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柴油机气缸体钻孔组合机床总体及后主轴箱设计

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关键词：: 柴油机气缸体钻孔组合机床总体整体后主轴箱设计

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1 前言

1.1 课题内容

本组课题是为保证S195柴油机气缸体三面孔加工及保证相应的位置精度，需设计一台三面精镗卧式组合机床。在完成“三图一卡”的基础上，主要完成机床总体和后主轴箱设计。

1.2 课题来由

1.2.1 课题背景

课题来源于盐城市江动集团。为保证S195柴油机气缸体三面各主要孔的加工精度及保证相应的位置精度，需要设计一台三面精镗的组合机床。

1.2.2 课题要求

本加工工序的内容是：左端：钻螺纹底孔14×Φ6.7，Φ12.4,表面粗糙度均为 Ra12.5。右端：钻螺纹底孔9×Φ6.7，Φ8.5, 表面粗糙度均为Ra12.5。后端：钻螺纹底孔6-Φ12.4，表面粗糙度均为Ra12.5。

为了保证零件的加工精度，在整个设计过程中应满足以下几点要求：

a.加工部位的位置尺寸应与定位基准直接发生关系。

b.机床应运转平稳，工作可靠，结构简单。

c.装卸方便，便于维修，调整。

d.当本工序有特殊要求时必须标明。

1.3 组合机床国内外发展概述

组合机床是以系列化、标准化的通用部件为基准，配以少量的专用部件组成的专用机床。组合机床是随着生产的发展，由万能机床和专用机床发展来的。这种机床既具有专用机床的结构简单、生产率和自动化程度较高的特点，又具有一定的重新调整能力，以适应工件变化的需要，组合机床可以对工件进行多面、多主轴加工。组合机床兼有低成本和高效率的优点，在大批、大量生产中得到广泛应用，并可用以组成自动生产线。

随着科学技术的进步和市场需求的变化，现代机械制造业得到了较快的发展。多品种、小批量生产方式将成为今后的主要生产形式，制造系统正向着柔性化、集成化、智能化的方法发展，机床越来越多地采用先进的技术，加工效率不断地提高。机械产品的加工精度日益提高，高精度的机床大量出现。为了适应生产发展的需要，机床夹具正在向柔性化、高效化、自动化、精度化、标准化方向发展。

1.4 本课题主要解决的问题和总体设计思路

1.4.1 主要解决的问题

A 组合机床工艺方案的拟定。

B 组合机床总体设计，主要完成“三图一卡”的设计。

a)工序图；

b)加工示意图；

c)机床联系尺寸总图；

d)生产率计算卡。

C 后主轴箱设计

a)左主轴箱装配图；

b)箱子补充加工图；

c)零件图；

d)有关计算、校核。

1.4.2 总体设计思路

后主轴箱的设计，首先，在完成对组合机床的总体设计并绘制出“三图一卡”的基础上，绘制后主轴箱设计的装配图；主轴箱设计是组合机床设计中的重要部分，主轴箱设计的合理与否，直接影响到被加工精度等参数。首先确定工件的定位与夹紧方式，然后进行误差分析，对主轴箱的主要零件进行结构设计和验算。

2组合机床总体设计

2.1工艺方案的拟定

2.1.1被加工零件的特点

本设计是为钻削ZH1105W柴油机气缸体的三面31个轴孔的工序而专门设计的，为了能到达质量好、效率高，我们采用了工序集中的原则进行设计。

机床的配置型式主要有卧式和立式两种。卧式组合机床床身由滑座、侧底座及中间底座组合而成，其优点是加工和装配工艺性好，无漏油现象；同时安装、调试与运输也都比较方便；而且机床重心较低，有利于减小振动。其缺点是削弱了床身的刚性，占地面积大。立式组合机床床身由滑座、立柱及立柱底座组成。其优点是占地面积小、自由度大、操作方便。其缺点是机床重心高、振动大。

由于被加工的零件为ZH1105W柴油机气缸体的三面31个孔，该柴油机的体积小、重量较重，且为三面加工。根据零件的特点及生产纲领，应选用卧式床身，通过左右后三个动力头驱动三个主轴箱对零件三端面的31个孔进行加工较为妥当。

