C650普通车床数控化改造进给系统的PMC设计
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C650普通车床数控化改造进给系统的PMC设计,c650,普通,车床,数控,改造,进给,系统,pmc,设计
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机 械 技 术 学 院 毕 业 设 计 任 务 书 课题名称 C650 普通车床数控化改造进给系统的 PMC 设计 指导教师（学院） 江宏辰 职称 高级工程师 指导教师（企业） 职称 专业名称 数控设备应用与维护 班级 数控设备 11031 学生姓名 邱陆金 学号 1060103125 课题需要完成的任务 ： 1. 查阅技术资料，进行 c650 普通车床数控化改造进给系统的 PMC 设计分析 结构功能比较。 2. 翻译相关英文资料。 3. 确定总体方案。 4. 完成相关的 PMC 程序 设计 。 5. 完成 结构总 体 PMC 程序 设计 。 6. 编写毕业设计说明书，完成 设计工作。 7. 整理毕业设计资料，完成答辩。 课题计划 ： 2 月 16 日 3 月 01 日；查阅技术资料， c650 普通车床数控化改造进给系统的 PMC 设计分析 结构功能比较。 3 月 02 日 3 月 05 日；翻译相关英文资料 。 3 月 06 日 3 月 10 日；完成总体方案。 3 月 11 日 3 月 15 日； 完成相关的 PMC 程序 设计 。 3 月 16 日 3 月 20 日； 完成 结构总 体 PMC 程序 设计 。 3 月 21 日 4 月 01 日； 编写说明书 。 4 月 02 日 4 月 09 日；整理毕业设计资料，完成答辩。 计划答辩时间 ： 2013 年 4 月 10-18 日 数 控 技 术 系 2013 年 1 月 16 日 nts 机械技术学院 毕 业 设 计 论 文 c650 普通车床数控化改造进给系统的 PMC 设计 学生姓名： 邱陆金 指导教师姓名： 江宏辰 高级工程师 所在班级 数控设备 11031 所在专业 数控设备应用与维护 论文提交日期 2013 年 4 月 日 论文答辩日期 20 年 月 日 答辩委员会主任 主答辩人 机械 技 术 系 2013 年 4 月 10 日 nts 1 无锡职业技术学院（论文） 开 题 报 告 （ 2013 届） 题 目 c650 普通车床数控化改造进给系统的 PMC 设计 指导教师 江宏辰 院 系 机 械 班 级 数控设备 11031 学 号 1060103125 姓 名 邱陆金 二一 三 年 一 月 二 日 nts 2 一、 毕业设计的内容和 意义 更新改造旧机床是最近几年发展起来的一个新兴产业，该设计是基于西门子数控系统，对 C650普通车床进行数控化改造中的 PLC控制部分研究设计。 采用 连线少、体积小、功耗小、控制速度快、可靠性高、功能完善的 PLC控制系统，来代替电气控制系统中继电器控制逻辑，配以合适的数控系统 ，可使机床控制功能更加丰富，自动化水平大大提高。 此次设计 从被控对象的 I/O点数和性价比高、综合成本低这几个主要原则出发，采用西门子的 802D数控系统和西门子的 S7-200的 PLC作为机床数控改造设计的控制装置。 主要进行了控制装置选型， PLC的地址分配和用梯形图编辑的 PLC控制程序设计。 改造后的机床在实现机床原有功能的基础上还增加了自动加工、自动换刀等多种功能。 二、研究的主要内容，拟解决的主要问题 （阐述的主要观点） 1. 普通机床的改造和前景 2. PLC 的基础知识 3 C650 普通车床电气控制 的概述 4 PLC 和系统的选型 5. PLC 编程及说明 三、文献综述 该车床控制系统采用 西门子 系统。其功能主要有读取零件的加工 G代码，编辑和编译 G代码，仿真加工 (包括加工前仿真和与加工同步仿真 )，回参考点，手工对刀，加工中断，超程软限位等功能。它可处理进给速度，主轴速度及转速方向，刀具信息， M功能等多种加工信息。加工过程中，软件界面的状态栏还可以显示出刀具当前的坐标，加工状态，加工时间等信息 。 参考文献： 1 陈泽宇 .数控机床装调 .武汉：华中科技大学出版社， 2012 2 周济 .周艳红 .数控加工技术 . 北京：国防工业出版社， 2002 3 王爱玲 .张吉堂 .吴雁 .现代数控原理及控制系统 .北京：国防工业出版社， 2002 4 李善术 .数控机床及其应用 .北京：机械工业出版社， 2001 nts 3 5 严爱珍 .机床数控原理与系统 .北京：机械工业出版社， 2000 6 余英良 .机床数控改造设计与实例 M.北京：机械工业出版社 1998 7 张新义 .经济型数控机床系统设计 M.北京 机械工业出版社， l994 8 张铮 机电控制与 PLC 北京：机械工业出版社， 2011 9 龚雯 .普通车床的数控改造 .机械工人， 1999 10 肖爱武 .普通车床数控改造初探 .机械制造与自动化， 2003 11 汪木兰 .数控原理与系统 .北京 :机械工业出版社， 2004 12 王兆义 .可编程控制器教程 M北京：机械工业出版社， 1995 13 刘金琪 .机床电气自动控制 M.哈尔滨 :哈尔滨工业大学出版社， 1999 14 倪森寿 .机械技术基础 .北京：人民邮电出版社， 2011 15 刘果 .数控技术 M.北京：中国劳动出版社， 2001 16 贾德胜 .PLC 应用开发实用子程序 .北京：人民邮电出版社出版， 2006 17 张燕华 .AutoCAD2005 机械制图 .北京：机械工业出版社， 2009 四、 研究内容 此次设计 从被控对象的 I/O点数和性价比高、综合成本低这几个主要原则出发，采用西门子的 802D数控系统和西门子的 S7-200的 PLC作为机床数控改造设计的控制装置。 因此在设计上，主要分为三大部分：主电路的设计、控制电路的设计以及驱动隔离电路的设计。 1. 普通机床的改造和前景 2. PLC 的基础知识 3 C650 普通车床电气控制的概述 4 PLC 和系统的选型 5. PLC 编程及说明 五、研究计划 2 月 18 日 3 月 10 日 熟悉本课题的基本要求，查找相关资料，撰写完成开题报告和英文资料的翻译 3 月 11 日 3 月 20 日 确定总体设计方案 ，画原理框图 3 月 21 日 3 月 28 日 设计单片机主控电路，设计各单元电路 3 月 29 日 4 月 4 日 设计绘制系统整体电气原理图 ，设计 CAD 图 nts 4 4 月 5 日 4 月 12 日 撰写论文 4 月 13 日 4 月 15 日 论文修改定稿 4 月 16 日 4 月 19 日 答辩准备 4 月 20 日 答辩 六 特色与创新 本论文特色与创新如下： 在此次的课题设计中， 我首次突破只有固定思维的改造进给系统部分，而是去改变做法去改造 PMC系统， PMC大家都不陌生，它是通过改造参数，编辑梯形图来控制机床，因此在 c650 普通车床的数控化改造中，它将是最难改造，而且必须克服的难题 。 PLC 是由 模 仿原继电器控制原理发展起来的，二十世纪七十年代的 PLC 只有开关量逻辑控制，首先应用的是汽车制造行业。它以存储执行逻辑运算、顺序控制、定时、计数和运算等操作的指令；并通过数字 输入和输出操作，来控制各类机械或生产过程。用户编制的控制程序表达了生产过程的工艺要求，并事先存入 PLC 的用户程序存储器中。运行时按存储程序的内容逐条执行，以完成工艺流程要求的操作。PLC 的 CPU 内有指示程序步存储地址的程序计数器，在程序运行过程中，每执行一步该计数器自动加 1，程序从起始步起 ， 依次执行到最终步，然后再返回起始步循环运算。 PLC 每完成一次循环操作所需的时间称为一个扫描周期。不同型号的 PLC，循环扫描周期在 1 微秒到几十微秒之间。 PLC 用梯形图编程，在解算逻辑方面，表现出快速的优点，在微秒量级，解算 1K 逻辑程序不到 1 毫秒。它把所有的输入都当成开关量来处理， 16 位为一个模拟量。大型 PLC 使用另外一个 CPU 来完成模拟量的运算。把计算结果送给 PLC 的控制器。相同 I/O 点数的系统，用 PLC 比用 DCS，其成本要低一些。 PLC 没有专用操作站，它用的软件和硬件都是通用的，所以维护成本比 DCS 要低很多。一个 PLC 的控制器，可以接收几千个 I/O 点。如果被控对象主要是设备连锁、回路很少，采用 PLC 较为合适。 