C8480普通车床数控化纵向改造-纵向进给机械参数-齿轮传动设计5张CAD图
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附录一：外文翻译翻译资料(中文)数控技术和数控装备数控技术和数控装备是制造工业现代化的重要基础。这个基础是否牢固直接影响到一个国家的经济发展和综合国力，关系到一个国家的战略地位。因此，世界上各工业发达国家均采取重大措施来发展自己的数控技术及其产业。在我国， 数控技术与装备的发展亦得到了高度重视，近年来取得了相当大的进步。特别是在通用微机数控领域，以 PC 平台为基础的国产数控系统，已经走在了世界前列。但是，我国在数控技术研究和产业发展方面亦存在不少问题，特别是在技术创新能力、商品化进程、市场占有率等方面情况尤为突出。在新世纪到来时，如何有效解决这些问题，使我国数控领域沿着可持续发展的道路，从整体上全面迈入世界先进行列，使我们在国际竞争中有举足轻重的地位，将是数控研究开发部门和生产厂家所面临的重要任务。 为完成此任务，首先必须确立符合中国国情的发展道路。为此，本文从总体战略和技 术路线两个层次及数控系统、功能部件、数控整机等几个具体方面探讨了新世纪的发展途径。1.发展具有中国特色的新一代 PC 数控系统数控系统是各类数控装备的核心，因此通过科技创新首先发展具有中国特色的新型数控系统，将是推动数控产业化进程的有效技术途径。 实践证明，10 年来我们所走的 PC 数控道路是完全正确的。PC 机（包括工业 PC）产量大、 价格便宜，技术进步和性能提高很快，且可靠性高（工业 PC 主机的 MTBF 已达30 年3）。 因此，以其作为数控系统的软硬件平台不但可以大幅度提高数控系统的性能价格比，而且还可充分利用通用微机已有软硬件资源和分享计算机领域的最新成果，如大容量存储器、 高分辨率彩色显示器、多媒体信息交换、联网通讯等。此外，以通用微机作为数控平台还可获得快速的技术进步，当 PC 机升级换代时，数控系统也可相应升级换代，从而长期保持 技术上的优势，在竞争中立于不败之地。 目前，PC 数控系统的体系结构有 2 种主要形式： （1）专用数控加 PC 前端的复合式结构；（2）通用 PC 加位控卡的递阶式结构。另外还有一种正在发展的数字化分布式结构。其方 案是将由 DSP 等组成的数字式伺服通过以光缆等为介质的网络与数控装置连接起来，组成 完整的数控系统。这种系统虽然性能很好，但由于开发和生产成本太高，近期难以被国内 广大用户所接受。我们认为上述结构并不是符合中国国情的最好方案，适合中国国情的应是将所有数控功能全软件化的集成式结构，因为这种结构的硬件规模最小，不但有利于 降低系统成本，而且更重要的是可以有效提高系统的可靠性。 几十年的经验表明，可靠性好坏是国产数控系统能否发展的关键。虽然影响数控系统 可靠性的因素很多，但过大的硬件规模和较低的硬件制造工艺水平往往对可靠性造成最大的威胁。以往，国产数控系统在总体设计时由于种种原因的限制，不得不选用技术指标不太高的普通 CPU，这样，为完成数控的复杂功能往往需要由多个 CPU 来组成系统，有时还需另加一些专用或通用硬件电路来实现数控系统的一些高实时性功能（如细插补、位置伺服控制等），从而造成系统硬件规模庞大。对于数控系统这种批量不大的产品，在国内现有 工艺条件下，很难从硬件制造的角度保证系统的可靠性，因而使得国产数控系统在生产现场的表现不佳，对国产数控系统的形象和声誉造成严重影响，使得不少用户现在还心有余悸。 因此， 我们在开发新型数控系统时，应优先选用新型高性能 CPU（如高主频的 Pentium II、Pentium III 等）作为系统的运算和控制核心，并尽量用软件来实现数控的所有功能。 这样，可大幅度减小系统硬件的规模。此外，还应在软件设计、电源设计、接插件设计与选用、接地与屏蔽设计和施工等方面采用强抗扰高可靠性设计与制造技术，从而全面提高 系统的可靠性。 由于一个新型高性能 CPU 可以代替数十个普通 CPU（如 80286、80386 等），因此，在基于高性能 CPU 的PC 平台上不仅可以完成数控系统的基本功能（如信息处理、刀补计算、插 补计算、加减速控制等）和开关量控制功能（内装 PLC），而且还可以完成伺服控制功能。 这样，以前由 DSP 完成的数字化伺服控制功能（如位置控制、速度控制、矢量变换控制等） 均可由 PC 中的 CPU 完成，从而实现内装式伺服控制， 这不仅有效缩小了数控部分的硬件规模，而且还大幅度缩小了伺服控制部分硬件规模。 这种具有内装 PLC 和内装伺服控制的全软件化集成式数控系统，其硬件规模将达到最小化，整个数控系统除一个 PC 平台外，剩下的只有驱动机床运动的功率接口和反馈接口。 这既有效提高了系统可靠性，又消除了信息传递瓶颈， 提高了系统性能，同时还可显著降低系统成本，使系统（包括电机）售价将可降至现有数控系统的一半左右。显然，这种高性能、高可靠性、低成本的新型数控系统将具有极强的竞争力，很有可能为开创中国数控的新局面作出贡献。2 推进数控功能部件的专业化生产解决数控系统问题后，如何实现数控机床的模块化设计与制造便是我国机床制造企业快速响应市场需求，在竞争中获胜的另一关键。要实现数控机床的模块化设计制造，必须解决数控机床功能部件的专业化生产问题。目前我国在这方面离实际需求还有相当大的差距。因此，在今后的若干年内，我们必须大力促进数控机床功能部件的开发和专业化生产。 其要点如下： (1)新型永磁电主轴单元电主轴已成为国际市场上最热门的数控机床功能部件。但目前这类产品几乎都为感应异步型，存在以下突出问题：转子上存在绕组，有大电流流过， 因此转子发热严重，直接影响主轴精度；低速出力小且转矩脉动大，难以满足宽范围切削要求；效率和功率因素低，不仅电机体积和重量大而且要求逆变器容量大、耗能多； 控制系统复杂、成本高。(2)廉价的高性能伺服系统 目前，一套进给交流伺服系统（驱动器+电机）的价格一般都在万元以上，主轴伺服系统的价格高达数万元，已成为降低国产数控机床成本的一大障碍。因此，应配合新型集成化国产数控系统的发展，大力开发廉价的高性能内装式伺服系统。由于内装式伺服的硬件部分只有电机和功率接口，充分利用我国的永磁资源优势， 通过专业化生产可以把电机的造价降下来，而采用智能化的 IPM 模块作为功率接口也很便宜，因此将内装式进给伺服的价格控制在数千元以内，将内装式主轴伺服的价格控制在 2 万元以内，将是完全可能的。 (3)直线交流伺服系统 直线交流伺服系统是下一世纪数控机床不可缺少的功能部件， 目前我国还没有成熟产品， 因此应加强研究、开发和推广应用。考虑到常规机床的防磁问 题较难解决，而并联机床的防磁相对容易，因此可为常规结构机床开发感应异步型直线电 机， 为并联结构机床开发永磁同步型直线电机，从而扬长避短，构成符合实际应用要求的新型高速高精度进给系统。在此基础上，可进一步开发将驱动与支承合二为一的磁悬浮工作台。 (4)高速高精度检测装置 高速高精度是下世纪数控机床发展的主题，这不但需要高性能的控制和驱动，同时还需要高品质的检测环节，因此应在现有技术基础上，进一步开发 0.1 m 以上精度的高速(60 m/min 以上)线位移传感器和 100 万脉冲/r 的角位移传感器， 此类技术国外对我国是封锁的。3 加速数控机床的全国产化，打好市场翻身仗数控产业化的最终成功将体现在数控机床的全国产化和市场占有率上。在上述总体战略指导下， 采取抓两头（低价位数控机床和高速高效数控机床） 、带中间 （普通数控机床） 、 促重型（重型关键装备）的方针，将是在国内市场上快速收复失地，在国际市场上稳步进军，最终打赢国产数控机床市场翻身仗的一种有效战术和策略。关于普通数控机床的发展已有许多文章作了专门论述，因此下面仅就低价位数控机床、高速高效数控机床和重型数控机床的发展问题作一讨论。 (1)大力发展低价位数控机床低价位机床是功能满足用户要求(无功能浪费)、技术指标适中、可靠性好、价格便宜的普及型数控机床。这类机床已成为国际市场上数控机床的发展趋势之一，也是国内众多用户渴求的产品，其市场前景相当广阔。然而，如果采用国外数控系统（包括伺服）按照传统思路来发展低价位机床，是很难将价格降至广大用户所能接受的水平的。因此，采用本文提出的新型集成化国产数控系统来发展高性能的低价位数控机床，将是一条最有希望成功的道路。只要有一定批量，由此构成的全国产普及型数控车床的售价完全可以控制在 10 万元以内，三坐标数控铣床可控制在 15 万元左右，加工中 心可控制在 20 万元左右。