鄭州科技學院 本科畢業設計 （外文翻譯） 題 目 普通 X62W 銑床的數控化改造設計 學生姓名 專 業 班 級 學 號 院 （系） 指導教師（職稱） 完成時間 設計 Q 扣 1： 1459919609 Q 扣 2： 1969043202 X62W CNC milling machine transformation 1 general CNC transformation of the need for analysis Our about 3200000 existing machine tools, the machine tool technology status of ageing is serious, according to statistics, about 30% of the total country equipment in more than 16 years, of which nearly 30% of age more than 26 years, all these show the present our country did not go mainly rely on progress of science and technology of machine tools to transform track. In addition, with the development of science and technology, production is dependent on the degree of equipment increases increasingly, the crop of the enterprise, quality, efficiency, cost, safety and environmental protection and labor emotions get equipment restrict, realize the modernization of enterprise oneself be imperative. But according to the data, our metal cutting machine tool production only accounted for similar equipment to have an amount 1 / 28, such as the annual production of all the machines used to replace the old machine tool needs 28 years so, our country is solved at present equipment technical progress is the main way of machine tools. 2 domestic and foreign research present situation In todays world, industrial developed country to machine tool industry height seriously, competing for the development of mechanical and electrical integration, high precision, high efficiency, high automation and advanced machine tool, in order to accelerate the industrial and economic development. For a long time, Europe and the United States, Asia in the international market are in fierce competition, has formed an invisible front, especially with microelectronics, computer technology, numerical control machine tools in the nineteen eighties later accelerated development, put forward more requirements of all users, had become the four big international machine tool exhibition to display machine tool manufacturers advanced technology, for the user, enlarge the market focus. The more famous control system : Japan FANUC series, Mitsubishi series, OKUNIA series, SODICK series, series of Hitachi, Germany SIEMENS series, DECKEL series, Heidenhain series, HELLER series, the United States ALLEN-BRADLEY ( AB ) series, CINCINNANTI series, Num series, FIDIA series of France, Italy, Spain, Switzerland FAGOR series, AG series of domestic series. In the United States, Japan and Germany and other developed countries, they will machine transformation as a new economic growth sector, the business scene, is in the golden age. As the machine tool and the continuous advancement of technology, machine tools transformation is a timeless issue. Transformation of Chinas machine tool industry, but also from the old to the industry into the digital technology-based new industries. In the United States, Japan, Germany, with machine tool of numerical control technical reformation and production line has a broad market, has formed a production line of CNC machine tool and the new industry. In the United States, reconstruction of machine tool industry called machine regeneration ( Remanufacturing ) industry. Engaged in renewable industrys well-known companies: Bertsche engineering company, ayton machine tool company, Devlieg-Bullavd ( PO ) services group, US equipment company. The United States company has been in China for the company. Rebuilding of machine tool industry in Japan called machine modified ( Retrofitting ) industry. Engaged in refitting industry well-known companies have: Doomsday engineering group, three post machinery company, Chiyoda engineering machine company, Nozaki engineering company, Hamada engineering company, Yamamoto engineering company. Catch up with the pace of computer system structure, accelerate the development of NC system for NC development speed, has become the main trend. The fourth generation computer engineering structure and microelectronic technology as the basis, make full use of existing computer hardware, software resources, development of bus type, module type, open type, embedded on a flexible NC system, which is suitable for machining complex parts, vertical machine tool with CNC system, but also for future automation upgrades the function may be expanded requirements. China s NC system development has the following 3 features: ( 1 ) system of high-grade numerical control technology has been a breakthrough. As of I type numerical control system, with multi axis linkage function, fast feed speed in 1.67m / s above, have stronger communication, management function. ( 2) universal CNC system is a mature technology. Beijing Machine Tool Research Institute BS9l system, these systems are generally equipped with CRT display, can be configured to DC and AC servo drive, 2 4 shaft linkage. ( 3) the economic type CNC system still has vast market prospect. As a result of this kind of system has the advantages of simple structure, cheap price, very suitable for small and medium enterprises in China, is