高速电主轴扭矩加载试验台的研制
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摘要
高速数控机床（CNC）是装备制造业的重点发展方向之一，是装备制造业的战略性产业。数控机床关键功能部件可靠性直接影响着整机可靠性水平,电主轴作为数控机床重要关键功能部件之一，研究其可靠性对提高数控机床整机可靠性提升具有重要意义。
关键功能部件是数控机床的重要故障源，由于功能部件比整机的体积小，且价格远远低于整机，可以采用实验室试验的方法，通过模拟实际加工工况，诱发或者加速促使功能部件发生故障，并测量其相关性能指标，找出发生故障的因素，获得故障数据，建立故障模型，对其可靠性指标进行评估，并对故障数据进行分析，从而提高关键功能部件的可靠性水平提高依据。实现了通过开发和研究功能部件的可靠性试验台来提高数控机床整机的可靠性的研究途径。
高速电主轴可靠性试验与测试平台用于测试数控机床及高速电主轴轴向窜动、径向跳动以及主轴温升等因素对电主轴工作可靠性的影响；评价工作前后电主轴的工作稳定性、可靠性和精度保持性等。根据申请课题的研究工作内容和主要目标，需研制通用型电主轴综合性能试验系统，并结合理论计算对高速电主轴的工作稳定性和可靠性进行综合测试与评估。
本论文将主要介绍高速电主轴的加载方案设计，包括非接触式加载和接触式加载方案，重点讨论对高速电主轴试验台的扭矩加载实验与数据分析。文中所述的电力测功加载系统的高速电主轴可靠性试验台能够完成功率22kW、转速为18000r/min以下的电主轴可靠性试验，较普通测试电主轴性能的试验台的功率、转速均大大提高；并完全能够实现高速电主轴的性能指标测试，如，电主轴温升控制，主轴的径向跳动和轴向窜动等试验；采用电力测功加载系统及压电陶瓷加载系统模拟主轴受力状况（包括径向力、轴向力与扭矩），实现电主轴的动态加载实验与测试；能够检测试验过程中的各种故障，记录试验过程中试验信息，并可进行记录和查询，通过组态软件和板卡及工控机配合的控制系统，对采集的参数数据进行可靠性分析，为提高电主轴的可靠性提供了定量数值评估平台。
预计试验台调试完成后，经过试验检测，可达到高速电主轴功能达标，运行稳定，在扭矩加载实验中性能良好的效果，并将获得一些试验数据。高速电主轴可靠性试验台的研制将对数控机床关键功能部件可靠性深入研究有着重要的意义。
High speed CNC machine tools is one of the developing direction and technologyfoundation of equipment manufacturing industry, and it is also a strategy industry forequipment manufacturing industry. The reliability of the key functional parts on CNCmachine tools effects on the reliability of the whole machine. As an important keyfunctional part, electric spindle’s reliability research has significant meaning forincreasing MTBF level for the whole CNC machine tools.
Key functional parts are CNC machine tools important sources of failure.Because its volume is little than a whole machine’s, and expense is less than a wholemachine, we can test it in a laboratory environment. We simulate real machiningworking conditions, induce or increase promoting component failure in laboratory,and measure its performance, identify the factors of failure, make statistics of failuredata, establish failure model, thereby the reliability of key functional parts has beenimproved. We achieved the way to improve the reliability of the CNC machine toolsthrough the development and study the reliability of the key functional parts.
High-speed electric spindle test and its test-bed are used to test axial runout,radial runout and spindle temperature rise of the electric spindles for CNC machinetools and machining centers and other factors impact on the reliability of electricspindle machining, and evaluate the electric spindle stability, reliability and accuracyto maintain before and after the machine tools working. According to the applyingsubject content and the main objective, we need to develop the comprehensiveperformance test system for general electric spindles, comprehensive test and evaluateon the stability and reliability of high-speed electric spindle combining with thetheoretical calculation.
The high-speed electric spindle’s reliability test-bed of electric dynamometerloading system described in this paper, is able to complete electric spindle reliabilitytest above18000r/min, greatly improve the speed than the ordinary electric spindleperformance test-bed. And it is able to achieve high-speed electric spindleperformance test absolutely, such as temperature rise control of the electric spindle,spindle radial runout and axial movement and other tests. It simulates spindle forcestatus (including radial force, axial force and torque) using electric dynamometerloading system and piezoelectric ceramic loading system to achieve electric spindledynamic loading experiments and tests. It is able to detect a variety of failure duringthe test, records information during the tests, and the data can be recorded and query,it collects parameter data for reliability analysis through configuration softwaretogether with boards and industrial computer control system, in order to provide aquantitative numerical evaluation platform to improve the reliability of the electricspindle.
After the test-bed debugging and a period of test and detection, the test results show that the high-speed electric spindle’s functions meet the standards, and it worksstable, it perform good in torque loading experiments. We got some test data, and alsofound some failures in the electric spindle. We recorded and analyzed the failures.The deep study on high-speed electric spindle reliability test-bed for the keyfunctional parts reliability of CNC machine tools has great significance.
