverter to work together, in order to achieve the various functions of the entire machine. Control system consists of hydraulic control system and electric control system, and the main design is hardware and software components of electric control system. Hardware components include the main circuit and control circuit, while the software components contain the procedures of PLC control and the screens of touch screen. Where the software part is the focus of this design, PLC control procedures include procedures for frequency control, servo positioning, feed fixture and the main fixture, while touch-screen screens are made up of a welcome screen, the main interface, the parameter setting screen, the automatically execute screen, the manually adjust screens and alarm screen, etc. Control procedures designed are reasonable and the man-machine screens are friendly, while the choice products of frequency inverter and touch-screen are Mitsubishi, which can be simulated by jointing collaboration with the PLC, debugging the correctness of PLC procedures and the screens of touch-screen.
Through designing the entirety and the control system of the shaping machine of the old rail, it can achieve the basic movements and performance of machine tools, for example, accurate servo positioning, reliable hydraulic clamping, precise motor speed, human-computer interaction intuitive and convenient, easy to operate, then workers can control machine movements by console and touch-screen, thereby achieving the milling conditions with high efficiency, high automation, high reliability, from the true meaning of achieving localization shaping machine of the old rail.
本课题采用的是PLC控制系统,以三菱PLC FX3U-128MRTES为核心,触摸屏和变频器协同工作,实现整个机床的各项功能。控制系统包括液压控制系统和电气控制系统,主要设计电气控制系统的硬件部分和软件部分。硬件部分包括主电路和控制电路,而软件部分包含PLC控制程序及触摸屏画面。其中软件部分是本次设计的重点,PLC控制程序包含了变频调速程序、伺服定位程序、进给夹具程序和铣削主夹具程序,触摸屏画面包含了欢迎画面、主界面、参数设置画面、自动运行画面、手动调节画面和报警画面等。所设计的控制程序合理,设计的人机画面友好,变频器和触摸屏选择的都是三菱的产品,这样可以与PLC协同进行联合仿真,调试PLC程序和触摸屏画面的正确性。
通过对旧轨整形机的总体和控制系统设计,能够实现机床的基本动作与性能,如伺服定位准确、液压夹紧可靠、电机转速精准,人机交互直观方便、操作简单,工人可以通过操作台和触摸屏来控制机床动作,从而实现高效率、高自动化、高可靠性的铣削,从真正意义上实现旧轨整形机的国产化。
The rail is the basis of railway equipment, and the performance of rail determines the safety and comfort of the train operation. The rail services online after a period of time, due to wear, which affects the performance, and it can be removed and processed to degrade into a "re-use rail" to continue to use. The shaping machine of the old rail is using to milling the unworn top surface and side of the rail, in order to achieve the purpose of extending the service life of the rail. At present, the shaping equipment of the old rail used in our country is imported in France, which is becoming old and difficult to maintenance, and this thesis is designed the localization shaping machine of the old rail.
This thesis uses a PLC control system, which is with Mitsubishi PLC FX3U-128MRTES as the core, and touch screen and inverter to work together, in order to achieve the various functions of the entire machine. Control system consists of hydraulic control system and electric control system, and the main design is hardware and software components of electric control system. Hardware components include the main circuit and control circuit, while the software components contain the procedures of PLC control and the screens of touch screen. Where the software part is the focus of this design, PLC control procedures include procedures for frequency control, servo positioning, feed fixture and the main fixture, while touch-screen screens are made up of a welcome screen, the main interface, the parameter setting screen, the automatically execute screen, the manually adjust screens and alarm screen, etc. Control procedures designed are reasonable and the man-machine screens are friendly, while the choice products of frequency inverter and touch-screen are Mitsubishi, which can be simulated by jointing collaboration with the PLC, debugging the correctness of PLC procedures and the screens of touch-screen.
Through designing the entirety and the control system of the shaping machine of the old rail, it can achieve the basic movements and performance of machine tools, for example, accurate servo positioning, reliable hydraulic clamping, precise motor speed, human-computer interaction intuitive and convenient, easy to operate, then workers can control machine movements by console and touch-screen, thereby achieving the milling conditions with high efficiency, high automation, high reliability, from the true meaning of achieving localization shaping machine of the old rail.
引文
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[2]阮友德.PLC、变频器、触摸屏综合应用实例.北京：中国电力出版社,2009.
[3]薛迎成.PLC与触摸屏控制技术.北京：中国电力出版社,2008.
[4]王淑英.电器控制与PLC控制技术.北京：机械工业出版社,2005.
[5]贺哲蓉,石帅军.流行PLC实用程序及设计(三菱FX2系列).西安：西安电子科技大学出版社,2006.
[6]李方园.变频器自动化工程实践.北京：电子工业出版社,2007.
[7]巫莉.电气控制与PLC应用.北京：中国电力出版社,2008.