通过以上分析，初定本次设计方案为卧式三面组合钻床，三个动力头左右后布置。

2.1.2工艺路线的确定

工艺路线如下：

工序1 铸造

工序2 时效

工序3 粗铣底面、顶面

工序4 粗铣左面、右面

工序5 粗铣前面、后面

工序6 精铣底面、顶面

工序7 精铣左面、右面

工序8 精铣前面、后面

工序9 三面粗镗孔

工序10 三面半精镗孔

工序11 三面精镗孔

工序12 钻左面、右面、后面孔

工序13 钻顶面、底面、前面孔

工序14 攻丝

工序15 钻、扩、铰顶杆孔

工序16 最终检验

工序12的加工内容为：

a) 左端，钻螺纹底孔14×φ6.7、φ12.4，表面粗糙度均为Ra12.5；

b) 右端，钻螺纹底孔9×φ6.7、φ8.5，表面粗糙度均为Ra12.5；

c) 后端，钻螺纹底孔6×φ12.4，表面粗糙度均为Ra12.5。

各孔的位置精度及具体要求详见ZH1105W气缸体的工序图。

内容简介：: .Automation in Construction 10 2001 477486rlocaterautconSemi-automatic control system for hydraulic shovelHirokazu Araya), Masayuki KagoshimaMechanical Engineering Research Laboratory, Kobe Steel, Ltd., Nishi-ku, Kobe Hyogo 651 2271, JapanAccepted 27 June 2000AbstractA semi-automatic control system for a hydraulic shovel has been developed. Using this system, unskilled operators canoperate a hydraulic shovel easily and accurately. A mathematical control model of a hydraulic shovel with a controller wasconstructed and a control algorithm was developed by simulation. This algorithm was applied to a hydraulic shovel and itseffectiveness was evaluated. High control accuracy and high-stability performance were achieved by feedback plusfeedforward control, nonlinear compensation, state feedback and gain scheduling according to the attitude. q2001 ElsevierScience B.V. All rights reserved.Keywords: Construction machinery; Hydraulic shovel; Feedforward; State feedback; Operation1. IntroductionA hydraulic shovel is a construction machinerythat can be regarded as a large articulated robot.Digging and loading operations using this machinerequire a high level of skill, and cause considerablefatigue even in skilled operators. On the other hand,operators grow older, and the number of skilledoperators has thus decreased. The situation calls forhydraulic shovels, which can be operated easily bywxany person 15 .The reasons why hydraulic shovel requires a highlevel of skill are as follows.1. More than two levers must be operated simulta-neously and adjusted well in such operations.)Corresponding author.E-mail address: arayahrknedo.go.jp H. Araya .2. The direction of lever operations is differentfrom that of a shovels attachment movement.For example, in level crowding by a hydraulicshovel, we must operate three leversarm, boom,.bucket simultaneously to move the top of a bucket.along a level surface Fig. 1 . In this case, the leveroperation indicates the direction of the actuator, butthis direction differs from the working direction.If an operator use only one lever and other free-doms are operated automatically, the operation be-comes very easily. We call this system a semi-auto-matic control system.When we develop this semi-automatic controlsystem, these two technical problems must be solved.1. We must use ordinary control valves for auto-matic control.2. We must compensate dynamic characteristicsof a hydraulic shovel to improve the precisionof control.0926-5805r01r$ - see front matter q2001 Elsevier Science B.V. All rights reserved.PII: S0926-5805 00 00083-2()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486478Fig. 1. Level crowding of an excavator and frame model of anexcavator.We have developed a control algorithm to solvethese technical problems and confirm the effect ofthis control algorithm by experiments with actualhydraulic shovels. Using this control algorithm, wehave completed a semi-automatic control system forhydraulic shovels. We then report these items.2. Hydraulic shovel modelTo study control algorithms, we have to analyzenumerical models of a hydraulic shovel. The hy-draulic shovel, whose boom, arm, and bucket jointsare hydraulically driven, is modeled as shown in Fig.2. The details of the model are described in thefollowing. 2.1. Dynamic model 6Supposing that each attachment is a solid body,from Lagranges equations of motion, the followingexpressions are obtained:22JuqJ cosuyuuqJ cosuyuuqJ sinuyuuqJ sinuyuuyK sinust.11l1212213133121221313311122J cosuyuuqJuqJ cosuyuuyJ sinuyuuqJ sinuyuuyK sinust.1212122223233121212323322222J cosuyuuqJ cosuyuuqJuyJ sinuyuuqJ sinuyuuyK sinust.131312323233313131232333331 .2.2where,Js m 1q m q m 1 q I ;Js111g1231112m 1 1qm 1 1; Jsm 1 1; Jsm 12q21g231g31331g3222g2m 12qI ; Jsm 1 1; Jsm 12qI ; K s3222332g3333g331.m 1qm 1 qm 1g;K s m 1qm 1g;1g1213122g233K sm 1g; and gsgravitational acceleration.33g3uis the joint angle,tis the supply torque, 1 isiiithe attachment length, 1is the distance betweengithe fulcrum and the center of gravity, m is the massiof the attachment, I is the moment of inertia aroundithe center of gravity subscripts is13, mean boom,.arm, and bucket, respectively .2.2. Hydraulic modelEach joint is driven by a hydraulic cylinder whoseflow is controlled by a spool valve, as shown in Fig.3. We can assume the following:1. The open area of a valve is proportional to thespool displacement.2. There is no oil leak.3. No pressure drop occurs when oil flows throughpiping.