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关键词：: 真空抬包设计大速比倾包系统 cad图纸

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真空抬包设计大速比倾包系统设计

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摘要

　　　真空抬包是电解铝冶炼过程中的一个重要设备，其主要功能是将电解槽中的电解铝液吸出并倒运至混合炉，是转运铝水的重要设备。真空抬包能够将电解槽中的电解铝液吸出并倒运到混合炉后浇铸成铝锭。该设备维护费用低、安全性高、工人劳动强度低等特点，一次可吸取几个电解槽内的铝液并直接送至混合炉，无需中途转浇包倒运，铝液热量损失小。该抬包采用正压喷射吸铝，改变了传统的负压直接吸铝，消除了负压吸铝对真空系统的危害，由于其可与电解槽共用一个气源，可省去整套真空系统，减少岗位配置，降低设备维护、检修费用，节约运行中的电费开支。

　　　真空抬包采用茶壶式浇包的结构形式，铝液从包底浇出，熔渣被挡在包内，撇渣效果好。减速机是抬包的倾转机构，采用3级蜗轮蜗杆减速机。由于抬包容积的增大，自重及盛铝量均增大，抬包的倾转力矩增大，手动倾转费力、效率低而且不安全，该减速机在结构形式设计为手动与电动均可，正常操作为电动，手动为检修和突发事故时用，手动与电动的切换采用爪式离合器，切换迅速方便，安全可靠。该减速机电动为三级蜗轮蜗杆减速，手动为两级蜗轮蜗杆减速，减速比大。

关键词：真空抬包、减速机、蜗轮、蜗杆

Abstract

　　Vacuum Ladle electrolytic aluminum smelting process is important for the equipment, Its main function is to the electrolytic aluminum electrolytic cell fluid aspirated and unlucky to mixed stoves, aluminum water transit is important equipment. Ladle vacuum can be electrolyzer the smelter was sucked out of the mix and unlucky after casting furnace into ingots. The equipment maintenance costs low, safe, low labor intensity characteristics, Several lessons can be a cell of molten aluminum and directly sent mixed furnace without the halfway turn Ladle unlucky. Al small liquid heat loss. Ladle the use of suction pressure spray of aluminum, changed the traditional vacuum suction direct aluminum, Elimination of aluminum suction vacuum system for the harm, because of their shared cell with a gas source. package can be saved vacuum system to reduce the allocation of posts, reducing equipment maintenance, repair costs, saving operation of the electricity bill.

　　Ladle using vacuum-pouring teapot packet structure, aluminum liquid poured from the underwrite that was blocking the slag ladle, skims good effect. Reducer is Ladle dip turn, used three worm-drive. Ladle volume due to the increase of self-respect and all aluminum volume increased, ladle the tilting torque increases, manual dumping switch effort, inefficient and unsafe, the slowdown in aircraft structure design of the manual and electric may, the normal operation of electric, Manual for Maintenance and use of emergency, manual and electrical switch using a claw-type clutch, switching speedy and convenient, safe and reliable. The electric drive for three worm-slow manual for the two worm-deceleration than decelerating.