[8]于庆广.可编程控制器原理及系统设计.北京：清华大学出版社,2004.
[9]王仁祥.常用低压电器原理及其控制技术.北京：机械工业出版社,2009.
[10]杨公训.可编程序控制器(PC)的抗干扰技术.北京：海洋出版社,1995.
[11]岳庆来.变频器、可编程序控制器及触摸屏综合应用技术.北京：机械工业出版社,2006.
[12]三菱电机.三菱图形操作终端GOT1000.三菱电机自动化(上海)有限公司.
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[14]严盈富.触摸屏与PLC入门.北京；人民邮电出版社,2006.
[15]廖常初.西门子人机界面(触摸屏)组态与应用技术.北京：机械工业出版社,2007.
[16]史悦.触摸屏技术及应用[.成都：电子科技大学出版社,2005.
[17]张运刚,宋小春.从入门到精通——三菱FX2N PLC技术与应用.北京：人民邮电出版社,2007.
[18]龚仲华,史建成.三菱FX／Q系列PLC应用技术.北京：人民邮电出版社,2006.
[19]郝丽娜.机械装备电气控制技术.北京：科学出版社,2006.
[20]刘金琪.机床电气自动控制.哈尔滨：哈尔滨工业大学出版社,1999.
[21]李登万.液压与气压传动.南京：东南大学出版社,2004.
[22]周恩涛.可编程控制器原理及其在液压系统中的应用.北京：机械工业出版社,2003.
[23]三菱电机.FX2N-10GM和FX2N-20GM硬件／编程手册.三菱电机自动化(上 海)有限公司,2000.
[24]三菱电机.三菱微型可编程控制器FX3U与FX3UC系列微型可编程控制器.三菱电机自动化(上海)有限公司,2005.
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[26]MITSUBISHI. AC SERVO DRIVE MELSERVO-J2-A SPECIFICATION AND MAINTENANCE MANUAL,2000.
[27]MITSUBISHI. MITSUBISHI ELECTRIC CC-LINK MANUAL,2001.
[28]MITSUBISHI. CC-LINK数字模拟变换模块用户参考手册,2000.
[29]三菱电机.FX系列特殊功能模块用户手册.三菱电机自动化(上海)有限公司,2000.
[30]MITSUBISHI. GT Designer2 Screen Design Manual. MITSUBISHI,2006.
[31]MITSUBISHI. GT Simulator2 Operation Manual. MITSUBISHI,2005.
[32]MITSUBISHI.图形操作终端GOT1000主机使用说明书.三菱电机自动化(上海)有限公司,2006.
[33]SIEMENS AG.. WINCC flexible2005-GettingStarted Options,2005.
[34]SIEMENS AG.. SIMATIC S7-200 Programmable Controller System Manual,2004.
[35]http://www. shtong. gov. cn/node2/node2245/node68716/node68724 /node68776/index. html.
[36]http://ls. ymmfa. com/j4. html.
[37]陈浩.案例解说PLC、触摸屏、及变频器综合应用.北京：中国电力出版社,2007.
[38]廖常初.FX系列PLC编程及应用.北京：机械工业出版社,2005.
[39]何波.电气控制及PLC应用.北京：中国电力出版社,2008.
[40]杨帮文.现代新潮传感器应用手册.北京：中国标准出版社,1989.
[41]葛唱虹.工业测控系统的抗干扰技术.北京：冶金工业出版社,2006.
[42]唐立伟.定位模块在玻璃钻孔加工中的应用.重庆科技学院学报.第10卷第4期.
[43]黄菊生,龚存宇,基于20GM定位模块数控系统的开发.湖南工程学院学报.第16卷第4期.
[44]李红,董伟等.基于FX2N-10GM定位模块的圆台磨床数控系统.控制与检测.2007年第11期.
[45]代灵.基于PLC和触摸屏的铜箔后处理控制系统设计.武汉理工大学硕士学位论文.2009.
[46]焦连岷.冲床的数控改造及全自动送料装置的研制.南京理工大学硕士学位论文.2007.
[47]张继和,张润敏,梁海峰.电机控制与供电基础.成都：西南交通大学出版社,2000.
[48]毕成恩.现代数控机床.北京：机械工业出版社,1993.
[49]韩安荣.通用变频器及其应用.北京：机械工业出版社,2000.
[50]陈绍华.机械设备电器控制.广州：华南理工大学出版社,1998.
[51]王仁祥,王小曼.通用变频器选型、维修与应用.北京：人民邮电出版社,2005.
[2]阮友德.PLC、变频器、触摸屏综合应用实例.北京：中国电力出版社,2009.
[3]薛迎成.PLC与触摸屏控制技术.北京：中国电力出版社,2008.
[4]王淑英.电器控制与PLC控制技术.北京：机械工业出版社,2005.
[5]贺哲蓉,石帅军.流行PLC实用程序及设计(三菱FX2系列).西安：西安电子科技大学出版社,2006.