PLC 由于采用通用监控软件，在设计企业的管理信息系统方面，要容易一些。 PLC 在实际中用的很多。只要有工业的地方，就 有 PLC 存在的机会。如果你就在机器制造、包装、物料输送、自动装配等行业中工作，那么你可能已经在使用它了 。如果没有的话，你就是正在浪费金钱和时间。几乎所有需要电气控制的地方都需要PLC。 可编程控制器得以迅速发展和广泛使用的原因是由于它具有继电器接触器控制装置和通用计算机以及其他控制系统所不具有的特点： (1) 运行稳定、可靠性高、抗干扰能力强 nts 5 (2) 设计使用和维护方便 (3) 编程御苑直观易学 (4) 与网络技术相结合 (5) 体积小、质量轻、能耗低 指导教师意见： 签名： 年 月 日 系毕业 设计（论文）工作指导小组意见： 签名： 年 月 日 二级学院 (直属系 )毕业设计（论文）工作领导小组意见： 签名： 年 月 日 nts数控应用与维护 一 system data input and output Data input and output: data can be divided into 6 types: 1, CNC parameter 2, the PMC parameters 3, pitch compensation parameters 4, the user macro variable values 5, tool compensation parameters 6, the processing program macros These data is the guarantee of the normal work of the system, so when replace the memory module in the system, must to input data to the memory module, and system battery aging, change not in time to also want to back to input data to the backup data memory module. When CNC machine work is normal, need to put these data backup, to use if needed. Each can separate input and output, these data can also be in the system is open, press and hold the CRT two of the most the right soft key below, according to clew operation can, in the debug when using this method is very convenient, as long as the incoming system PMC parameters, other parameters are passed in when the phone is switched on or reset. 二 the spindle system fault and judgment Nc machine tool spindle in a very wide scope in continuous adjustable speed, wide constant power range. When screw thread processing with the machine, must stop and constant line speed processing, and other functions, the main shaft to put forward the corresponding feed control and position control requirements, at this point, the spindle drive system is also known as the spindle servo system. When the spindle servo system failure occurs, there are usually three forms. It is displayed on the CRT or operation panel and the alarm information; Two is main shaft driving device YongBao lights or digital pipe display the spindle drive failures; Three is the spindle didnt work normal, but no any alarm message. Spindle servo system common faults as follows. 1, due to electromagnetic interference, shielding and grounding measures and spindle speed command signal and feedback signal interference, make the spindle drive appears random and irregular fluctuations. Interference phenomenon is: when the spindle rotational speed is equal to zero, the spindle still reciprocating rotation, adjust the balance of zero velocity and drift compensation can eliminate faults. 2, overload ntsCutting dosage is too large, frequent positive and negative, etc all can cause overload alarm. Specific performance for the spindle motor overheating. 3, spindle orientation jitter Spindle orientation control (also known as the spindle positioning control) function and characteristics. Spindle orientation control is the spindle parked in a fixed position accurately, so as to exchange tool in this location, fine boring cutter and gear shift back, common has the following two types: (1) magnetic sensor electric control must stop. Magnet is installed on the spindle after section, magnetic sensor installed on the spindle box, and other installation location determines spindle must stop point, magnets and magnetic sensor spacing between add and subtract 0.5 1.5 (mm). (2) coding ware appliances must stop control. By or in the machine tool spindle box installed in the spindle motor is installed directly on a photoelectric encoder to realize accurate control, must stop Angle can be arbitrary set, 4077 available