still the most widely applied in CNC system. A typical Nanjing generous JWK series. Our country is big country of production of machine tools, it is the use of power. NC machine tool is the key to the development of machinery industry products, Chinas CNC machine tool in machine tool products in the proportion of the overall low level of. But our country is a developing country, a lot of enterprises financial weakness, not likely to spend a lot of money on a lot of new CNC machine tools, while a large number of universal machine tool can not be all eliminated. Therefore, the transformation of general machine tools CNC machine is a effective way to improve the rate of NC machine tools transformation, less cost, reform targeted, time is short, after the transformation of the machine tool are able to overcome the original machine faults and problems, high production efficiency. 3 basic scheme comparison and selection NC transformation of the main general plan shall include the following contents: the servo drive system, numerical control device selection, electrical equipment, mechanical design, CNC hardware system. Show cent to narrate as follows. The 3.1 servo drive system Servo system is a important part of NC machine tool, its performance will directly affect the machining accuracy, surface quality and production efficiency, it can be divided into 3 kinds, namely, open loop, closed loop, loop. 3.1.1 open loop system Open loop system is the most simple servo, stepper motor as the open loop system main device, it has the advantages of simple structure ( electrical control and drive circuit is simple ), small volume, light weight, low price, convenient repair and maintenance characteristics 3.1.2 closed loop system Closed loop system, its structure is complex, technical difficulty is great, testing and repair more difficult, cost is high. Closed loop control can achieve good accuracy of machine tools, to compensate for mechanical transmission system in a variety of error, eliminate the gap, interference on the accuracy of processing, generally applied to the high requirements of NC equipment. 3.1.3 semi closed loop system Semi closed loop system with closed-loop system similar to, the position detection device is mounted on the execution component, but mounted on the drive motor end or the end of the drive rod, indirectly measured actuator position or displacement. Due to its wide range of speed ( 0.1 - 3OOO R / rain ), strong overload capacity, and the feedback control, the precision can reach 0.01 0.001nlln, as fast as 0.5 m / s, so its performance is far superior to the stepping motor open loop control, and the feedback link does not include most of mechanical transmission components, simple debugging ratio closed loop, the system stability can be easily ensured, than the closed loop is easy to realize. Therefore, using a closed-loop system, is more reliable and feasible. 3.1.4 AC, DC servo motor comparison Closed loop, half closed loop system can be AC or DC servo motor, the AC speed regulation gradually expanding the scope of application, seems to have replaced DC servo trend. But AC servo control of complicated structure, high technical difficulty, popularity is not wide, and the price is high ( DC servo motor 1.5 20000 yuan / Taiwan, AC servo motor is 2 - 30000 ) in addition, compared to the DC servo motor AC servo motor with large inertia, the small inertia, debugging difficulty big, when the sources are more difficult to repair components. DC servo motor principle similar to DC motor, control system technology is more mature, s pread wide, its main drawback is the large volume, large weight, but also with the commutator and brush, increased repair workload. Through the comparison, the success rate, technical difficulty, precision and investment and other factors, decided to adopt DC servo loop control. 3.2 numerical control device Numerical control device also has a variety of scheme selection. For example, can all of its own design, production； can use SBCs or STD module control； can use readily available numerical control device for a small number of applicable changes or matching. In the factorys practical application, generally use the following 2 kinds of solution. A kind of circumstance is required for the function and requirement of ready-made CNC device can meet, then used mostly to buy ready-made products solution, because of own design is not only a waste of time, investment is not necessarily can save investment, more often, and quality do not necessarily guarantee. Another kind of circumstance is not to buy off-the-shelf products to achieve some special function, then mostly adopt buy price performance ratio as high performance close to the device, and then to supplement or transformation, at least also bought STD template or industrial control computer, single board computer to make. According to the selected DC servo drive and processing requirements, the numerical control device can realize closed loop ( loop ) of control, provides the analog control signal, receives the half closed loop feedback signal to control； three coordinate axis of motion, wherein at least to simultaneously control linkage to complete the arc differential complement； in the processing of can use different size cutter, CNC device with cutting tool radius and length compensation in NC machining, so according to the contour programming and can adapt to the size of tool change, in order to meet the needs of future development and clear structure, decided to adopt the STD template, modular design. 