PLC and exchanging the servo system to bore the application in the milling machine in numerical control
Foreword
A type is the rectangular aluminium base station of Q7 in the products that are developed newly, should process two flat blind holes of 3.7* 1.65 above, because the precision prescribed is high, the batch is large, so unable to process on the drilling machine the traditional jig, also it is very difficult to process on traditional milling machine, it is very low even can process efficiency, and the apparatus losses and the power consumption is very great. The processing of this work piece has very extensive representativeness, a lot of products produced have similar requirements, for this reason, we design manufacturing an apparatus used in this kind of product process – -General numerical control bores the milling machine.
A summary
The control box adopts PLC, and add the man-machine interface and revise, presume the program parameter, and run the situation display is controlled, the programmable content of setting up the man-machine interface. The triaxiality the whole figure exchanges the servo system, every axle servomotor drives the ball screw through connecting with the axial organ, by moving work bench and basic shaft furnished with the guide rail of the straight line and milling the head, it positions accurately, fast. The basic shaft mills the head controlled by the frequency converter, according to cutting tool, work piece and feeding amount, to set up the basic shaft reasonable rotational speed, and presume in the procedure its start stops. Every axle sets up and carries terminal sensor and original point sensor two times, cool and lubricate and unusually measure, reveal the warning message at alarm lamp and man-machine interface. To facilitate debugging and overhauling, every operation have the manual function, such as every axle speed is moved manually, level rotating, cutting fluid and lubricating the switch,etc. rapidly of basic shaft. This whole lathe although half close cycle control, option, assemble, program composition and operate rationally, precision and stability can meet the instructions for use.
Second, hardware disposition
PLC chooses forever great FBS-40MCT, this type machine has higher cost performance, the volume is small, the function is strong, input 24 o’clock, have 16 high-speed counter among them, the intersection of frequency and reachable 120K, export 16 o’clock, 4 the intersection of axle and marching in that or export integration inside while being servo, the intersection of output frequency and reachable 120K, make it stand up very much convenient not to employ, the interstar connection is simple. The software WinProladder of programming has the title of ladder-diagram master, is easy to learn and use and powerful, edit, monitor, except that fault,etc. operate very conveniently, and key set, mouse inquire with online instant command function and operation is guided, make editing, input efficiency double.
The joint distributes: Function as the initial point switch, should branch off on several enter points at a high speed in Z picture signal which chooses every axle servomotor, by stopping resetting the initial point of lathe, such regular joints as test other limit switch, function switch, liquid level can be inserted sequentially sequentially. X, Y, the intersection of Z and triaxial servomotor connect with the first 3 axle export some while being servo, basic shaft the intersection of level and speed, cooling, alarm,etc. connect in the others exporting on the some.
X, Y, Z3 axle servo system choose identically, exchanges the servo driver 0040E-CBCEE-02 in ES serial the whole figures when with the profit, and the servomotors 60CB040C-2DE6E of serial small inertias 60. This servo system function is more complete, such as dynamic braking, electronic gear, adding the deceleration etc. automatically, possess input of many kinds of pulse series, it is more complete to protect the function too, unusually,etc. there are voltage shortage, overvoltage, excessive load, over load, rotoplug, stalling, position overproof, Coder. Connect to PLC according to the driving means of opening a way of the collecting electrode in this apparatus, the frequency of highest pulse input is 200K, servo ON, Z looks signal,etc. make and connect correspondingly too.
The frequency converter chooses rich DZB70B0015L2A that insulted, the specification is single-phase 1500W, 400Hz, many leg speeds are for the editor to use. Because the not frequent speed changing while using normally, so speed adjustment is presumed and does not draw, regulate only on the frequency converter operation panel, presume two speeds, is used for processing at a high speed, low speed is used in the knife correctly. Regulate the correlation parameter to match with the basic shaft, such as fundamental frequency, group pressing, upper frequency limit, carrier frequency of running,etc., and change the corresponding jumper wire.
The basic shaft has not adopted the traditional way, but according to the requirements of the processing, adopt the electric basic shaft that the engraving machine uses, the ADX80-24Z/1 type that the fields lying fallow in rotation of Anyang must be safe, its volume is little, the noise is low, the diameter has 80mm only, makes the whole headstock easy to seal wholly like this, can prevent causing the damage on guide screw and guide rail that piece splashes the Z axis while processing effectively, also make headstock appearance seem esthetic. Its highest rotational speed is 24000 rpms, makes the normal service speed have an appropriate excess range to transfer to by 6000-14000. The man-machine interface chooses the man-machine electronic common programmable text display unit MD204L, it can monitor, revise PLC internal register or number value and state of the electrical relay in the form of characters or pilot lamp,etc..