此价位的国产数控机床将是具有较强竞争力的。 (2)加速开发高速高效数控机床高速高效是数控机床发展的另一大潮流。发展高速高效数控机床的技术途径可有以下几条：通过提高切削速度和进给速度，从而达到成倍提高生产效率，有效提高零件的表面加工质量和加工精度并解决常规加工难以解决的某些特殊材料（如铝钛合金、模具钢、淬硬钢）和特殊形状零件（如复杂薄壁零件）的高效加工问题。通过工艺复合，减少工件的安装次数，有效缩短搬运和装夹时间。例如，将五面五轴加工中心与立车复合构成万能加工中心， 可实现一次装卡完成零件的大部分（或全部） 加工。采用高速高精度圆周铣加工孔和以螺旋轨迹插补实现不钻底孔的直接攻丝等新加工方法，大幅度减少换刀次数，提高加工效率。为数控机床开发智能寻位加工功能，消除对精密夹具和人工找正的依赖，有效缩短单件小批加工的准备时间。 (3)突破重型数控机床的设计制造技术重型数控机床（特别是多坐标重型数控机床） 是国民经济和国防生产中的重大关键设备，属于战略物资，真正先进的重型数控机床国外是不可能卖给我们的，因此，在我国下世纪数控产品的发展中必须依靠自己的力量进行解决。发展重型数控机床必须有过硬的基础，我们在数控机床国产化的进程中应不断总结经验，加强基础技术和关键技术研究，充分发挥我国产学研相结合的优势， 各部门通力合作、 共同努力，争取在下世纪初取得突破性进展。 目前，在发展重型数控机床中除需加强基础理论研究外，还应加强其关键技术研究。 例如， 重型机床的控制就是需要加以特殊解决的关键问题。因重型机床加工的工件特别昂贵不允许报废，为了确保机床工作可靠，在数控系统中可采用双（或多）CPU 冗余工作方案，以确保运算和控制的绝对正确，并在出现故障时自动诊断、自动修复或自动替补，确保加工不出问题。此外，在电源上可采取双蓄电池供电的全隔离供电方案，即一组电池在 给系统供电时，可对另一组电池进行充电，电网与控制系统是完全隔离的。这就彻底消除 了重型车间中电网电压波动厉害、干扰严重对数控系统造成的影响，从而有效保证系统的 可靠性。又如，重型数控机床的驱动也是一大关键问题。当行程长度超过 5 m，普通滚珠丝杆就难以胜任大负荷的传动，因此目前一般采用预加负载的双齿轮-齿条机构、静压蜗 杆-蜗母条机构、四足（或双足）爬行进给机构等来实现长行程传动。但这些方案存在结 构复杂、速度和加速度低、动态性能差、难以达到高精度、维护保养复杂等问题。为此可发展阵列式高效直线电机直接驱动技术和空间并联机构驱动技术， 以新的途径来解决重型数控机床的高速、高精度驱动问题。除此之外，机床结构的优化设计、长行程精密检测、 重力变形补偿、 切削力变形补偿、 热变形补偿等也是重型数控机床中必须解决的关键问题， 必须予以充分重视。 制定符合中国国情的总体发展战略，确立与国际接轨的发展道路，对 21 世纪我国数控技术与产业的发展至关重要。本文在对数控技术和产业发展趋势的分析，对我国数控领域存在的问题进行研究的基础上，对 21 世纪我国数控技术和产业的发展途径进行了探讨，提出了以科技创新为先导，以商品化为主干，以管理和营销为重点，以技术支持和服务为后盾，坚持可持续发展道路的总体发展战略。在此基础上，研究了发展新型数控系统、数控 功能部件、数控机床整机等的具体技术途径。 我们衷心希望，我国科技界、产业界和教育界通力合作，把握好知识经济给我们带来的难得机遇，迎接竞争全球化带来的严峻挑战，为在 21 世纪使我国数控技术和产业走向世界的前列，使我国经济继续保持强劲的发展势头而共同努力奋斗！附录二：翻译原文NC technology and NC equipmentNC technology and NC equipment manufacturing industry is an important foundation for modernization. This is the basis of a strong direct impact on the countrys economic development and comprehensive national strength, and bearing on a countrys strategic position. Therefore, the worlds industrialized countries have taken significant steps to develop their own technologies and their industrialization NC. In China, the CNC technology and equipment development has also been a high degree of attention in recent years has made considerable progress. Particularly in the area of general computer numerical control, PC-based platform for domestic CNC systems, has been at the forefront of the world. China, however, is in NC technology research and development industries also have many problems, particularly in the ability of technological innovation and commercialization process, and other aspects of market share is even more conspicuous. In the arrival of the new century, how to effectively solve these problems, Chinas NC areas along the path of sustainable development, from the overall comprehensive entered the ranks of the advanced world, we in the international competition in a pivotal position, will be NC research and development departments and manufacturers facing the important task. To accomplish this task, first of all, must be established in line with Chinas national conditions and development. Therefore, this article from the overall strategic and technical level and two line CNC system, functional components, NC complete machine, and several specific aspects of the development in the new century means.1 Development with Chinese characteristics and a new generation of PC NC systemNC system is the core of all types of CNC equipment, first through the development of scientific and technological innovation with Chinese characteristics, the new NC system, will be to promote the industrialization process of NC effective technical means. Practice has proven that the past 10 years we are moving in the PCNC road is completely