　　　Keywords : vacuum ladle, reduction gears, worm gears, Worm

前言……………………………………………………………………………………1

1 项目分析……………………………………………………………………………3

　　1.1 真空抬包系统现有情况………………………………………………………3

　　1.2 本次设计改进所要解决的问题………………………………………………3

2 真空抬包总体设计方案……………………………………………………………5

3 大速比倾包系统设计………………………………………………………………6

　　3.1 倾转力矩的分析………………………………………………………………6

　　　3.1.1 空包包体的倾转力矩 …………………………………………………6

　　　3.1.2 余留铝液的倾转力矩 …………………………………………………7

　　　3.1.3 摩擦力矩 ………………………………………………………………9

　　　3.1.4 结论分析 ………………………………………………………………9

　　3.2 减速机构的分析………………………………………………………………9

　　　3.2.1 蜗轮蜗杆减速机介绍 …………………………………………………9

　　　3.2.2 传动比的分配…………………………………………………………11

　　　3.2.3 电动机的选择…………………………………………………………11

　　　3.2.4 蜗轮蜗杆设计…………………………………………………………11

4 真空抬包工艺参数 ………………………………………………………………21

5 主要部分的设计计算与校核 ……………………………………………………22

　　5.1 吊钩处………………………………………………………………………22

　　5.2 吊臂处………………………………………………………………………22

　　5.3 吊臂与包体连接处…………………………………………………………23

6 经济性分析 ………………………………………………………………………24

总结 …………………………………………………………………………………25

致谢 …………………………………………………………………………………27

参考文献 ……………………………………………………………………………28

前言

　　　众所周知，铝资源是铝业乃至国家铝工业的生存之基本和发展之本。是中国铝业如何实现铝矿资源持续稳定供应，是中围铝工业在市场竞争中求得生存并实现可持续发展必须要解决的重大课题。我国氧化铝工业的产量山l999年的146．1万吨增至2004年的700万吨，午均增幅为27．08％。但是，随着国内新建氧化铝企业生产能力的不断释放，市场竞争同趋激烈。自中国加入世界贸易组织后，逐渐实现了贸易白由化，进口氧化铝随着关税的逐步降低，配额等数量限制措施的消除都导致我国氧化铝企业受到国外氧化铝企业的冲击。随着氧化铝生产能力的提高，铝土矿一氧化铝一电解铝产业链中的瓶颈逐渐向铝土矿转移。在氧化铝的产量规模方面，我国一直遵循稳步提高的原则。但近几年来，我国氧化铝的增长速度明显加快。2000~2004年，氧化铝产量从432万吨增长到700万吨，年均增幅为12．3％，但是仍然难以满足铝业的要求，因此，从2001年开始，我围氧化铝进口量每年都以100万吨的速度递增。2004年我国共进口587万吨氧化铝，达到当年同内氧化销产茸的83％，是当年国内氧化铝需求的45％，比2000年我国进口氧化铝188万吨增张399万吨，累计增加2l3％。但是随着我国氧化铝产量的逐渐提高，氧化铝进口增幅正在下降。2006年前5 个月我国氧化铝产量98.8万吨，同比增长49．33％，其中非中铝公司，产量为98．8万吨，同比增长67．8％。同期氧化铝进口量278万吨，同比下降8．52％，特别自3月份

以来，连续3个月出现口氧化铝负增长。与此同时，中国氧化铝的出口量在不断增加。有报告显示，中围将在2008年成为氧化铝的纯出口国。

　　　真空抬包是电解铝冶炼过程中的一个重要设备，主要功能是将铝电解槽中的电解铝液吸出并倒运至混合炉，本抬包适用于铝铸造行业，既可直接采用负压吸铝，也可通过喷射器利用压缩空气抽真空吸铝，抬包减速机为手动、电动两种操作均可，并可采用爪式离合器进行切换，抬包包衬采用重质浇注料整体浇注，强度高，使用寿命长。包体上焊接固定有喷嘴、吸铝管和出铝口，吊装总成连接机架，机架上装有传动机构，包盖上锁紧装置采用肘节式压紧，包盖侧板与连接板一端铰接，连接板另一端与肘节式把手铰接，肘节式把手前端与T型导杆横边一端固定连接，导杆横边另一端与侧板铰接，导杆坚边装有螺栓，包盖上与螺栓对应处固定有凸台。真空抬包系统，结构简单，性能好，容积大，大大提高生产率，降低成本，非常适用于电解铝生产线。

　　　本次毕业设计对中原铝业河南分公司机械制造分公司的真空抬包系统，在原有的基础之上及厂里工程技术人员和老师的指导下进行改进和优化设计，得到现在的设计成果。以降低产品成本，最大的发挥原有产品的效能，提高产品的竞争力，提高经济效益，以适应竞争日益激烈的市场，为企业创造效益。也使我们的设计水平得到提高，提高了动手及创造的能力，是理论与实践的结合，使大家明确设自己设计目的和设计原则，为日后的工作打下一个良好的基础。　

1.项目分析

1．1真空抬包系统现有情况：

　　　中国铝业河南分公司电解厂原电解槽为60kA自焙槽，年产铝量为3万吨，采用容重为2吨的真空抬包来吸铝，并配合5吨的敞口包来倒运即可满足生产的需要。随着电解技改扩建项目的完成，电解槽变为85kA预焙槽，电解厂年产铝量为5万吨，为解决铝液抽吸运转效率低下、铝液热量损失大的问题，需要研发容重为 4~6 吨无需中转浇包倒运的真空抬包。随着国内一些大型预焙电解槽的研发成功，电流已陆续提高至160kA.200kA.280kA.320kA，电解槽产铝量大增，小型吸铝真空抬包已不能满足生产的需要。

