防窜焊接滚轮架窜动检测及防窜控制系统设计说明书[带图纸].doc

重庆理工大学毕业论文防窜焊接滚轮架：窜动检测及防窜控制系统设计目录摘要····························································································IAbstract···························································································II1.绪论··························································································11.1国内外焊接滚轮架发展现状······················································11.2课题的研究内容及意义·······························································22.防窜焊接滚轮架系统的结构设计及工作原理···········································22.1系统的结构设计·······································································22.2系统的工作原理·······································································33.筒体轴向窜动的理论分析···································································33.1焊接过程中常出现的一些问题·····················································33.2轴向窜动的主要原因·································································43,3滚轮架简体轴向窜动机理···························································53.4焊件不发生轴向窜动的充分条件··················································64.筒体轴向窜动的检测、调节及执行机构设计···········································74.1轴向窜动检测··········································································74.2调节方式的选择·······································································84.3调节执行机构的调节原理···························································94.4升降装置的选型·····································································105.系统控制部分················································································125.1系统硬件部分设计··································································125.1.1PLC控制器····································································125.1.2步进电机的计算与选型·····················································165.1.3步进电机驱动器的选用····················································215.1.4联轴器的选择································································225.1.5位移传感器选型·····························································225.1.6限位开关选型································································235.1.7控制面板的设计·····························································235.2系统软件部分设计··································································235.2.1防窜控制模式选择··························································245.2.2主程序控制图·································································255.2.3梯形图程序···································································256.总结···························································································29参考文献·························································································30文献综述·························································································31重庆理工大学毕业论文防窜焊接滚轮架：窜动检测及防窜控制系统设计I摘要焊接滚轮架是在焊接生产中与焊接工序相配一种辅助装置。在大厚壁、大型化、高容量、耐磨蚀的锅炉、石油、化工压力容器的焊接过程中，由于筒体的几何形状的不规则（偏离理想回转体）和焊接滚轮架的制造安装误差等原因，筒体在滚轮架上转动时，会不可避免的发生轴向窜动，从而影响环缝的焊接质量。本课题从理论上深入分析了筒体在焊接过程中产生轴向窜动的主要原因，分析了筒体轴向位移的调节机理，同时提出了采用螺旋升降装置和步进电机传动，用PLC控制器以脉冲控制的方式使步进电机精准的控制升降台的上升和下降的位移。此防窜焊接控制系统有效地解决了窄间隙埋弧焊、内壁堆焊的问题，智能化控制焊接过程中出现的轴向窜动，此设计实现了精密化、大型化、数字化、智能化等优点。