Third, software design
Find whether the hand-operated switch is effective, if the hand-operated switch utilizes every manual controlled switch to carry out the manual operated project effectively promptly first after the starting up. If the hand-operated switch is invalid, will start the initial point to reply the preface of return journey, every axle resets the initial point of lathe, go back Z axis go back other two axle again first, go on get the next step after initial point of all axles reset success. If cutting tool and the intersection of frock and clamp, work procedure have change, can reset, get, process, prepare state than carry on right, take correctly, open to the intersection of knife switch and the intersection of start and right of procedure, 3 axle part knife correctly, namely look for the initial point of work piece, utilize every axle to move the speed of the switch and move every axle manually, make three surfaces of the work piece touch the revolutionary cutting tool of low speed separately, just run into. To after being fine, until one hundred sheetses of OK confirm correctly, input knife, mend and then, through program manipulation, namely form work piece initial point 0 o’clock such as programming, calculate the cutting tool route according to the drawing according to this 0 o’clock at the time of programming, can make operator’s thinking clear, editor’s operation is simple. Operator’s editor is the user program, can edit the orbit of the cutting tool, it is every axle that moves the coordinate, and migration velocity, circulating the cycle index when processing,etc.. When or use the present procedure after finishing the procedure, namely reset to and prepare the state: Every axle is moved over into original location – an appropriate position, it is convenient, difficult when touch the cutting tool to load and unload the work piece, install the work piece, can begin to process according to starting, the basic shaft operates, the cooling fluid is opened, every axle presumes coordinates are moved according to the procedure. When processing finishing, the lathe is reset, namely every axle is moved over into the original location again, the basic shaft stops, cool and close, can unload the work piece at this moment, finish the processing course.
The flow process chart of the work piece, take Q7 products as examples, 15 work pieces of clamping last time of positioner, 30 flat blind holes of 3.7 need processing, the cutting tool chooses 2 edge tungsten steel end-milling cutters of 3.7, bore and pare processing, bore and pare deep 1.65mm. Close to the fixed good positioner of alignment on the work bench while preparing the state, after pressing start, the basic shaft is rotated, when the basic shaft will reach the rated revolution soon, X, Y-axis operate to the first to process the work station at the same time, only first X, the intersection of Y and the intersection of work piece and coordinate value of hole, cooling fluid open at this moment and Z axis drop to the processing district fast, namely the intersection of milling cutter and end touch work piece, process soon, become, enter speed, begin, bore, sharpen, process with slow worker rapidly. Act as, process, reach, set for depth deeply ‘ 1.65mm) When, Z axis drive milling cutter lift rapidly, for touch work piece and positioner for being accurate at the the intersection of milling cutter and the intersection of end and horizontal direction height that lift. The procedure carries on comparison operation, judges and processes whether it is over or not after the counter is added by 1, if deny, then X, Y-axis continues operating to and making and processing the work station, and then repeat the Z axis and drop and process movements. Such as process, finish, the intersection of output and the intersection of counter and Summanden, basic shaft stall and cooling fluid shut off, give out 5s acoustooptic information reporting at the same time, in order to remind operators, every axle is moved over into the original location: The Z axis reaches the top; The X-axis reaches the left end; The Y-axis reaches the external. Lift off after the positioner, one process cycle, finish, install positioner according to start, start, process by the next promptly.
Four, some electric measures focused on
1.The major loop is installed the residual current circuit-breakers additionally, all install the appropriate circuit breaker in corresponding loop.
2. plus PLC and the powers of servo system respectively by power supply filter.
3.Every direct-flow relay coil negative peak diode of joining-up in parallel, exchange the capacitance-resistance of joining-up in parallel of contactor coil and absorb the loop.
4.Lubricate, basic shaft cool, set up the intersection of liquid level and low alarm equipment.
5.Servo control lines, man-machine interface communication wires,etc. uses the shielded wire, and is far away from the power line.
6.Route in the drag chain, use the flexible cable that is able to bear rolling over and and try hard to increase the bending radius of the drag chain.
7.The frequency converter keeps certain distance with PLC, servo driver,etc..