1．2 本次设计改进所要解决的问题：

　　　吸铝真空抬包在外形上一般为普通倾注式锥桶形真空抬包，在结构上可分为包体、人孔、吊架、吸铝管、减速机及真空管等几部分，减速机可以手动操作。真空抬包主要用于电解铝厂，工作时直接采用负压吸铝，需要单独配置一套真空系统，由于吸入空气温度较高，真空泵一般采用水环真空泵，设备配置价高。抬包的清渣、检修及砌包衬均通过人孔进行，极为不便。为提高使用效率，使用时往往需要大型敞口浇包配合使用，这样会带来铝液热量的损失。而需解决这些问题所采用的方法是：

　　　包盖与包体的密封及防变形措施。对于大型吸铝真空抬包，包体直径较大，包盖与包体法兰采用凸凹止口密封，密封件为石棉盘根。由于包盖与包体受热不均以及包体在起吊时的受力不均，容易导致包盖与包体法兰止口错位，从而引起密封不严。对于这个问题，一方面要加强包体与包盖强度，包体与包盖均需加筋，采用厚法兰。另一方面要采用合理的密封方式，可将包盖法兰嵌入至包体法兰内，形成双重止口密封，一旦小止口密封失效，可启用大止口密封。

　　　包衬及吸铝管使用寿命。对于小型吸铝真空抬包，由于其直径小、高度低，采用耐火砖砌包衬，其强度足可满足其使用寿命，对于大型吸铝真空抬包，由于其容积大，包衬必需采用浇注料整体浇注，其强度才可满足使用寿命。吸铝管属耗损件,为提高其使用寿命,可采用耐温900℃以上的耐热铁铸造，并需进行热处理，耐热铁材质中Si含量不可过高，以防止和电解槽中的氟化盐发生化学反应，影响吸铝管使用寿命。

　　　转轴位置的确定及倾转力矩的计算。对于大型吸铝真空抬包，由于采用电动操作，从操作安全的观点出发，转轴位置应高于空包和满包的重心。抬包倾转力矩M 包括空抬包包体所引起的转矩M1，以及在浇注过程中由于铝液不断倾出，余留在抬包内的铝液所引起的转矩M2，此外还有转轴与其轴颈的摩擦力矩M3，三者均为转角θ的函数。　M=M1+M2+M3　　　　　　　　　　　　　

2．真空抬包总体设计基本方案

1．外形为圆柱状，方便制作、节省材料，与同体积锥桶形真空抬包相比，散热面积小，有利于保温。虽然锥桶形抬包比圆柱状抬包更有利于清理熔渣及残余铝液，但对于大容积抬包清除残渣已较为方便。

　　　2．采用茶壶式浇包的结构形式，铝液从包底浇出，熔渣被挡在包内，撇渣效果好。抬包带包盖，包盖与包体采用活节螺栓连接，固定方便。包盖与包底封头采用平底封头。抬包大修、清渣、砌包衬均可开盖进行，十分方便。考虑到抬包的少量清渣、日常检修以及解决抬包在使用间歇中自身散热的问题，在包盖上设立了人孔。

　　　3．包嘴盖设计成快开的结构形式，包嘴盖与包口管铰接，并采用搭扣来控制包嘴盖的开启与关闭，使用安全方便。

　　　4．采用喷射器利用压缩空气抽真空吸铝。考虑到电解槽工作时，打壳下料、母线提升等工序均采用压缩空气工作，因此可与电解槽共用一个气源，减少设备配置。

　　　5．喷射器由工作喷嘴、负压室、扩压管、接收室、消声器等组成，压缩空气通过收缩的喷嘴后，在负压室内形成一束高速射流，吸卷负压室内的空气一起进入扩压管，在扩压管内减速扩压后进入接收室，最后在接收内消音后排出至大气。

　　　6．减速机是抬包的倾转机构，由于抬包容积的增大，自重及盛铝量均增大，抬包的倾转力矩增大，手动倾转费力、效率低而且不安全，该减速机在结构形式设计为手动与电动均可，正常操作为电动，手动为检修和突发事故时用，手动与电动的切换采用爪式离合器，切换迅速方便，安全可靠。该减速机电动为三级蜗轮蜗杆减速，手动为两级蜗轮蜗杆减速，减速比大。