parameters for debugging. FANUC companies using electric spindle orientation, it is using or magnetic sensors mounted on the spindle position encoder as the position feedback components, by their output signals, make main shaft accurate positioning on the specified location. The advantages of using electric main shaft orientation is: 1) dont need a mechanical positioning components, simply connect the position encoder or magnetic sensor, spindle positioning control can be realized; 2) reduce the orientation time, can be in shaft under high speed rotation orientation directly, without using the reduction gear, so the directional time was greatly shortened; 3) only need a simple sequence control, simple operation, only need to spindles directional signals, directional signals and high/low speed signal can complete spindle orientation control; 4) high reliability because the directional when all adopt the electronic parts and no mechanical wearing parts, so it is not affected by the external shocks, etc, high reliability; 5) high precision and rigidity, electric main shaft orientation control can completely meet the requirements of automatic tool change; 6) the spindle orientation control, is actually based on spindle speed control adds a position control loop. Is able to detect the position of the spindle, it is necessary to adopt magnetic sensor and position encoder detecting element. 4,spindle abnormal noise and vibration Must first distinguish abnormal noise or vibration occurs in the mechanical parts of the spindle or electric drive part. nts(1) abnormal noise occurred during deceleration process, usually caused by a driving gear, such as the regeneration of ac drive circuit fault. (2) the abnormal noise when constant rotational speed, but by looking at the spindle motor whether free parking in the process of noise and vibration to the difference, if any, the main mechanical parts have problem. (3) check whether the vibration cycle about speed. Like has nothing to do, is the spindle drive has not adjust good, such as, should check whether the mechanical parts of the spindle is good, the speed sensor is bad. 5,spindle motor does not turn CNC system to the spindle drive unit in addition to rotational speed analog control signal, and can make the control signal, usually for DC + 24 v relay coil voltage. (1) check the CNC system for speed control signal output, and generally change the line of main shaft encoder. (2) check whether can make the signal is switched on. Through the CRT, the status of the I/O, PMC ladder diagram, the analysis of machine tool spindle to confirm the start conditions, meets such as lubrication and cooling. (3) the spindle drive failure. (4) the spindle motor fault. (5) main external encoder failure. 6, serial spindle system operation performance tuning Through to the spindle servo system parameters adjustment, can change a serial of spindle system performance, so as to obtain the best system performance. It should be noted that this kind of parameters have been adjusted when delivery from factory, it is usually not need to adjust, only after the replacement of the spindle system of some hardware, just need to adjust the parameters. Adjust the operating parameters as follows. Displayed on the screen shaft adjustment interface. Spindle servo system parameters adjustment in the spindle under the interface, so first to confirm in the CRT screen shaft adjustment interface. Method is based on the setting of parameters in the 3111 SPS signal displayed on the CRT screen spindle adjustment interface is determined. The parameter