缸頭5個螺紋孔鉆孔專機設計,缸頭5個螺紋孔鉆孔專機設計,螺紋,羅紋,鉆孔,專機,設計 無錫太湖學院 　信 機　系 　機械工程及自動化 　專業(yè) 畢 業(yè) 設 計論 文 任 務 書 一、題目及專題： 1、題目　　缸頭5個螺紋孔鉆孔專機設計　 　 2、專題　 　 二、課題來源及選題依據 本課題來源于生產實踐。隨著工業(yè)生產規(guī)模化、專業(yè)化、集中化、高度機械化乃至自動化的步伐的加快，在進行工件加工時，要求考慮使用專用機床和夾具。組合機床和組合機床自動線是一種專用高效自動化技術裝備,目前,由于它仍是大批量機械產品實現高效、高質量和經濟性生產的關鍵裝備,因而被廣泛應用于汽車、拖拉機、內燃機和壓縮機等許多工業(yè)生產領域。某企業(yè)因生產發(fā)展需要，擬開發(fā)缸頭5個螺紋孔鉆孔專機，因此選定缸頭5個螺紋孔鉆孔專機設計為本次設計課題。 三、本設計（論文或其他）應達到的要求： ①學習獨立查閱參考文獻的能力； ②繪制加工零件的加工工序圖，加工示意圖； ③完成缸頭5個螺紋孔鉆孔專機總體結構和主要部件（機床夾具、組合機床多軸箱）設計； ④設計說明書一份，不少于10000字，必須有相關的計算和說明； ⑤專業(yè)外語文獻翻譯不少于一萬字符； ⑥熟悉CAD制圖軟件，了解所設計的傳動系統(tǒng)。 四、接受任務學生： 機械94 班 　　姓名 黃麗萍 五、開始及完成日期： 自2012年11月12日 至2013年5月25日 六、設計（論文）指導（或顧問）： 指導教師　　　　　　　簽名 簽名 　　　　　　　簽名 教研室主任 　　　　　　〔學科組組長研究所所長〕　　　　　　　簽名 　　 　　系主任 　　　　　　簽名 2012年11月12日 編號 無錫太湖學院 畢業(yè)設計（論文） 相關資料 題目： 缸頭5個螺紋孔鉆孔專機設計 信機 系 機械工程及自動化專業(yè) 學 號： 　　　 0923155　　　　 學生姓名： 黃 麗 萍 指導教師： 　 劉新佳 （職稱：副教授） （職稱： ） 2013年5月25日 目 錄 一、畢業(yè)設計（論文）開題報告 二、畢業(yè)設計（論文）外文資料翻譯及原文 三、學生“畢業(yè)論文（論文）計劃、進度、檢查及落實表” 四、實習鑒定表 無錫太湖學院 畢業(yè)設計（論文） 開題報告 題目： 缸頭5個螺紋孔鉆孔專機設計 信機 系 機械工程及自動化 專業(yè) 學 號： 0923155 學生姓名： 黃麗萍 指導教師： 劉新佳 （職稱：副教授 ） （職稱： ） 2012年11月23日 課題來源 本課題來源于工程生產實際。 科學依據（包括課題的科學意義；國內外研究概況、水平和發(fā)展趨勢；應用前景等） （1）課題的科學意義 隨著工業(yè)生產規(guī)?；I(yè)化、集中化、高度機械化乃至自動化的步伐的加快，在進行工件加工時，要求考慮使用專用機床和夾具。組合機床和組合機床自動線是一種專用高效自動化技術裝備,目前,由于它仍是大批量機械產品實現高效、高質量和經濟性生產的關鍵裝備,因而被廣泛應用于汽車、拖拉機、內燃機和壓縮機等許多工業(yè)生產領域。某企業(yè)因生產發(fā)展需要，擬開發(fā)缸頭5個螺紋孔鉆孔專機，因此選定缸頭5個螺紋孔鉆孔專機設計為本次設計課題。 （2）國內外研究概況、水平和發(fā)展趨勢： 我國加入WTO以后，制造業(yè)所面臨的的機遇和挑戰(zhàn)并存。組合機床行業(yè)適時調整戰(zhàn)略，采取了積極的應對策略，出現了產銷兩旺的良好勢頭，截止2002年9月份，組合機床行業(yè)企業(yè)僅組合機床產品一項，據不完全統(tǒng)計產量已達800余臺，產值達3個億以上，較2001年同比增長了10%以上，另外組合機床行業(yè)工業(yè)增加值、產品銷售率、全員工資總額、出口交貨值等經濟指標均有不同程度的增長，新產品，新技術較去年均有大幅度提高，可見行業(yè)企業(yè)運營狀況良好。 組合機床及其自動線是集機電于一體的綜合自動化程度較高的制造技術和成套工藝裝備。它的特征是高效、高質、經濟實用，因而被廣泛應用于工程機械、交通、能源、軍工、輕工、家電等行業(yè)。我國傳統(tǒng)的組合機床及組合機床自動線主要采用機、電、氣、液壓控制，它的加工對象主要是生產批量比較大的大中型箱體類和軸類零件（近幾年研制的組合機床加工連桿、板件等也占一定份額）。隨著技術的不斷進步，一種新型的組合機床——柔性組合機床越來越受到人們的青睞，它應用多位主軸箱、可換主軸箱、編碼隨行夾具和刀具的自動更換，配以可編程控制器、數字控制等，能任意改變工作循環(huán)控制和驅動系統(tǒng)，并能靈活適應多品種加工的可變可調的組合機床。另外，近年來組合機床加工中心、數控組合機床、機床輔機（清洗機、裝配機、綜合測量機，試驗機、輸送線）等在組合機床行業(yè)中所占份額也越來越大。 研究內容 ①學習獨立查閱參考文獻的能力； ②完成缸頭5個螺紋孔鉆孔專機總體結構和主要部件（機床夾具、組合機床多軸箱）設計； ③能夠繪制出加工工序圖，加工示意圖，填寫機床生產率計算卡。 擬采取的研究方法、技術路線、實驗方案及可行性分析 本課題是根據工程實際的需要所做的研究，是工廠在現實生產作業(yè)中對于改進零件加工工藝方案，提高工廠的生產率和質量，為減少生產成本，取得更好的經濟效益而提出來的。我所設計的組合機床內容包括初步確定專機設計總體方案，繪制加工工序圖和加工零件圖，繪制機床聯(lián)系尺寸圖，編制生產率卡，設計機床夾具，繪制機床夾具總圖，設計機床多軸箱，繪制多軸箱總圖。 研究計劃及預期成果 研究計劃： 2012年11月12日-2012年12月2日：按照任務書要求查閱論文相關參考資料，填寫畢業(yè)設計開題報告書。 2012年12月3日-2013年1月20日：進行畢業(yè)實訓。 2013年1月21日-2013年3月1日：填寫畢業(yè)實習報告，并開始著手畢業(yè)設計零件圖紙的分析 2013年3月1日-2013年3月8日：專業(yè)機床總體方案初步構思。 2013年3月11日-2013年3月15日：專業(yè)機床總體方案設計。 2013年3月18日-2013年3月29日：繪制零件加工工序圖。 2013年4月1日-2013年4月5日：繪制機床聯(lián)系尺寸圖。 2013年4月8日-2013年4月12日：填寫生產率計算卡。 2013年4月15日-2013年4月26日：專用夾具的設計。 2013年4月29日-2013年5月10日：多軸箱的設計，草圖繪制。 2013年5月13日-2013年5月17日：檢查，修改，完善說明書。 2013年5月20日-2013年5月25日：資料整理裝訂，準備答辯。 預期成果：設計圖樣及設計說明書一套 特色或創(chuàng)新之處 從企業(yè)實際需求出發(fā)，在全面分析被加工零件的基礎上，指出現有設備的不足，不僅工人勞動強度大，而且生產效率低，不利于保證零件加工精度，采用組合機床的創(chuàng)新設計可解決上述問題。 已具備的條件和尚需解決的問題 已經進過專業(yè)課程設計等的相關訓練，還經過畢業(yè)實習的實習。此外，為了本次畢業(yè)設計進行了前期調研，相關資料的搜集，已做好技術設計的相關準備工作，設計思路及方案已基本明確。 但任有問題尚需解決，如組合機床整體方案的設計、多軸箱的設計等，還需根據零件圖進行詳細的分析設計等，其中依舊存在著一定問題。 指導教師意見 指導教師簽名： 年 月 日 教研室（學科組、研究所）意見 教研室主任簽名： 年 月 日 系意見 主管領導簽名： 年 月 日 英語原文： Integrated Machine and Control Design Abstract— In this paper, we describe a systematic design procedure for reconfigurable machine tools and their associated control systems. The starting point for the design is a set of operations that must be performed on a given part or part family. These operations are decomposed into a set of functions that the machine must perform and the functions are mapped to machine modules, each of which has an associated machine control module. Once the machine