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486479Fig. 2. Model of hydraulic shovel.4. The effective sectional area of the cylinder isthe same on both the head and the rod sides.In this problem, for each joint, we have thefollowing equation from the pressure flow character-istics of the cylinder:ViA h sKX P ysgn XPyP2(. .ii0iisii1i1iKwhen,KscB2rgP sP yP0ii1i1i2iwhere, A seffective cross-sectional area of cylin-ider; h scylinder length; X sspool displacement;iiP ssupply pressure; P scylinder head-side pres-si1isure; P scylinder rod-side pressure; V soil vol-2iiume in the cylinder and piping; B sspool width;igsoil density; Ksbulk modulus of oil; and csflow coefficient.2.3. Link relationsIn the model shown in Fig. 1, the relation be-tween the cylinder length change rate and the attach-mentrotationalangularvelocityisgivenas .follows: 1 boomfu.11h1su1OA OC sinuqb.1111sy,22(OA qOC q2OA OC cosuqb.111111 .2 arm.fu,u212h2suyu21.O A O C sinuyuqbqa22222122sy,22(.O A qO C q2O A O C cosuyuqbqa222222222122 .3 bucketwhenO D sO B sB C sC D33333333YhA B B C sinuyuqgyaqu.3333332332fu,ussy.3 .32322Yuyu(A BqB Cq2A B B C cosuyuqgyaqu.323333333332332()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486480Fig. 3. Model of hydraulic cylinder and valve.2.4. Torque relationsFrom the link relations of Section 2.3, the supplytorquetis given as follows, taking cylinder frictioniinto consideration:tsyfuP1 A qfu,uP1 A.1111121222qfu,uP1 A y Cfuu.32333c1111qsgnuFfu4. ./1111tsyfu,uP1 A y Cfu,uuyu./221222c221221qsgnuyuFfu,u.5/212212tsyfu,uP1 A y Cfu,uuyu./332333c332332qsgnuyuFfu,u.5/323323Where, Cis the viscous friction coefficient andciF is kinetic frictional force of a cylinder.i2.5. Response characteristics of the spoolSpool action has a great effect on control charac-teristics. Thus, we are assuming that the spool hasthe following first-order lag against the referenceinput.1XX sX .5 .iiTSq1spiWhere, XXis the reference input of spool dis-iplacement and Tis a time constant.spi3. Angle control systemAs shown in Fig. 4, the angleuis basicallycontrolled to follow the reference angleuby posi-gtion feedback. In order to obtain more accuratecontrol, nonlinear compensation and state feedbackare added to the position feedback. We will discussdetails of these algorithms as follows.3.1. Nonlinear compensationIn the ordinary automatic control systems, newcontrol devices such as servo valves are used. In oursemi-automatic system, in order to realize the coexis-tence of manual and automatic operations, we mustuse the main control valves, which are used inmanual operation. In these valves, the relation be-tween spool displacement and open area is nonlinear.Then, in automatic operation, using this relation, thespool displacement is inversely calculated from therequired open area, and the nonlinearity is compen-.sated Fig. 5 . .Fig. 4. Block diagram of control systemu.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486481Fig. 5. Nonlinear compensation.3.2. State feedbackBased on the model discussed in Section 2, if thedynamic characteristics for boom angle control arelinearized in the vicinity of a certain standard condi-tionspool displacement X, cylinder differential10.pressure P, and boom angleu, the closed-loop11010transfer function can be expressed byKpusug6 .1132a s qa s qa sqK210pwhere, Kis position feedback gain; andpfuACfu.1101c1110a sq02 AP yP.KP yP(1s111001s1110XJqJ cosuXqJ cosuXquX?4.10111221323a s12 A fuP yP.1110s1110CfuV.c11101qA KKP yP(101s1110V JqJ cosuXqJ cosuXquX?4.1111221323a s.2A fuKKP yP.