set to SPS. 3111, no. 1 1. After adjustment parameters, according to the following adjustments on the screen can display the corresponding spindle operation interface. Display way: (1) press the SYSTEM key, select the parameters such as interface; (2) according to continue menu; (3) press the soft key/SP. Also, according to main shaft set adjustment interface; nts(4) with the soft key can select the following interface: SP. The SET : spindle setting interface. (SP. Top: spindle adjustment interface. SP. MON : spindle monitoring interface. 三 servo system fault Due to the number of empty control core of the system is to numerical control of machine tool feed part of, and feed is controlled by servo motor servo unit, and drive the ball screw, done by rotary encoder position feedback elements, forming a half closed loop position control system. So the action of the servo system in CNC machine is quite important. Servo system fault is generally controlled by the servo unit, servo motor, speed motor, encoder, etc problems caused. For example: a CNC grinding machine, E shaft dresser is out of control, E shaft can back to the reference point, but automatic trimming or semi-automatic, movement speed, until they hit the limit switch. Observe the failure process, found the limit switch, the display of the coordinates is far less than the actual value, must be is a question of position feedback. But change feedback on board and the encoder has failed to solve the problem, after careful study, found that E axis dresser is made up of Z axis movement, general back at a reference point, E shaft in the side of the Z axis, and finishing, E axis dresser is Z axis to the middle. For this we have done the experiment, E axis finisher will be moved to the Z axis, and then back to the reference point, then back to the reference point is out of control phenomenon, we conclude that may be due to E axis dresser reciprocating movement, often lead to E axis feedback cable is broken, and poor contact. School line confirmed our judgment, find the breakpoint, welding and take prevention measures, make the machine back to work. 四 Troubleshooting of common method when there is alarm happen CNC system failure, maintenance personnel do not be eager to begin processing, but should be more observation and experiment was carried out. 1. The full survey fault site maintenance personnel obtain first-hand material is this one of the important means. Survey to operators on one hand, ask for details of the whole process of failure, check fault record sheet, to understand what happened phenomenon, had to take what measures, etc.; On the other hand, to the scene to do meticulous exploration. From the appearance of the system to the system inside the printed circuit board should be carefully check whether there are abnormal. Upon confirmation of system power on, without danger, can live, if you have any abnormal observation system of CRT display content and so on. 2. Careful analysis the cause of the fault current CNC system intellectualized degree is low, system is not automatically diagnose the exact cause of failure. Is often the same alarm, can have a variety of causes, not likely to reduce the fault a part of a specific. Therefore, based on the analysis of the cause of the malfunction, must be open-minded. Often have this kind of situation, since a portion of the diagnosed system is faulty, but investigate its ntsorigin, but not in CNC system, but in the mechanical parts. So, either in the CNC system, high-voltage electrical machine tool, or mechanical, hydraulic, pneumatic, etc., as