correct. PC machines (including industrial PC) output is big, cheap, technological progress, and quickly improve performance, and high reliability (MTBF host PC industry has reached 30 3). Therefore, as a CNC system with the hardware and software platform can greatly improve the cost-NC system, but also make full use of existing generic computer hardware and software resources and sharing the latest achievements in the field of computers, such as large memory capacity, high - color display, multimedia information exchange, networking and communications. In addition, as the common computer platform can also access NC rapidtechnological progress, when PC-upgrading, NC system can also be corresponding upgrades to maintain long-term technical advantages in the competition to be invincible.At present, the PC architecture CNC system comes in two main forms: (1)for the front of the PC and NC composite structure; (2) General and PC-card-hierarchical structure. Another is the development of a number of distributed architecture. DSP will be its programmer is composed of digital servo through the media, such as fiber optic cable network to link up with the NC device, the NC formed a complete system. Although the performance of this system is very good, but because of the high costs of development and production, the recent difficult to be accepted by domestic users. We believe that the above-mentioned structure is not in line with Chinas national conditions the best solution to Chinas national conditions should be all full-function CNC Softwares integrated structure, such as the structure of the smallest hardware, and is conducive to lower system costs, but, more importantly, can effectively improve the reliability of the system. Decades of experience show that the reliability of domestic CNC system is good or bad can the key to development. Although the NC system reliability impact of a number of factors, but the large-scale hardware and the hardware manufacturers lower level of reliability tend to pose the greatest threat. Previously, domestic CNC system in the design, the limit for a variety of reasons, do not have to use too much technical indicators ordinary CPU, so, for the completion of the complex function NC often need more CPU to component systems, and sometimes plus some special need or common hardware circuit NC system to achieve real-time high of some functions (such as small interpolation, position servo control, etc.), resulting in large-scale system hardware. NC system for small quantities of such products in the country under the conditions of the existingprocess, it is difficult from the perspective of hardware manufacturers ensure that the reliability of the system As a result, domestic production in the NC system at the poor performance of the domestic few control system the image and reputation of a serious impact makes many users now also fear. Therefore, we in the development of the new NC system, priority should be given to selection of new high-performance CPU (such as the high-speed Pentium II, Pentium III, etc.) as a system and control core computing, and software to achieve as far as possible all the features of NC . This can drastically reduce the size of the system hardware. Also, the software design, power supply design, the design and selection of connectors, grounding and shielding design and construction, such as the adoption of strong anti-nuisance high reliability design and manufacturing technology, and thereby improve the reliability of the system. Since a new high-performance CPU can replace