机械毕业设计（论文）-基于PLC的数控车床控制系统的设计.doc

编编 号号 无锡太湖学院 毕毕业业设设计计（论论文文） 题目：题目： 基于基于 PLCPLC 的数控车床控制的数控车床控制 系统的设计系统的设计 信机 系系 机械工程及自动化 专专 业业 学 号： 学生姓名： 指导教师： （职称：副教授 ） （职称： ） 2013 年 5 月 25 日 无锡太湖学院本科毕业设计（论文）无锡太湖学院本科毕业设计（论文） 诚诚 信信 承承 诺诺 书书 本人郑重声明：所呈交的毕业设计（论文） 基于 PLC 的 数控车床控制系统的设计 是本人在导师的指导下独立 进行研究所取得的成果，其内容除了在毕业设计（论文）中特 别加以标注引用，表示致谢的内容外，本毕业设计（论文）不 包含任何其他个人、集体已发表或撰写的成果作品。 班 级： 机械 94 学 号： 0923177 作者姓名： 2013 年 5 月 25 日 I 无无锡锡太太湖湖学学院院 信信 机机 系系 机机械械工工程程及及自自动动化化 专专业业 毕毕 业业 设设 计计论论 文文 任任 务务 书书 一、题目及专题：一、题目及专题： 1、题目 基于 PLC 的数控车床控制系统的设计 2、专题 二、课题来源及选题依据二、课题来源及选题依据 现代工业制造量很大，产品质量要求很高，传统的加工方法已经 基本无法打到生产的要求。为了能够在保证产品质量的前提下，最大 地提高工作效率，就必须采用先进的数控加工手段。数控系统就是指 械运动及加工过程进行数字化信息控制的所具备相应的硬件和软件 的总和。 数控技术在制造业中占有举足轻重的地位，甚至一定程度上代 表该国家的机械发展水平。如今数控技术已成为机械工业的自动化 三大支柱之一，从而成为世界各国学术界研究的重点和热点。目前我 国主要使用的还是以经济型车床为主，多以德国西门子和日本法兰 克系统为主体，但我国国产系统的发展潜力不容忽视。 三、本设计（论文或其他）应达到的要求：三、本设计（论文或其他）应达到的要求： 熟悉数控系统的发展历程，特别是近十几年来基于 PLC 的控制 系统； II 熟悉数控车床，包括机械结构、控制系统结构、工作原理等； 合理设计控制系统中各个子系统的控制方案； 掌握控制系统的各个硬件电路的设计以及运动控制器的连线与 PLC 的配线； 熟练 PLC 进行对数控系统进行软件编程，给出 PLC 控制步进电 机、主轴电机和系统报警程序； 熟练使用 MATLAB 进行所设计的系统仿真。 四、接受任务学生：四、接受任务学生： 机械 94 班班 姓名姓名 五、开始及完成日期：五、开始及完成日期： 自自 2012 年年 11 月月 12 日日 至至 2013 年年 5 月月 25 日日 六、设计（论文）指导（或顾问）：六、设计（论文）指导（或顾问）： 指导教师指导教师 签名签名 签名签名 签名签名 教教研研室室主主任任 学科组组长研究所学科组组长研究所 所长所长 签名签名 系主任系主任 签名签名 2012 年年 11 月月 12 日日 III 摘摘 要要 采用数控车床控制系统进行机械加工具有加工精度高、生产效率高、改善劳动力条 件、利于生产管理现代化的特点，极大满足对产品多样化的需求。 论文以数控车床为研究对象，对其基于PLC的控制系统进行了设计。 主要有一下几点内容： （1）提出了基于PLC数控车床的控制系统设计的总体方案：伺服驱动控制系统设计 方案、联动控制设计方案等。简单的地进行了对数控车床的主要机械结构、控制系统结 构以及数控车床工作原理和流程介绍 ； （2）较为详细地进行了数控车床控制的设计，其中包括元器件选则，硬件电路设计， 和相关模块的接线，如运动控制器的接线，PLC配线等以及PLC对步进电机、主轴电机、 电路报警的程序设计； （3）采用Matlab进行对本次设计中的进给系统进行仿真，进行了模型的建立，仿真 数据的分析。 关键词：关键词：PLC；数控车床；控制系统；仿真 IV Abstract The machining operation employs CNC lathe control system, and with the features of high precision, high production efficiency, improved labor conditions, conducive to production and modern management, which can greatly meet the diverse needs of the product. The study object of this paper is CNC lathe, and the main contents of its PLC-based control system designs are as following: the overall design program of PLC-based CNC lathe control system: design programme of servo drive control system, design programme of linkage control. A brief introduction about CNC lathe mechanical structure, control system structure as well as CNC lathe working principle and process are given; Give a detailed introduction on CNC lathe control design, including the components selection, hardware circuit design, wiring with related modules, such as motion controller wiring, PLC wiring as well as PLC program design on stepper motor, spindle motor and circuit alarm; To simulate the feed system by using Matlab, establish model, and carry out the analysis ofthe simulation data. Keywords: PLC; CNC lathes; control system; simulation V 目目 录录 摘 要.III ABSTRACT.IV 目 录 .V 1 绪论.1 1.1 数控系统的发展.1 1.1.1 国外数控系统发展.1 1.1.2 国内数控发展.1 1.2 数控加工的意义.2 1.3 PLC 在数控车床上功用、优点.3 1.4 课题研究背景及意义.4 1.4.1 研究意义.4 1.4.2 研究内容.4 2 基于 PLC 数控车床控制系统的设计方案.5 2.1 数控车床简介.5 2.1.1 数控车床机械结构.5 2.1.2 控制系统的组成.5 2.1.3 数控车床工作原理和流程.6 2.2 控制系统设计流程.6 2.2 控制系统设计方案.6 2.2.1 伺服驱动控制系统设计方案.6 2.2.2 联动控制设计方案.7 2.2.3 主轴控制系统设计方案.8 2.3 数控车床控制系统关键技术.9 2.4 本章小节.10 3 基于 PLC 数控车床控制系统的设计.11 3.1.器件选择.11 3.2 硬件电路设计.12 3.2.1 主电路设计.12 3.2.2 供电电源电路.13 3.2.3 供电电源接线.14 3.2.4 交流控制电路.15 3.2.5 直流控制电路.17 3.2.6 步进电机驱动电路设计.18 3.2.7 运动控制器设计.18 3.2.8 PLC 配线设计.20 3.3 软件设计.21 3.3.1 P LC 对步进电机控制程序设计.21 VI 3.3.2 PLC 对主轴电机控制程序设计.23 3.3.3PLC 故障报警设计.25 3.4 本章小结.26 4 基于 MATLAB 的仿真设计 .27 4.1MATLAB介绍.27 4.2 建立系统仿真模型.27 4.3 仿真结果及分析.27 4.4 本章小结.28 5 结论与展望.29 5.1 结论.29 5.2 不足之处及未来展望.29 致 谢.30 参考文献.31 1 1 绪论绪论 1.1 数控系统的发展数控系统的发展 数控系统（numerical control system）是数字控制系统的简称，它是机械运动及加工 过程进行数字化信息控制的所具备相应的硬件和软件的总和。 1.1.1 国外数控系统发展国外数控系统发展 采用数控技术进行机械加工的想法最早是在上个世纪40年代初提出。 第一阶段：数控阶段（NC）时间：19591970年 第一代数控系统（电子管数控系统）：1952年，由美国的著名麻省理工学院（MIT） 与美国帕森斯公司(Parsons Co)合作研发出世界上第一台三坐标的数控铣床，标志着数控 系统由此诞生。 第二代数控系统（晶体管数控系统）：借助于1959年电子相关行业研发的出晶体管 元件，并结合印刷电路板技术在电子计算机上的应用，数控系统成功地步入了第二代。 与此同时美国的耐.