soon as possible the cause of the failure, should be as comprehensive as possible, make a comprehensive judgment and selection, and then through the necessary test, achieve the purpose of diagnosis and troubleshooting eventually. Due to numerical control system fault and not easy to find another important reason is the interference. According to experience, to roughly the following several reasons. (1) machine tool factory assembly process of assembly process not reflected in the interference of the roughly as follows. (1) with no grounding method. Some machine tool production in order to conveniently, came to the ground and as a consequence, multipoint earthing form a circulation. (2) due to the improper site selection or poor contact, and even virtual welding caused the grounding resistance caused by the larger noise. CNC (3) system with the host signal communication, there are many is to use shielded wire connection, if the shielding misconduct, no connection in accordance with the relevant provisions is also a factor in causing interference. (2) high voltage interference of nc machine tools in high voltage contactor, relay cabinet etc. Interference sources of electromagnetic component is CNC system. Ac contactor, ac motor frequent starting, stop, the electromagnetic induction phenomenon will make the CNC system control circuit, such as peak or the wave surge noise is interfering with the normal work of the system. Therefore, must to the electromagnetic interference measures to eliminated. Is usually used in ac contactor coil or the ends of the ac motor in the three-phase input parallel RC network, and in the dc contactor or inverting dc solenoid valve coil at both ends into a fly-wheel diode and so on way to inhibit the electrical interference of the noise . But to note, these are merged into the absorption of the connection to the network should not be greater than 20 cm, otherwise, its effect is not ideal. At the same time, to check power supply control circuit of the input part of the CNC system, also want to take action. General multi-purpose surge absorber in parallel between the power cord, which can effectively absorb the peak voltage in grid, play a protective role. (3) power line interference caused by a lack of local areas in China power grid and power supply frequency instability, and user factory allocation unreasonable factors such as power line interference. Phenomenon can be summarized as overpressure, undervoltage, phase and frequency drift noise, harmonic distortion and common mode noise and norm, etc. To feed power supply electric circuit interference can adopt the following measures 五 the PMC CNC system PMC is called a programmable machine tool controller, PLC is specially used to control the machine tool. In numerical control machine tool, except for continuous control of each axis position, also need to such as spindle rotation and reversing, starting and stopping the feed movement, knife library and change the knife manipulator ntscontrol, workpiece clamping loosen, exchange of workbench, sequential control with auxiliary motion of the cooling and lubrication, etc. Sequence control information is mainly the input/output (I/O) control, such as control switch, input components such as switches, pressure switches and temperature switches, relays, contactors and solenoid valve control output components such as; Along with the spindle of the feed servo drive and servo drive can make control and alarm processing machine tool, etc. CNC machine USES the programmable logic controller (PLC) to complete the above