dozens of ordinary CPU (such as the80286,80386, etc.), therefore, based on the high-performance CPU on the PC platform, not only can fulfill the basic functions of CNC system (such as information processing, knives meeting, interpolation, acceleration and deceleration control, etc.) and on-off control function (PLC contents), but also to be completed servo control functions. Thus, before the completion of the DSP digital servo control functions (such as position control, speed control, transformation vector control, etc.) from a PC can be completed in the CPU, thus realizing the contents of servo controls, which not only effectively reduce the size of the hardware part of NC , but also significantly reduce the servo control of the hardware scale. Such contents PLC and servo control of the entire contents of the integrated software CNC system, the hardware will reach its minimum, the entire CNC system, in addition to a PC platform, the only remaining driver of the sports machine interface and feedback power interface. This not only effectively improve the reliability of the system, eliminating the transmission of information bottlenecks, improve system performance, but can also significantly reduce system cost, the system (including motor) to the existing price will be about half the CNC system. Obviously, this high performance, high reliability, low cost, the new NC system is highly competitive, is expected to open up a new situation in China to contribute to NC. In addition, the integration of PC NC system there is a big advantage, that is easy to achieve open architecture. This is because such a system is the hardware itself has been completely open, open a CNC system completely in software, as long as the proper formulation of standards and protocols,information processing, path interpolation, acceleration and deceleration control, Switch control to servo control can be achieved and opening up, thus greatly facilitate user access.2 NC components advancing specialized productionNC system to resolve the problem, how to achieve CNC machine tool design and manufacture of modular machine tool manufacturing enterprises in China is the rapid response to market demand, competition won another key. CNC machine tools to achieve the design and manufacture of modular, we must solve the NC machine tool components of specialized production. China in this regard from the actual demand there is still a considerable gap. Therefore, in the next few years, we must vigorously promote the CNC machine tool components and the development of specialized production. The main points are as follows: (1) New permanent magnet electric spindle, spindle units on the international market has become the most popular CNC machine tool features. But almost all of these products for asynchronous induction type, presence following major problems: there rotor windings, highcurrent flow, heat rotor serious direct impact on the spindle precision; small andlow-speed output torque ripple, be difficult to meet the wide range of cutting requirements; efficiency and low power factor, not only motor size and weight requirements of the inverter and a large capacity, energy and more complex control system, the high cost. (2) Cheap, high-performance servo system is, a feed AC servo system (motor + drive) prices are generally inthe million more than the price axis servo system up to a few million, has become a lower domestic CNC machine tools the cost of a major obstacle. Therefore, should be in line with the new integrated domestic CNC system development, vigorously develop