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内容简介：: 14. CNC MACHINES Computer Numerical Control machines use a computer to guide a process that might otherwise be done manually. 14.1 MACHINE AXES14.2 NUMERICAL CONTROL (NC) The use of numerical data to drive a machine for processes such as,- milling- turning- drilling- grinding- shot peening- tube bending- flame cutting- automated knitting machines- automatic riveting- etc. Basic components of NC systems,- program- controller unit- machine tool Most suited to,- parts are pr ocessed frequently in small lot sizes- complex part geometry- close tolerances on workpart- many oper ations on part in processing- large amounts of metal to be removed- engineering design will possibly change- parts that are too expensive for mistakes The methods for developing NC programs include,- manual part programming- computer-assisted part programming- computer gener ated programs The manual and computer aided methods use various NC programming languages,- APT (Automatically Programmed Tools)- AUTOSPOT (Automatic System for Positioning Tools)- SPLIT (Sundstrand Processing Language Internally Translated)- COMPACT II- ADAPT (ADaptation of APT)- EXAPT (Extended Subset of APT)- UNIAPT These languages are used by a parts programmer to define the motion of the cutting tool. The languages may be preprocessed, and then used for a number of various control types, such as,- punched paper tape- Computer Numerical Control (CNC)- Direct Numerical Control (DNC) The automatic methods work with geometry created in a CAD program.14.2.1 NC Tapes NC Progr ams are preprocessed on computers, and punched onto paper or mylar tapes. Simple NC machines can use a tape reader to direct the machine. Problems,- required storage, transportation, and manual loading of NC tapes- has to reread the tape for each new part- tapes tend to wear, and become dirty, thus causing misreadings- the mechanical parts in the readers reduced reliability- testing had to be done on the NC machine- no program editing abilities (increased lead time) The end of tapes was the result of two competing developments- DNC used remote computers to replace tape readers, these were displaced in most cases by CNC- CNC allowed the use of a local computer to overcome problems with tapes, and the problems with distant computers. While CNC was used to enhance tapes for a while, they eventually allowed the use of other storage media, and cur rently program transfer media are not required. 14.2.2 Computer Numerical Control (CNC) A computer controller is used to drive an NC machine directly. Characteristics are,- controls a single machine- located very close to machine tool- allows storage/retrieval/entry of NC programs without preprocessing of NC code Advantages of CNC,- progr am is only entered into memory once, so it is more reliable- the programs can be tested and altered at the machine- increased flexibility and control options on the local computer- easy to integrate into FMS systems The Background,- the problems with NC tapes were approached using DNC networks- the communication problems with DNC systems became obvious, and local computers were added to act as tape readers which would read tapes once, and play them back to the NC machine indefinitely- CNC controllers began using other storage media like magnetic tapes, and floppy disks- CNC now offers features like,- local programming,- communication over interfaces,- hard disk storage,- program simulation- etc. ASIDE: Direct Numerical Control is similar to CNC, except a remote computer is used to control a number of machines. This gives the advantage of more computer power. This approach is no longer popular, as the dropping cost of computers offsets any advantages. Some companies use proprietary NC Languages,such as the example of DYNA Mill NC code shown later These machines are often programmed by downloading NC code from a computer, or manually programming the controller computer. Future trends involve,- adaptive feed rates to increase speeds as the metal removal rate varies- tool wear detection 14.2.3 Direct/Distributed Numerical Control (DNC) Uses a few methods,- the oldest methods used modems, and a mainframe which emulated a tape reader, to control the NC machine (no storage)- a more recent advance used a local computer which acts as a storage buffer. Programs are downloaded from the main DNC computer, and then the local controller feeds instructions to the hardwired NC machine, as if they have been read from tape.