functions, input/output (I/O) failure is the most common operation process of nc machine tool failure, this is because of the various input/output parts subject to mechanical wear and tear, oil and gas erosion, the influence of such factors, cause the loss of switch reliability failure caused by machine tool movement disorders. FANUC numerical control input/output done by PMC control, therefore, clear of nc machine tools PMC control signal is a representation of the object and the status, help to input/output control of the fault diagnosis. Horizontal machining center, for example: a factory equipment FANUCoi - Mc system, manipulator tool change interrupt knife library. CNC machine tool change system in the implementation of transfer instructions without action, mechanical arm stopped in the middle of the stroke position, CRT display alarm number, check the manual that said the alarm tool change system manipulator position detection switch signal to 0 and library change knife position error. Failure analysis: according to the alarm content, and can diagnose faults occurred in the toolchanger and knife library, as there is no signal sent to the corresponding position detection switch PMC input interface, which can lead to machine tool change. Cause switch no signal output for two reasons: one is caused by pressure or mechanical reasons action does not reach the designated position and the switch is not induction; The second is inductive proximity switch failure. First check the knife in the library is close to switch, use a thin iron to induction switch, proximity switch to detect knife library part whether failure. Close to two proximity switch in the toolchanger mechanical arm, one is the remove arm switch SQ1, another is the switch for SQ2 arm retraction. Stopped in the middle of the stroke position due to the mechanical arm, the two switch output signal are both switch for the 0 after the test is normal. Mechanical device; Arm back the movement is controlled by the solenoid valve Y21, electromagnetic valve Y21 manually; Returned the mechanical arm to arm retracted position, machine back to normal, it shows that hand control solenoid valve can make the tool change device orientation, so as to rule out the air pressure or the mechanical block caused the possibility of tool change system does not reach the designated position. Fault handling: analysis by above knowable, PMC input signal is normal, the output action executed correctly, problems within the PMC or improper operation, after operation to observe, tool change time interval is more than ntstwice the requirements of the PMC, PMC program execution errors caused by the cause of failure. Reset the storage tool storage time parameter values, added tool change back to normal. For all alarm number without alarm message alarm, must check the PMC data bits, and compared with the normal data, clarify the meaning of the data bits are said, to take corresponding measures. 六 numerical control machine tool maintenance Numerical control machine tool because of its function, structure and system, the maintenance of the content and rules also has its distinguishing feature each, specific should according to the type, model and practical usage, and the machine specification requirements, to develop and build up the necessary maintenance on a regular basis, grading system: 1, make the machine keep good lubrication condition Regularly check the cleaning, the automatic lubrication system, add or replace oil and grease oil, make the screw, guide rai
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