关键功能部件是数控机床的重要故障源，由于功能部件比整机的体积小，且价格远远低于整机，可以采用实验室试验的方法，通过模拟实际加工工况，诱发或者加速促使功能部件发生故障，并测量其相关性能指标，找出发生故障的因素，获得故障数据，建立故障模型，对其可靠性指标进行评估，并对故障数据进行分析，从而提高关键功能部件的可靠性水平提高依据。实现了通过开发和研究功能部件的可靠性试验台来提高数控机床整机的可靠性的研究途径。
高速电主轴可靠性试验与测试平台用于测试数控机床及高速电主轴轴向窜动、径向跳动以及主轴温升等因素对电主轴工作可靠性的影响；评价工作前后电主轴的工作稳定性、可靠性和精度保持性等。根据申请课题的研究工作内容和主要目标，需研制通用型电主轴综合性能试验系统，并结合理论计算对高速电主轴的工作稳定性和可靠性进行综合测试与评估。
本论文将主要介绍高速电主轴的加载方案设计，包括非接触式加载和接触式加载方案，重点讨论对高速电主轴试验台的扭矩加载实验与数据分析。文中所述的电力测功加载系统的高速电主轴可靠性试验台能够完成功率22kW、转速为18000r/min以下的电主轴可靠性试验，较普通测试电主轴性能的试验台的功率、转速均大大提高；并完全能够实现高速电主轴的性能指标测试，如，电主轴温升控制，主轴的径向跳动和轴向窜动等试验；采用电力测功加载系统及压电陶瓷加载系统模拟主轴受力状况（包括径向力、轴向力与扭矩），实现电主轴的动态加载实验与测试；能够检测试验过程中的各种故障，记录试验过程中试验信息，并可进行记录和查询，通过组态软件和板卡及工控机配合的控制系统，对采集的参数数据进行可靠性分析，为提高电主轴的可靠性提供了定量数值评估平台。
预计试验台调试完成后，经过试验检测，可达到高速电主轴功能达标，运行稳定，在扭矩加载实验中性能良好的效果，并将获得一些试验数据。高速电主轴可靠性试验台的研制将对数控机床关键功能部件可靠性深入研究有着重要的意义。
High speed CNC machine tools is one of the developing direction and technologyfoundation of equipment manufacturing industry, and it is also a strategy industry forequipment manufacturing industry. The reliability of the key functional parts on CNCmachine tools effects on the reliability of the whole machine. As an important keyfunctional part, electric spindle’s reliability research has significant meaning forincreasing MTBF level for the whole CNC machine tools.
Key functional parts are CNC machine tools important sources of failure.Because its volume is little than a whole machine’s, and expense is less than a wholemachine, we can test it in a laboratory environment. We simulate real machiningworking conditions, induce or increase promoting component failure in laboratory,and measure its performance, identify the factors of failure, make statistics of failuredata, establish failure model, thereby the reliability of key functional parts has beenimproved. We achieved the way to improve the reliability of the CNC machine toolsthrough the development and study the reliability of the key functional parts.
High-speed electric spindle test and its test-bed are used to test axial runout,radial runout and spindle temperature rise of the electric spindles for CNC machinetools and machining centers and other factors impact on the reliability of electricspindle machining, and evaluate the electric spindle stability, reliability and accuracyto maintain before and after the machine tools working. According to the applyingsubject content and the main objective, we need to develop the comprehensiveperformance test system for general electric spindles, comprehensive test and evaluateon the stability and reliability of high-speed electric spindle combining with thetheoretical calculation.
The high-speed electric spindle’s reliability test-bed of electric dynamometerloading system described in this paper, is able to complete electric spindle reliabilitytest above18000r/min, greatly improve the speed than the ordinary electric spindleperformance test-bed. And it is able to achieve high-speed electric spindleperformance test absolutely, such as temperature rise control of the electric spindle,spindle radial runout and axial movement and other tests. It simulates spindle forcestatus (including radial force, axial force and torque) using electric dynamometerloading system and piezoelectric ceramic loading system to achieve electric spindledynamic loading experiments and tests. It is able to detect a variety of failure duringthe test, records information during the tests, and the data can be recorded and query,it collects parameter data for reliability analysis through configuration softwaretogether with boards and industrial computer control system, in order to provide aquantitative numerical evaluation platform to improve the reliability of the electricspindle.
After the test-bed debugging and a period of test and detection, the test results show that the high-speed electric spindle’s functions meet the standards, and it worksstable, it perform good in torque loading experiments. We got some test data, and alsofound some failures in the electric spindle. We recorded and analyzed the failures.The deep study on high-speed electric spindle reliability test-bed for the keyfunctional parts reliability of CNC machine tools has great significance.
引文
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