- the newer methods use a central computer which communicates with local CNC computers (also called Direct Numerical Control) DNC controllers came before CNC machines, but as computer technology impr oved it became practical to place a computer beside the NC machine, and DNC changed in form. Characteristics of modern DNC systems are,- uses a server (with large storage capacity) to store a large number of part programs。- the server will download part programs on demand to local machines- may have abilities to,- display and edit part programs- transmit operator instructions and other data needed at the machines- collect and process machine status information for management purposes Advantages are,- eliminates the need for NC tapes (the advantages are obvious)- design changes are immediate- NC programs may be edited quickly- can be used to support an FMS system- increase efficiency of individual machine tools- more shop up-time than with stand alone machines- simplifies implementation of group technology, computer aided process planning, and other CIM concepts-reduces peripheral costs with NC tapes A Brief History, Mid 60s- concept proved by Cincinnati Milacron and G.E.- telephone links used to send instructions from large computers to hard wired NC machines. Basically replaced a tape reader. 1970- several commercial DNC systems announced. Mid 70s- Aerospace companies used DNC because of the large number of distributed -machines in their facilities. Initial resistance to DNC technology was (previously) based on,- high cost of computer hardware- the number of machines which could be controlled by one computer was limited- computer sof tware was limited for maintenance, scheduling, control, and data collection- a backup computer was usually required- was hard to justify on the basis of downloading parts programs when downloading programs there are two popular opinions,- a program should only be downloaded in part, this accommodates easy engineering changes in a real-time environment.- many programs should be downloaded to the local controller to provide protection against system failure, and eliminating the cost of real-time response in the DNC centr al computer.14.3 EXAMPLES OF EQUIPMENT The number of NC machines available commercially will be well into the thousands. 14.3.1 EMCO PC Turn 50 This is a small desktop lathe capable of turning parts in metal. The basic physical specifications are, Cutting volume radial travel 48mm rad axial travel 228mmMax.holding volume radial 30-65mm axial 300mm 12mm by 12mm Max.tool size max 80mmm diaChuck 130-3000rpmSpindle 0.001mmResolution 0-750mm/minFeed =600N below 500mm/minFeed force 100/110/230VAC,0-6KVAPower 840 by 695 by 345 mm The basic sequence of operations for this machine are,1. Unpack components.2. Connect devices to power, air supply, and attach interface cables 3. Install RS-485 card in PC.4. Install software.5. Test basic system (Done initial setup here).6. Start and initialize lathe and PC with software.7. Setup tools for new job. Find zero positions/offsets, and enter values for turret.8. Load NC code.9. Simulate program.10.Load stock and close automatic chuck.11.Close door.12.Run program on Lathe.13.Open door and open chuck.14.If cutting a similar part go to step 8, if doing a new setup go to step 7. 