the contents of cheap, high-performance servo system. The contents of the hardware only servo motor and power interface, and make full use of Chinas permanent resource advantages, and specialized production by the motor can cost down, and the intelligent use of IPM as a power module interfaces are cheap, will be the contents of feed servo control in the price of several thousand dollars within, the contents of spindle servo control in the price of less than 20,000 yuan, it is entirely possible. (3) linear AC servo system linear AC servo system is the next century CNC machine toolindispensable components, the present China has not yet mature product, it should strengthen the research, development and application. Taking into account conventional machine Magnetically-shielded problem more difficult to solve, and the Magnetically-shielded PMT relatively easy, conventional structure for the development of machine-linear asynchronous induction motor, parallel structure for the development of permanent magnet synchronous machine type linear motor, thereby exceed and with a practical application of a new-type high-speed high-precision feed system. On this basis, the drive will be further developed with the support of the combined magnetic levitation table. (4) high-speed high-precision detection device is high-speed high-precision CNC machine tool development of the next century is the main theme and not only need high-performance control and drive, but also need high-quality examination link, it should be based on existing technology, further development of 0.1 m above the precision of high-speed (60 m / min or more) and linear displacement sensor 1 million pulses / r the angular displacement sensor, such technology is abroad on Chinas blockade.3 CNC machine tools to accelerate production of the country, and win market overtakeNC industrialization of ultimate success will be reflected in the CNC machine tool production and market share. In the overall strategic guidance, the implementation of grasping two (low-efficiency and high-speed CNC machine tool CNC Machine), with the middle (general CNC machine tool), and promoting heavy (heavyequipment key) approach, in the domestic market will be fast recover the lost land, in the international market steady advance toward the end to fight domestic CNC machine tool market overtake an effective tactics and strategies. On the general development of CNC machine tools has made numerous articles devoted to, the following low-only NC machine tools, high-speed CNC machine tools and heavy efficient CNC machine tool development issues are discussed. (1) Vigorously develop low-cost CNC machine tool is the low-cost machine functions to meet user requirements (no functional waste), technical indicators moderate, reliability, and the popularity of cheap NC machine tools. Such machines have become an international market trends in the development of CNC machine tools, and is one of many domestic users aspirations of the product,a broad market prospect. However, if a foreign NC system (including servo) in accordance with the traditional way of thinking to develop low-cost machine, it is difficult to cut their prices to be acceptable to the vast number of users level. Thus, the application of this new type of integration of the domestic CNC system to the development of high-performance low-cost CNC machine tools, will be one of the most successful road hope. As long as a certain volume, which constitutes the middle of the universal CNC lathe can control the price at 100,000 yuan within the 3D CNC milling