(111001s1110This system has a comparatively small coefficienta , so the response is oscillatory. For instance, if in1our large SK-16 hydraulic shovel, Xis 0, the10coefficients are given as a s2.7=10y2, a s6.001=10y6, a s1.2=10y3. Addingthe acceleration2feedback of gain K , to this the upper loop in Fig.a.4 , the closed loop transfer function is given asKpusu.7 .1r132a s q a qKs qa sqK.21a0pAdding this factor, the coefficient of s2becomeslarger, thus, the system becomes stable. In this way,acceleration feedback is effective in improving theresponse characteristics.However, it is generally difficult to detect acceler-ation accurately. To overcome this difficulty, cylin-der force feedback was applied instead of accelera-.tion feedback the lower loop in Fig. 4 . In this case,cylinder force is calculated from detected cylinderpressure and filtered in its lower-frequency portionwx7,8 . This is called pressure feedback.4. Servo control systemWhen one joint is manually operated and anotherjoint is controlled automatically to follow the manualoperation, a servo control system must be required.For example, as shown in Fig. 6, in the level crowd-ing control, the boom is controlled to keep the arm.end height Z calculated fromuanduto refer-12ence Zr. In order to obtain more accurate control, thefollowing control actions are introduced.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486482 .Fig. 6. Block diagram of control system Z .4.1. Feedforward controlCalculating Z from Fig. 1, we obtainZs1 cosuq1 cosu.8 .1122 .Differentiating both sides of Eq. 8 with respectto time, we have the following relation,Z1 sinu22usyyu.9 .121 sinu1 sinu1111The first term of the right-hand side can be taken.as the expression feedback portion to convert Z tou, and the second term of the right-hand side is the1.expressionfeedforward portionto calculate howmuchushould be changed whenuis changed12manually.Actually,uis determined using the difference2value of Du. To optimize the feedforward rate,2feedforward gain Kis tunned.ffThere may be a method to detect and use the arm.operating-lever condition i.e. angle instead of armangular velocity, since the arm is driven at an angu-lar velocity nearly proportional to this lever condi-tion.4.2. Adaptie gain scheduling according to the atti-tudeIn articulated machines like hydraulic shovels,dynamic characteristics are greatly susceptible to theattitude. Therefore, it is difficult to control the ma-chine stably at all attitudes with constant gain. Tosolve this problem, the adaptive gain schedulingaccording to the attitude is multiplied in the feedback.loop Fig. 6 . As shown in Fig. 7, the adaptive gain.KZ or Kuis characterized as a function of twovariables,uXand Z.uXmeans how the arm is22extended, and Z means the height of the bucket.5. Simulation resultsThe level crowding control was simulated byapplying the control algorithm described in Section 4to the hydraulic shovel model discussed in Section 2.In the simulation, our large SK-16 hydraulic shovel.was employed. Fig. 8 shows one of the results. Fiveseconds after the control started, load disturbance()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486483Fig. 7. Gain scheduling according to the attitude.was applied stepwise. Fig. 9 shows the use of feed-forward control can reduce control error.6. Semi-automatic control systemBased on the simulation, a semi-automatic controlsystem was manufactured for trial, and applied to theSK-16 shovel. Performance was then ascertained byfield tests. This section will discuss the configurationand functions of the control system.6.1. ConfigurationAs illustrated in Fig. 10, the control system con-sists of a controller, sensors, manmachine interface,and hydraulic control system.The controller is based on a 16-bit microcomputerwhich receives angle input signals of the boom, arm,and bucket from the sensor; determines the conditionof each control lever; selects control modes andcalculates actuating variables; and outputs the resultsfrom the amplifier as electrical signals. The hy-Fig. 8. Simulation result of level crowding.draulic control system generates hydraulic pressureproportional to the electrical signals from the electro-magnetic proportional-reducing valve, positions thespool of the main control valve, and controls theflow rate to the hydraulic cylinder.In order to realize high-speed, high-accuracy con-trol, a numeric data processor is employed for theFig. 9. Effect of feedforward control on control error of Z.