14.3.2 Light Machines Corp. proLIGHT Mill This is a small desktop lathe capable of turning parts in metal. The basic physical specifications areCutting Volume Max. Holding VolumeMax. Tool SizeSpindle 200-5000rpmResolutionFeed 50ipm x,y and 40ipm zFeed ForcePowerDimensionsWeightController IBM compatible computerControl Interface IBM compatible computerProgramming G-Codes and Dos softwarSpindle 1 H.P. The basic sequence of operations for this machine are,1. Unpack components.2. Connect devices to power, air supply, and attach interface cables.3. Install software.4. Test basic system (Done initial setup here).5. Start and initialize mill and PC with software.6. Setup tool for new job. Find zero position/offset.7. Load NC code.8. Simulate program.9. Run pr ogram on Mill.10. If cutting a similar part go to step 7, if doing a new setup go to step 14.4 PRACTICE PROBLEMS14.5 TUTORIAL - EMCO MAIER PCTURN 50 LATHE (OLD) The lathe is shipped with software that is meant to emulate shop floor interfaces. We donnot have the standard keyboard, so we need to use special key stroke sequences on the PC keyboard. Procedure:1. Connect the air supply to the lathe and make sure that the regulator on the lathe is between 25 and 75 psi - 50 psi is good. Ensure that the lath is connected to the PC with the DNC cable. The computer card must also have a terminator on the second connector - this is an empty connector. Turn on the lathe, and the PC.2. Once the PC is booted, run the emco control software. The screen may come up with warnings. If these warnings dont disappear when you hit ESC call the instructor.3. First we must zero the lathe. To do this first hit F1 and then F7?-ZRN. A small label ZRN should appear near the bottom of the screen. Press 4 on the number pad of the keyboard - the lathe should move in the x dir ection. Next, press 8 on the keyboard, the lathe should move in the z direction. After all motion has stopped the lathe is calibrated, and it will be put in jog mode.4. You can move the lathe with the keys on the number pad as well as perform other function.4 - move carriage left6 - move carriage right2 - cross slide out8 - move cross slide in7 - turn spindle on6 - turn spindle off2 - turn on/off chip blower1 - turn tool turret+/- - increase/decrease feed5. You can now put the mill in MDI mode by pressing F1 then F6?-MDI. Push the door open and hold it for a second, it will then stay open. Clear the error on the screen with ESC and press the chuck should open and close. Mount a work piece and then close the door.6. Put the computer in program mode -14.6 TUTORIAL - PC TURN 50 LATHE DOCUMENTATION: (By Jonathan DeBoer) SETUP:The lathe is controlled by a computer through an RS485 port. RS485 is a serial data bus that can be chained from one device to another and must be terminated.The controlling computer must be running Windows 3.1 or 3.11 and must have the RS485 card installed. Windows 95 will not get along with the interface card, and the software refuses to use an RS232 port with an RS485 adapter. The machine should have as few peripherals as possible; if one device happens to use any of the IRQs/DMAs/IO ports as the RS485 card, there will be problems. So remove sound cards, extra interface cards, etc. The RS485 card has two DB9F connectors on the back, plug the cable from the lathe in one and a terminator in the other.Install WinNC (the control software) under Windows 3.1. There are two disks; the installer and a machine data disk.The lathe needs to be plugged in to the computer, to a power outlet (of course), and to an air supply at 50-75 psi (less than 50 and there isnt enough pressure to open the door). A pressure gauge is on the left side of the machine, all plugs/etc are on the right. POWER ON/OFF:To Turn On: Turn on the computer and machine. To turn on the machine, turn the key on the right side. On the computer, launch Windows if neccisary. Once windows is running, launch WinNC. Make sure NumLock is on befo re launching WinNC. WinNC will then establish communication with the machine.To Turn Off: To just shut off the lathe but not the computer, just turn the key on the lathe. An error will co me up in WinNC indicating it lo st RS485 communication. Not to worry; when the lathe is turned back on later, hit ESC and the error will go away.To turn off both, exit WinNC by hitting Alt-F4 and then exit Windows. Then Simply switch off both the machine and the computer. OPERATION:Some notes:The EMCO software is distinguished by having the most counter-intuitive, unnatu-ral, information-withholding, and ornery interface known to man. Most technical references available are in German。