不仅提高了生产效率而且确保批量生产过程中焊接质量的稳定性，节省因窜动进行人工调节的时间，减少劳动力，提高焊接的精度和质量，降低成本。关键词:窜动理论分析窜动检测调节执行机构硬件部分设计软件部分设计重庆理工大学毕业论文防窜焊接滚轮架：窜动检测及防窜控制系统设计IIAbstractWeldingrollerbedisintheweldingproductionandweldingprocesstomatchanauxiliarydeviceTheWeldingandProductioninthebigThick-Cliff、TheLarge-Scale、High-Content、Endure-AblationofthepressurevesseloftheBoiler、Oil、chemical,becauseofreasonoftheabnormityofgeometry-formofthecylinder(departureidealgyrationobject)andtheerrorofthemanufacture-installation,thecylinderwheelontherollerbed,inevitablyitwilloccuraxialdrifting,sothataffecttheweldingquality.Thistopicofcylinderwereanalyzedtheoreticallyintheweldingprocesstoproduceaxialchannelingmove,themainreasonoftheregulationmechanismofcylinderaxialdisplacementareanalyzed,atthesametimeputsforwardadoptingspiralliftinggearandstepmotordriving,PLCcontrollertocontrolbymeansofpulsetomakeprecisesteppermotorcontroldisplacementoftheriseandfalloftheliftingplatform.Theantichannelingweldingcontrolsystemcaneffectivelysolvethenarrowgapsubmergedarcwelding,theweldingproblem,intelligentcontrolintheweldingprocessoftheaxialchannelingmove,thisdesignimplementsthemotors,large-scale,digitalandintelligentadvantages.Notonlyimprovestheproductionefficiencyandensurethestabilityofweldingqualityinmassproductionprocess,saveforchannelingmanuallyadjusttime,reducethelaborforce,improvetheaccuracyofweldingandquality,reducecosts.Keywords:DynamicanalysisTheaxialdynamicdetectionAdjusttheactuatorThehardwarepartofthedesignSoftwarepartdesign重庆理工大学毕业论文防窜焊接滚轮架：窜动检测及防窜控制系统设计11绪论1.1国内外焊接滚轮架发展现状近年来，随着我国改革开放进程的深化，随着中外合作合作生产和引进技术生产的机械产品日益增多，促进了我国焊接结构用量的迅速增加。尤其是为满足我国石油、化工、交通、能源等工业的迅猛发展，大厚壁、大型化、高容量、耐磨蚀、耐动载的锅炉、石油、化工压力容器的用量更是日益增加，其接头的焊接质量要求也越来越高，并且在实际生产中要求有较高的生产效率。防窜焊接滚轮架就是在上述焊接生产中与焊接工序相配合，有利于实现焊接生产机械化，自动化，有利于提高装配焊接质量，促使焊接生产效率提高的一种辅助装置和设备。焊接滚轮架是借助主动滚轮与焊件之间的摩接力带动焊件旋转的变位机械。在筒形工件内外环缝的焊接中，组合式焊接滚轮架逐渐取代长轴式、固定式等焊接滚轮架，获得了广泛的应用，但如何合理的控制其焊接时的轴向窜动及主动轮的转速仍值得分析。组台式焊接滚轮架主要由主动轮座、从动轮座、支架三部分组成。支架相当于机座，轮座坐在其上对工件起支承作用，其中主动轮座还起驱动作用。这三部分自成独立单元，人们可利用其数量的协调变化组合成能驱动各种长度、各种直径、不同重量筒形工件的焊接滚轮架。但是，作为标准组台，是由两个支架和四个轮座组成的，其中至少有一个轮座是主动轮座。我国在1990年颁布的焊接滚轮架的行业标准（ZBJ/T33003-1990）中规定：主动滚轮的圆周速度应在660m/h范围内无级可调，速度波动量按不同的焊接工艺要求，要低于±5±10，滚轮转速应稳定、均匀，不允许有爬行现象。按GB150规定制造的筒体类工件在防轴向窜动滚轮架上进行焊接时，在整个焊接过程中允许工件的轴向窜动量为±3mm。国外于20世纪80年代中期推出的防止焊件轴向窜动焊接滚轮架，能将焊件的窜动量控制在±2mm以内。我国近年来也有个别工厂生产过防窜动滚轮架，但在实用性和可靠性方面，与国外产品相比还存在着差距。国外在80年代初期研制开发了一种防止工件轴向窜动的焊接滚轮架。如瑞典伊萨（ESAB）、意大利安莎多（ANSALDO）和英国（BODE）公司等都推重庆理工大学毕业论文防窜焊接滚轮架：窜动检测及防窜控制系统设计2出了这种产品。国外所研制的防轴向窜动焊接滚轮架与国内常规的焊接滚轮架相比，增加了一套高可靠度的轴向位移自动调节系统。在焊接过程中能同步调节筒体的姿态，使焊接过程可靠实施，大大提高了生产效率，同时可得到高质量的焊接接头。相比国外，我国防轴窜焊接滚轮架的研制还处于初始阶段，据调查，至今国内尚无正式厂家能够制造抽比较成熟的产品，生产中主要是依靠引进国外的设备，如兰州石油化工机械厂、哈尔滨锅炉厂、齐齐哈尔第一重型机械厂等，都是从国外引进的防轴向窜动的焊接滚轮架。这样，一方面要花费大量的外汇，另一方面也远远不能满足国内日益增长的焊接生产需要。1.2课题的研究内容及意义本课题主要研究的内容是：深入分析出现窜动的原因以及窜动机理；设计防窜滚轮架控制系统（包括控制部分软硬件、梯形图、电气原理）；焊接滚轮架的轴向窜动问题一直是各大企业及各使用者所关心的重要问题，本课题能从理论上有效的解决焊接滚轮架在焊接过程中出现轴向窜动的问题，提高焊缝的精度和质量；同时也提高我自己在这方面的知识。2防窜焊接滚轮架系统的结构设计及工作原理2.1系统的结构设计防窜滚轮架系统主要由驱动滚轮架，从动滚轮架，调节装置，电气控制系统，PLC，步进电机等组成。主动滚轮架的滚轮旋转采用交流变频电机驱动、变频调速，具有调速范围宽，转动平滑性好等特点；从动滚轮架装置是由底座、滚轮、滚轮座、防窜滚轮装置等组成，其底座固定；防窜滚轮装置由从动滚轮装置和升降机构组成，升降机构包括蜗轮丝杆升降机构、升降限位开关等。采用步进电机驱动升降机的升降，根据位移传感器检测到的工件轴向窜动信号，自动纠正工件的轴向窜动。主要用于管道、容器、锅炉、油罐等重型圆筒形工件的装配与焊接。若对从动滚轮的高度做适当的调整后还可进行锥体、分段不等径回转体的装配与焊接。