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486484Fig. 10. Schema of control system.controller, and a high-resolution magnetic encoder isused for the sensor. In addition to these, a pressuretransducer is installed in each cylinder to achievepressure feedback.The measured data are stored up to the memory,and can be taken out from the communication port.6.2. Control functionsThis control system has three control modes,which are automatically switched in accordance withlever operation and selector switches. These func-tions are the following .1 Level crowding mode: during the manual armpushing operation with the level crowding switch,the system automatically controls the boom and holdsthe arm end movement level. In this case, the refer-ence position is the height of the arm end from theground when the arm lever began to be operated.Operation of the boom lever can interrupt automaticcontrol temporarily, because priority is given to man-ual operation. .2Horizontal bucket lifting mode: during themanual boom raising operation with the horizontalbucket lifting switch, the system automatically con-trols the bucket. Keeping the bucket angle equal tothat at the beginning of operation prevents materialspillage from the bucket. .3Manual operation mode: when neither thelevel crowding switch nor the horizontal bucket lift-ing switch are selected, the boom, arm, and bucketare controlled by manual operation only.The program realizing these functions is primarilywritten in C language, and has well-structured mod-ule to improve maintainability.7. Results and analysis of field testWe put the field test with the system. We con-firmed that the system worked correctly and theeffects of the control algorithm described in Chaps. 3and 4 were ascertained as follows.7.1. Automatic control tests of indiidual attach-mentsFor each attachment of the boom, arm, and bucket,the reference angle was changed 58 stepwise fromthe initial value, and the responses were measured;thus, the effects of the control algorithm described inChap. 3 were ascertained.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 477486485Fig. 11. Effect of nonlinear compensation on boom angle.7.1.1. Effect of nonlinear compensationFig. 11 shows the test results of boom lowering.Because dead zones exist in the electro-hydraulicsystems, steady-state error remains when simple po-sition feedback without compensation is applied OFF.in the figure . Addition of nonlinear compensation.ON in the figure can reduce this error.7.1.2. Effect of state feedback controlFor the arm and bucket, stable response can beobtained by position feedback only, but adding ac-celeration or pressure feedback can improve fast-re-sponse capability. As regards the boom, with onlythe position feedback, the response becomes oscilla-tory. Adding acceleration or pressure feedback madethe response stable without impairing fast-responsecapability. As an example, Fig. 12 shows the testresults when pressure feedback compensation wasapplied during boom lowering.7.2. Leel crowding control testControl tests were conducted under various con-trol and operating conditions to observe the controlFig. 12. Effect of pressure feedback control on boom angle.Fig. 13. Effect of feedforward control on control error of Z.characteristics, and at the same time to determine theoptimal control parameters such as the control gains.shown in Fig. 6 .7.2.1. Effects of feedforward controlIn the case of position feedback only, increasinggain Kto decrease error DZ causes oscillation duepto the time delay in the system, as shown by AOFFBin Fig. 13. That is, Kcannot be increased. Apply-ping the feedforward of the arm lever value describedin Section 4.1 can decrease error without increasingKas shown by AONB in the figure.p7.2.2. Effects of compensation in attitudeLevel crowding is apt to become oscillatory at theraised position or when crowding is almost com-pleted. This oscillation can be prevented by changinggainKaccording to the attitude, as has beenpdiscussed in Section 4.2. The effect is shown in Fig.14. This shows the result when the level crowdingwas done at around 2 m above ground. Compared tothe case without the compensation, denoted by OFFin the figure, the ON case with the compensationprovides stable response.Fig. 14. Effect of adaptive gain control on control error of Z.()H. Araya, M. KagoshimarAutomation in Construction 10 2001 4774864867.2.3. Effects of control interalThe effects of control interval on control perfor-mance were investigated. The results are:1. when the control interval is set to more than100 ms, oscillation becomes greater at attitudeswith large moments of inertia; and2. when the control interval is less tha

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