The software periodically pops up error messages for minor and major errors. Errors can be dismissed by pressing ESC. If they dont go away, there is a problem that needs to be looked into.At the bottom of the screen is a menu of options you can select with the F3-F7 keys. This is called the softkey list by the Emco documentation, and will henceforth be referred to as the menu.A note on coordinates: The X axis is into/out of the material. X = 0 should be the center of rotation. As long as X is a positive value, moving along X in the positive is moving the tool out of the material and away from center. Moving along X in the negative is moving into the material and toward center.The Z axis is along the length of the part (along the axis of rotation). Moving along Z in the negative direction is moving toward the spindle head (to the left, facing the machine). Moving along Z in the positive direction is moving away from the spindle head (to the right, facing the machine)。Modes:The software is ruled by mo des. What mode the software is in determines what it can do and what it displays. I f something doesnt work or doesnt look right, check what mode the software is in. Remember operational modes are set independently of display modes. The operational mode can be EDIT but programs cannot be edited until the view mode is set to PRGRM, and vice versa.Hit F1 to get a menu of operational modes: ZRN mode is used for zeroing the tool position. This should be done the first thing afterthe machine is turned on. JOG is used for manual control of the lathe. MDI is used for changing tools, opening chuck, etc. (actually, you can do all this with JOG) EDIT is used for editing, loading, and exporting programs. AUTO is used for running programs.Hit F12 to get display modes:Note: when you switch view modes, the menu changes.The default is ALARM mode, which displays operator messages and alarms. Hit F3 to display alarms, F5 to display operator messages.POS mode displays positions.Hit F3 to display the current absolute position, F4 for the current relative position, and F5 for a variety of details. PRGRM mode displays the program. Hit F3 to display the program code, hit F4 for a list of all the programs available. If the operational mode is EDIT, you can also edit the code when you hit F3 。 OFFSET is used for displaying and changing offset values. Hit F3 for wear adjustment and F4 for geometry. These are both parameters for tools.Data for up to 16 tools can be stored at once. Hit F5 for work shift. This is how the working reference point is set. See below. PARAM is used for changing setup parameters and viewing system information. Hit F3 for setup see below for details. Hit F4 for diagnostics on the RJ485 por t and the software version。 GRAPH is used to simulate output with a graphThe fact that all these modes must share the menu can cause confusion.Remember that if you should be seeing a menu and you arent, the menu you are looking for may be behind the one you are seeing. For example, when you switch to a display mode, you should see the menu f or that display mode. If you hit F1, that menu is covered up by the menu to select an operational mode. Once you select something from that menu, you will see the view modes menu again.Keyboard control:Note on keyboard control: Many of the keys outlined in the manual are for German keyboards only and are mapped differently on US keyboards. Use this as reference, NOT the manual:Alt-F4 - ExitESC - Dismiss error messageF1 - mode menuF3 thru F7 - select item from current menuF11 - scroll through menus when they are too wide to fit on the screen (like the MORE key on a Ti-85 calculator)F12 - function key menuCtrl- - open/close chuck (must not be in EDIT mode, door must be open)Ctrl- - open/close door (spindle must be off)Ctrl-1 - change tool (must not be in EDIT or ZRN mode, door must be closed)Ctrl-2 - Turn on/off blowerCtrl-6 - Turn off spindle (JOG mode)Ctrl-7 - Turn on spindle (JOG mode, door must be shut)arrows - move cursor in the editoron the numeric keypad:4 - move -Z in JOG mode, or zero Z axis in ZRF mode6 - move +Z in JOG mode, or zero Z axis in ZRF mode2 - move -X in JOG mode, or zero X axis in ZRF mode8 - move +X in JOG mode, or zero X axis in ZRF mode5 - zero both axis in ZRF mode From：Integration and Automation of Manufacturing Systemsby Hugh Jack14.