杜列克公司（Keaney (2)Information processing, processing, transmission technology; (3)Automatic control technology; (4)Servo drive technology; (5)Technology of the sensor; (6)Software engineering ,etc. Development trend of a numerical control technology The application of numerical control technology has not only brought the revolutionary change to manufacturing industry of the tradition, make the manufacturing industry become the industrialized symbol , and with the constant development of numerical control technology and enlargement of the application, the development of some important trades (IT , automobile , light industry , medical treatment ,etc. ) to the national economy and the peoples livelihood of his plays a more and more important role, because the digitization that these trades needed to equip has already been the main trend of modern development. Numerical control technology in the world at present and equipping the development trend to see, there is the following several respect 1- in its main research focus. 1 A high-speed, high finish machining technology and new trend equipped The efficiency, quality are subjavanufacturing technology. High-speed, high finish machining technology can raise the efficiency greatly , improve the quality and grade of the products, shorten production cycle and improve the market competitive power. Japan carries the technological research association first to classify it as one of the 5 great modern manufacturing technologies for this, learn (CIRP) to confirm it as the centre in the 21st century and study one of the directions in international production engineering. 无锡太湖学院学士学位论文 2 In the field of car industry, produce one second when beat such as production of 300,000 / vehicle per year, and many variety process it is car that equip key problem that must be solved one of; In the fields of aviation and aerospace industry, spare parts of its processing are mostly the thin wall and thin muscle, rigidity is very bad, the material is aluminium or aluminium alloy, only in a situation that cut the speed and cut strength very small high, could process these muscles, walls. Adopt large-scale whole aluminium alloy method that blank pay empty make the wing recently, such large-scale parts as the fuselage ,etc. come to substitute a lot of parts to assemble through numerous rivet , screw and other connection way, make the intensity , rigidity and dependability of the component improved. All these, to processing and equipping the demand which has proposed high-speed, high precise and high flexibility. According to EMO2001 exhibition situation, high-speed machining center is it give speed can reach 80m/min is even high , air transport competent speed can up to 100m/min to be about to enter. A lot of automobile factories in the world at present, including Shanghai General Motors Corporation of our country, have already adopted and substituted and made the lathe up with the production line part that the high-speed machining center makes up. HyperMach lathe of U.S.A. CINCINNATI Company enters to nearly biggest 60m/min of speed, it is 100m/min to be fast, the acceleration reaches 2g, the rotational speed of the main shaft has already reached 60 000r/min. Processing a thin wall of plane parts, spend 30min only, and same part general at a high speed milling machine process and take 3h, the ordinary milling machine is being processed to need 8h; The speed and acceleration of main shaft of dual main shaft lathes of Germany DMG Company are up to 120000r/mm and 1g. In machining accuracy, the past 10 years, ordinary progression accuse of machining accuracy of lathe bring 5m up to from 10m already, accurate grades of machining center from 35m, rise to 11.5m, and ultraprecision machining accuracy is it enter nanometer grade to begin already (0.01m). In dependability, MTBF value of the foreign numerical control device has already reached above 6 000h, MTBF value of the servo system reaches above 30000h, demonstrate very high dependability . In order to realize high-speed, high finish machining, if the part of function related to it is electric main shaft, straight line electrical machinery get fast development, the application is expanded further . 