machine can be controlled in 15 million, the processing centre can be controlled at 20 million . The price of domestic CNC machine tools will be a stronger competitive. (2) To accelerate the development of efficient high-speed high-speed CNC machine tool CNC machine tool development efficiency are another major trend. Development of efficient high-speed CNC machine tool technology can be a way to the following: through increased cutting speed andfeed rate, doubling their production to achieve efficient and effective processing improve thesurface quality of parts and machining accuracy and solve difficult to resolve conventional processing some special materials (such as aluminum titanium, mold steel, hardened steel) and the special shape of components (such as complex thin-walled parts) efficient processing problems. through the composite process, reduce the number of the installation of the work piece,effectively shorten the handling and clamping time. For example, five 5-axis machining center with a composite legislation cars universal machining centre will achieve a complete card with the majority of parts (or all) processing. circle in a high-speed high-precision milling and processing hole in a spiral path interpolation does not realize the direct drilling Bottom Tapping new processing methods, and substantial reductions in the number of ATC and improve processing efficiency. CNC machine tool development for intelligent searching machining functions, and the elimination of artificial precision fixture is to find the dependence of the effective shortening of single pieces of small-batch processing time to prepare. (3) breakthrough heavy CNC machine tool design and manufacturing technology heavy CNC machine tool (especially heavy multi-axis CNC machine tools) is the national economy and national defense production of critical equipment, are strategic commodities, real advanced heavy foreign NC Machine Tool it is impossible to sell us, therefore, in our country the next century NC product development must rely on its own strength to solve. CNC machine tool development must have a heavy perfect basis, we in CNC machine tools in the process of China should constantly sum up experience, strengthenbasic research and key technologies, and give full play to Chinas advantages of combining production and research, the collaboration of different departments together strive to make a breakthrough early in the next century progress. At present, the development of CNC machine tools, in addition to heavy need to strengthen basic theoretical research, but also to strengthen their research of key technologies. For example, heavy machine control is a special need to be resolved key issues. Due to heavy machining of work pieces not particularly expensive scrapped, in order to ensure that the machine is reliable and in the CNC system of dual-use (or) CPU redundancy programmer of work to ensure that the operation and control of the absolutely correct, and in the event of failure automatic diagnosis, auto repair or replacement automatically ensure that no processing problems. In addition, the power supply can be taken on the dual-battery-powered electricity-wide isolation, that is a battery power supply to the system, to be carried out on another group of rechargeable batteries, power grids and control system is completely isolated. This workshop complete elimination of the heavy fluctuations in the power grid voltage powerful, serious interference on the impact of the NC system, which
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