数控机床计算机数控机床使用一台计算机引导一个可能需要手工完成的过程14.1机床坐标轴14.2 数字化控制使用数字数据驱动机器进行的加工过程如下-铣削-车削-钻削-磨削-喷丸加工- 折弯-火焰切割-自动化编制机-自动铆接-等数控系统的基本组成部分-程序-控制器单元-机床设备最适合于-频繁加工的小批量零件-复杂的部分几何体-工件上的紧公差部分-加工过程中操作量大的部分-大量的金属切削-工程设计可能变化时-价值昂贵不允许报废的零件开发数控程序的方法包括-手工零件编程-计算机辅助编程-计算机编程手工和计算机辅助方法采用各种数控编程语言-自动编程工具-用于工具定位的自动化系统-桑斯川特内部转换处理语言-紧凑型 2- APT改编语言- APT 的扩展子集- UNIAPT这些语言是通过一部分编程人员定义切削刀具的动作来使用的这些语言可以进行预处理，然后为一系列不同的控制类型所使用，例如-穿孔纸带-计算机数字控制（CNC）-直接数字控制（DNC）自动化方法与CAD程序中创建的几何体一起工作14.2.1数控条带数控程序在计算机上进行预处理，并在纸条或胶带上打孔简单的数控机床可以使用条带带阅读器来指挥机器相关问题-数控条带所必需的存储，传输，手动装载-必须为每个新零件重读条带-磁带往往磨损，变脏，从而导致误读-阅读器很慢，并且可能在复杂零件上产生滞留标记-阅读器里的机械零件降低了可靠性-测试必须在数控机床上完成-没有程序编辑能力（增加了所需的时间）条带的结束是两种发展相互竞争的结果-分布式数控使用远程计算机来代替条带阅读器，但这些在大多数情况下被计算机数控所取代-计算机数控还允许在本地计算机上使用以克服条带和远程计算机的问题。虽然一段时间内计算机数控被用来加强条带性能，但计算机数控最终被允许使用其他存储介质，并且目前不需要程序传输介质14.2.2计算机数字控制一个电脑控制器是用来直接驱动数控机床的特点是-控制一台机器-位于非常接近机床的地方-允许没有预处理的数控代码进行数控程序存储/输入/检索数控的优势， - 程序只输入到内存中一次，所以它更可靠 - 该程序可以在机器测试和修改 - 在本地计算机上增加了控制选项增强了灵活性- 易于集成到柔性制造系统相关背景-使用DNC网络处理与数控条带有关的问题-使用DNC系统的通讯问题变得显著，并且本地计算机被添做能读取条带一次并可以让数控机床无限回放的的条带阅读器-数控控制器开始使用其他像磁带，软盘之类的存储器-数控现在提供的功能如下 -本地程序 -接口通信 -硬盘存储 -程序仿真 -等旁白：除了一台远程计算机用来控制许多机器之外，直接数控与计算机数控很相似。这给出了更强大的计算机功能的优势。由于电脑成本下降抵消了任何优势，这种方法不再流行。有些公司使用专用的数控语言，例如最近展示的德纳铣削数控代码这些机器经常冲电脑上下载数控代码编程，或手工对控制器电脑进行编程。未来走向涉及- 根据不同的金属切削速率自动调整进给速度以提高加工速度- 刀具磨损检测14.2.3直接/分布式数控（DNC）使用了以下几种方法-最古老的是使用调制解调器和一台仿效条带阅读器的主机来控制数控机床（不能存储）-一个新近的方法是使用一台用作存储缓冲的本地电脑。从主计算机数控主机上下载程序，然后本地控制器像从纸带上读取程序一样把程序提供给数控机床-较新的方法是使用一台能与本地数控电脑交互的核心电脑（也称作直接数字控制） DNC控制器产生于CNC机床之前，但由于计算机技术的发展DNC变的比在数控机床旁放置计算机实用并且DNC在形式上产生了变革现代的DNC系统的特点是-使用服务器（有很大的存储容量）来存储大量的零件程序 -服务器将根据需要把零件程序下载到本地机床上有能力- 显示和编辑零件程序- 传送机床上需要的操作指令和其他数据- 收集和处理用来操纵机床的状态信息优点- 不再需要数控条带（优点是显而易见的）- 即时的设计变更- 数控程序编辑快速- 可以用来支持FMS系统- 提高了单个机床的效率- 比单个机床有更多的工厂运行时间- 简化成组技术，计算机辅助工艺规划和其他计算机集成制造内容的实施- 减少使用数控纸带的额外花费历史概述,60年代中期- 辛辛那提米拉克龙概念和GE证明- 电话链接用来从大型计算机向硬件连接的数控机床发送指令，这从根本上取代了读带器 1970- 几个商业的DNC系统公布 70年代中期- 航天公司因为他们工厂里有大量的分布式机床而使用DNC DNC技术最初的阻碍是（以前）基于-计算机硬件的高额成本-一台计算机能控制的机器数量是有限的- 计算机软件因为维护调度控制和数据收集而受限制- 通常需要一台备份计算机- 在下载部分程序的基础上很难调整下载程序时，有两种流行的观点- 一个程序只能被部分下载, 这在现实环境中很容易改变原先的工程设计- 许多程序被下载到本地控制器来提供保护以应对系统故障,并消除在DNC中心计算机实时响应的成本。14.3 设备实例可以商用的数控机床数目数以千计14.3.1 EMCO PC Turn 50这是一台能车削金属零件的小型台式机床基本物理技术规格是,切削用量径向进给48mm.轴向进给228mm最大余量径向30-65mm 轴向300mm 每次12mm最大刀具尺寸直径最大80mm卡盘转速 130-3000 r/min主轴 0.001mm切削速度 0-750 mm/min进给速度 600N 以下 500mm/min进给力 100/110/230VAC, 0-6KVA时力为840 , 695, 345/mm这种机床的基本操作流程是1. 解装组件.2. 将设备连接到电源，气源并附加接口电缆. 3. 在PC机上安装RS-485卡4. 安装软件5. 测试基础系统 (已经安装在上面).6. 使用软件启动并初始化机床和电脑7. 设置新的工作工具，找到坐标零点/偏移量，并输入到控制中心8. 装载数控代码9. 程序仿真10.装载工件使卡盘自动加紧11.关闭机床车门12.在机床上运行程序13.打开车门并松开卡盘.14.如果切削相似的工件则转到步骤8，如果加工新的工件则转到步骤7 14.3.2 Light Machines Corp. proLIGHT Mill 这是一台能车削金属零件的小型台式机床基本物理技术规格是切削用量最大余量最大刀具尺寸主轴转速 200-5000 r/m切削速度进给速度进给力功率 50ipm x,y and 40ipm z尺寸规格重量控制器 IBM compatible computer控制接口 IBM compatible computer程序编制 G-Codes and Dos software主轴 1 H.P.这种机床的基本操作流程是,1. 解装组件.2. 将设备连接到电源，气源并附加接口电缆3. 安装软件4. 测试基础系统 (已经安装在上面).5. 使用软件启动并初始化机床和电脑6. 设置新的工作工具，找到坐标零点/偏移量7. 装载数控代码8. 程序仿真9. 在机床上运行程序10. 如果切削相似的工件则转到步骤7，如果加工新的工件则转到步骤6.14.4实践中的问题 14.5 EMCO MAIER PCTURN 50 LATHE (OLD)使用指南车床是与用来模拟制造现场界面的软件一起发货的。我们没有标准键盘，所以我们需要使用计算机键盘上的特殊击键顺序。步骤:1.把车床连接上气源病确保车床上的校准器在25到75psi之间50psi最好。确保车床用DNC线缆连接到PC机上。计算机卡在第二个接口（这是一个空接口）上有一个终止器。打开电脑和车床。2.一旦电脑被启动，运行emco控制软件，屏幕上就可能出现警告。如果按ESC键警告不消失就叫教员。3.首先我们必须将车床置零。这样做先要按F1然后F7？-ZRN。一个小ZRN标志会出现在屏幕底部。按下键盘数字行的4车床在X方向移动。接着按下键盘上的8，车床在Z轴方向移动。在所有动作停止后车床被校正好，并被设置在手动手动进给模式。4.你可以像执行其他功能一样使用数字行的键操作车床。4 向左移动底座6 向右移动底座2 移出刀架8 移入刀架7 主轴开6 主轴关2 打开/关闭切屑清洁机1 转动刀具转台+/- - 增大/减小进给量5.你现在可以通过按F1然后按F6-MDI把机床置于MDI模式。推开车门并停留片刻，车门将保持打开状态。使用ESC并按下SFT键清除屏幕上的错误卡盘会松开和夹紧。安装工件然后关闭车门。6. 把计算机置于编程模式-14.6 PC TURN 50 机床文件资料教程: (Jonathan DeBoer著) 设定: 车床

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