1.2 Link and process and compound to process the fast development of the lathe in 5 axes Adopt 5 axles to link the processing of the three-dimensional curved surface part, can cut with the best geometry form of the cutter , not only highly polished, but also efficiency improves by a large margin . It is generally acknowledged, the efficiency of an 5 axle gear beds can equal 2 3 axle gear beds, is it wait for to use the cubic nitrogen boron the milling cutter of ultra hard material is milled and pared at a high speed while quenching the hard steel part, 5 axles link and process 3 constant axles to link and process and give play to higher benefit. Because such reasons as complicated that 5 axles link the numerical control system , host computer structure that but go over, it is several times higher that its price links the numerical control lathe than 3 axles , in addition the technological degree of difficulty of programming is relatively great, have restricted the development of 5 axle gear beds. At present because of electric appearance of main shaft, is it realize 5 axle complex main shaft hair structure processed to link greatly simplify to make, it makes degree of difficulty and reducing by a large margin of the cost, the price disparity of the numerical control system shrinks. So promoted 5 axle gear beds of head of complex main shaft and compound to process the development of the lathe (process the lathe including 5). At EMO2001 exhibition, new Japanese 5 of worker machine process lathe adopt complex main shaft hair, can realize the processing of 4 vertical planes and processing of the wanton angle, make 5 times process and 5 axles are processed and can be realized on the same lathe, can also realize the inclined plane and pour the processing of the hole of awls. Germany DMG Company exhibits the DMUVoution series machining center, but put and insert and put processing and 5 axles 5 times to link and process in once, can be controlled by CNC system or CAD/CAM is controlled directly or indirectly. 1.3 Become the main trend of systematic development of contemporary numerical control intelligently, openly, networkedly. 基于 PLC 的数控车床控制系统的设计 3 The numerical control equipment in the 21st century will be sure the intelligent system, the intelligent content includes all respects in the numerical control system: It is intelligent in order to pursue the efficiency of processing and process quality, control such as the self-adaptation of the processing course, the craft parameter is produced automatically; Join the convenient one in order to improve the performance of urging and use intelligently, if feedforward control , adaptive operation , electrical machinery of parameter , discern load select models , since exactly makes etc. automatically; The ones that simplified programming , simplified operating aspect are intelligent, for instance intelligent automatic programming , intelligent man-machine interface ,etc.; There are content of intelligence diagnose , intelligent monitoring , diagnosis convenient to be systematic and maintaining ,etc. Produce the existing problem for the industrialization of solving the traditional numerical control system sealing and numerical control application software. A lot of countries carry on research to the open numerical control system at present, such as NGC of U.S.A. (The Next Generation Work-Station/Machine Control), OSACA of European Community (Open System Architecture for Control within Automation Systems), OSEC (Open System Environment for Controller) of Japan, ONC (Open Numerical Control System) of China, etc. The numerical control system melts to become the future way of the numerical control system open. The so- called open numerical control system is the development of the numerical control system can be on unified operation platform, face the lathe producer and end user, through changing, increasing or cutting out the structure target(numerical control function), form the serration, and can use users specially conveniently and the technical know-how is integrated in the control system, realize the open numerical control system of different variety , different grade fast, form leading brand products with distinct distinction. System structure norm of the open numerical control system at present, communication norm , disposing norm , operation platform , numerical co