[6]李方园.变频器自动化工程实践.北京：电子工业出版社,2007.
[7]巫莉.电气控制与PLC应用.北京：中国电力出版社,2008.
[8]于庆广.可编程控制器原理及系统设计.北京：清华大学出版社,2004.
[9]王仁祥.常用低压电器原理及其控制技术.北京：机械工业出版社,2009.
[10]杨公训.可编程序控制器(PC)的抗干扰技术.北京：海洋出版社,1995.
[11]岳庆来.变频器、可编程序控制器及触摸屏综合应用技术.北京：机械工业出版社,2006.
[12]三菱电机.三菱图形操作终端GOT1000.三菱电机自动化(上海)有限公司.
[13]李方园.人机界面设计与应用.北京：化学工业出版社,2008.
[14]严盈富.触摸屏与PLC入门.北京；人民邮电出版社,2006.
[15]廖常初.西门子人机界面(触摸屏)组态与应用技术.北京：机械工业出版社,2007.
[16]史悦.触摸屏技术及应用[.成都：电子科技大学出版社,2005.
[17]张运刚,宋小春.从入门到精通——三菱FX2N PLC技术与应用.北京：人民邮电出版社,2007.
[18]龚仲华,史建成.三菱FX／Q系列PLC应用技术.北京：人民邮电出版社,2006.
[19]郝丽娜.机械装备电气控制技术.北京：科学出版社,2006.
[20]刘金琪.机床电气自动控制.哈尔滨：哈尔滨工业大学出版社,1999.
[21]李登万.液压与气压传动.南京：东南大学出版社,2004.
[22]周恩涛.可编程控制器原理及其在液压系统中的应用.北京：机械工业出版社,2003.
[23]三菱电机.FX2N-10GM和FX2N-20GM硬件／编程手册.三菱电机自动化(上 海)有限公司,2000.
[24]三菱电机.三菱微型可编程控制器FX3U与FX3UC系列微型可编程控制器.三菱电机自动化(上海)有限公司,2005.
[25]MITSUBISHI. Positioning Control Training Manual. MITSUBISHI, 2000.
[26]MITSUBISHI. AC SERVO DRIVE MELSERVO-J2-A SPECIFICATION AND MAINTENANCE MANUAL,2000.
[27]MITSUBISHI. MITSUBISHI ELECTRIC CC-LINK MANUAL,2001.
[28]MITSUBISHI. CC-LINK数字模拟变换模块用户参考手册,2000.
[29]三菱电机.FX系列特殊功能模块用户手册.三菱电机自动化(上海)有限公司,2000.
[30]MITSUBISHI. GT Designer2 Screen Design Manual. MITSUBISHI,2006.
[31]MITSUBISHI. GT Simulator2 Operation Manual. MITSUBISHI,2005.
[32]MITSUBISHI.图形操作终端GOT1000主机使用说明书.三菱电机自动化(上海)有限公司,2006.
[33]SIEMENS AG.. WINCC flexible2005-GettingStarted Options,2005.
[34]SIEMENS AG.. SIMATIC S7-200 Programmable Controller System Manual,2004.
[35]http://www. shtong. gov. cn/node2/node2245/node68716/node68724 /node68776/index. html.
[36]http://ls. ymmfa. com/j4. html.
[37]陈浩.案例解说PLC、触摸屏、及变频器综合应用.北京：中国电力出版社,2007.
[38]廖常初.FX系列PLC编程及应用.北京：机械工业出版社,2005.
[39]何波.电气控制及PLC应用.北京：中国电力出版社,2008.
[40]杨帮文.现代新潮传感器应用手册.北京：中国标准出版社,1989.
[41]葛唱虹.工业测控系统的抗干扰技术.北京：冶金工业出版社,2006.
[42]唐立伟.定位模块在玻璃钻孔加工中的应用.重庆科技学院学报.第10卷第4期.
[43]黄菊生,龚存宇,基于20GM定位模块数控系统的开发.湖南工程学院学报.第16卷第4期.
[44]李红,董伟等.基于FX2N-10GM定位模块的圆台磨床数控系统.控制与检测.2007年第11期.
[45]代灵.基于PLC和触摸屏的铜箔后处理控制系统设计.武汉理工大学硕士学位论文.2009.
[46]焦连岷.冲床的数控改造及全自动送料装置的研制.南京理工大学硕士学位论文.2007.
[47]张继和,张润敏,梁海峰.电机控制与供电基础.成都：西南交通大学出版社,2000.
[48]毕成恩.现代数控机床.北京：机械工业出版社,1993.
[49]韩安荣.通用变频器及其应用.北京：机械工业出版社,2000.
[50]陈绍华.机械设备电器控制.广州：华南理工大学出版社,1998.
[51]王仁祥,王小曼.通用变频器选型、维修与应用.北京：人民邮电出版社,2005.