3.3 other electrical devices In numerical control transformation, also needs to be combined with the numerical control device and servo drive configuration characterized by other electrical parts, including the strong and weak electrical signal conversion, transmission or processing necessary. The input / lucky bird out interface to consider whether isolation, shielding requirements； in addition, but also configure the needed power, all kinds of protection circuit, auxiliary circuit detecting display. 3.4 mechanical parts In the equipment of numerical control transformation, although is the core part of CNC, involve more is microelectronics and electrical, but not of all. If you ignore the mechanical aspects according to the characteristics of CNC machine tools for the corresponding necessary changes, or in the transformation of the design and manufacture of endless and reasonable, the results will give numerical control transformation brings beat all difficulties, and may even lead to failure because of mechanical problems. 3.5 CNC numerical control system The CNC system is composed of CPU memory template； servo motor interface circuit board； the keyboard, display interface circuit board and a switch quantity input, output interface circuit board. Each template main function is as follows. 3.5.1CPU memory board The board carried out various data operations, timer in the intervention, timing execution system program, coordination, management of various parts of the circuit to work. In addition, also has a power down protection, power on reset and generates a pulse signal and other functions. At the same time, board memory, for storing system software, computing the results of staging and storage parts processing program. Plate communication Interface for the boards and peripherals to provide a convenient communication. 3.5.2 servo motor interface circuit board The plate is connected to the servo motor and the CPU bridge. CPU issued a servo motor control instruction code, through the template D / A conversion, operational amplifier after being sent to the motor drive source, thus realizing the electrical automatic control. At the same time the motor running state, through the detecting device of the pulse, in the plate after processing, in the form of code into CPU, CPU adjust motor control instruction, thereby forming displacement closed loop system. If the pulse signal by F / V conversion, can get the speed control unit feedback voltage, which constitute a closed loop system. X62W 銑床數控化改造 1.普通機床數控化改造的必要性分析 我國現有機床 320 多萬臺，這些機床技術狀況老化嚴重，據統計，全國 30%左右設備在 16 年以上，其中近 30%的役齡超過了 26 年，這些都說明目前我國還沒有走上主要依靠科技進步對機床進行改造的軌道。另外，隨著科技的進步，生產依賴于設備的程度日益增大，企業的產量、質量、效率、成本、安全及環境保護和勞動情緒都受設備的制約，實現企業的現代化己勢在必行。但據資料介紹，我國的金屬切削機床年產量僅占同類設備擁有量的 1/28，如將 每年生產的全部機床用來更換舊機床需要 28 年所以，我國目前解決設備技術進步的主要途徑是機床改造。 2.國內外研究的現狀 當今世界，工業發達國家對機床工業高度重視，競相發展機電一體化、高精、高效、高自動化先進機床，以加速工業和國民經濟的發展。長期以來，歐、美、亞在國際市場上相互展開激烈競爭，己形成一條無形戰線，特別是隨微電子、計算機技術的進步，數控機床在 20 世紀 80 年代以后加速發展，各方用戶提出更多需求，早己成為四大國際機床展上各國機床制造商競相展示先進技術、爭奪用戶、擴大市場的焦點。較著名的控制系統有 :日本 FANUC 系列、 Mitsubishi 系列、OKUNIA 系列、 SODICK 系列、日立系列、德國 SIEMENS 系列、 DECKEL 系列、Heidenhain 系列、 HELLER 系列、美國 ALLEN-BRADLEY(AB)系列、 CINCINNANTI系列、法國 Num 系列、意大利 FIDIA 系列、西班牙 FAGOR 系列、瑞士的 AG 系列、國產系列等。 在美國、日本和德國等發達國家，它們將機床改造作為新的經濟增長行業，生意盎然，正處在黃金時代。由于機床以及技術的不斷進步，機床改造是個 “ 永恒 ” 的課題。我國的機床改造業，也從老的行業 進入到以數控技術為主的新的行業。在美國、日本、德國，用數控技術改造機床和生產線具有廣闊的市場，己形成了機床和生產線數控改造的新的行業。在美國，機床改造業稱為機床再生(Remanufacturing)業。從事再生業的著名公司有 :Bertsche 工程公司、 ayton機床公司、 Devlieg-Bullavd(得寶 )服務集團、 US 設備公司等。美國得寶公司己 在中國開辦公司。在日本機床改造業稱為機床改裝 (Retrofitting)業。從事改裝業的著名公司有：大限工程集團、崗三機械公司、千代田工機公司、野崎工程公司、濱田 工程公司、山本工程公司等。 趕上計算機體系結構前進的步伐、加快數控系統的開發速度，已成為數控發展的最主要趨勢。以第四代計算機的工程結構和微電子工藝技術為基礎，充分利用現有微機的硬件、軟件資源，發展總線式、模塊式、開放型、嵌入式的柔性數控系統，使之即適合加工復雜零件、分立式機床用的數控系統的組成，又適合未來自動化升級時功能可擴展的要求。 我國數控系統發展具有以下 3 個特征： (l)高檔數控系統技術已經突破。如華中 I 型等數控系統，都具有多軸聯動功能，快速進給速度在 1.67m/s 以上，具有較強的通信、管理功能。 (2)普及型數控系統技術已經成熟。如北京機床研究所的 BS9l 系統，這些系統一般配有 CRT 顯示器，可配置直流和交流司服驅動， 24 軸聯動。 (3)經濟型數控系統仍有廣闊的市場前景。由于這類系統結構簡單，價格便宜，非常適合中小型企業，目前仍是我國應用面最廣的數控系統。比較典型的有南京大方的 JWK 系列。 我國是機床生產大國，又是使用大國。數控機床是機械工業發展的關鍵產品，我國的數控機床在機床產品中的比例總體水平低。但是我國是發展中國家，許多企業財力薄弱，不可能花費大量的資金添置許多全新的數控機床，同時大量的通用機床 不可能全部淘汰。 因此，把普通機床改造為數控機床則不失為是一條提高數控化率的有效途徑，機床改造花費少，改造針對性強，時間短，改造后的機床大多能克服原機床的缺點和存在的問題，生產效率高。 3.基本方案的比較和選擇 數控改造主要的總體方案應包括以下內容：伺服驅動系統選擇，數控裝置的選擇，電氣設備選擇， 機械部分設計，數控硬件系統等組成。現分述如下。 3.1 伺服驅動系統 伺服系統作為數控機床的重要組成部分，它的性能優劣直接影響著機床的加工精度，表面質量和生產效率，它基本可以劃分為 3 種，即開環、閉環、半閉環。 3.1.1 開環系統 開環系統是最簡單的伺服系統，步進電機作為開環系統的主要裝置，它具有結構簡單 (電器控制和驅動電路也簡單 )，體積小，重量輕，價格便宜，使用維修方便等特點 3.1.2 閉環系統 閉環系統其結構復雜，技術難度大，測試和維修困難較多，造價也高。閉環控制可以達到很好的機床精度，能補償機械傳動系統中的各種誤差，消除間隙、干擾等對加工精度的影響，一般應用于要求高的數控設備中。 3.1.3