is constructed from a set of modules, the machine control modules are connected. An operation sequence control module, user interface control module, and mode-switching logic complete the control design. The integration of the machine and control design and the reconfigurability of the resulting machine tool are described in detail. I. Introduction In today’s competitive markets, manufacturing systems must quickly respond to changing customer demands and diminishing product life cycles. Traditional transfer lines are designed for high volume production, operate in a fixed automation paradigm, and therefore cannot readily accommodate changes in the product design. On the other hand, conventional CNC-based “flexible” manufacturing system offer generalized flexibility but are generally slow and expensive since they are not optimized for any particular product or a family of products. An effort at the University of Michigan aims to develop the theory and enabling technology for reconfigurable machining systems. Instead of building a machining system from scratch each time a new part is needed, an existing system can be reconfigured to produce the new part. In this paper, we describe how an integrated machine and control design strategy can result in machine tools which can be quickly and easily configured and reconfigured. In order to provide exactly the functionality and capacity needed to process a family of parts, RMTs are designed around a given family of parts. Given a set of operations to be performed, RMTs can be configured by assembling appropriate machine modules. Each active module in the library has a control module associated with it. As the mechanical modules are assembled, the control modules will be connected and the machine will be ready to operate. Extensive and time-consuming specialized control system design will not be required. Section II describes how the machine is designed from a set of basic machine modules, This research was supported in part by the NSF-ERC connected in a well-defined fashion, and Section III describes how the control is similarly assembled from a library of control modules. This modular construction of the machine and control allows for many levels of reconfigurability as described in Section IV. The paper concludes with a description of future work in Section V. II. Machine Design Ongoing work on manufacturing system configuration at the University of Michigan addresses the problem of starting from a part (or part family) description and extracting the machining operations necessary to produce the part(s). The operations are grouped according to tolerance, order of execution, and desired cycle time of the system, with the intention that each operation “cluster” can be produced on a single machine tool. The operation cluster considered here is to drill a set of holes for the cam tower caps on V6 and V8 cylinder heads shown in Figure 1. The input to the reconfigurable machine tool design procedure is the cutter location data generated by a process planner for this operation cluster. data includes positioning and drilling information. The RMT design procedure consists of three main stages: task clarification, module selection, and evaluation. After a brief literature review, these three stages will be outlined in this section. A. Related research Since reconfigurability is a relatively new concept in machining systems, there is little, if any, published literature on the design of reconfigurable machine tools. However, modular machine tools have been on the market for several years, and some of the published articles on modular robots, modular machines and assembly do have some relevance to the design of reconfigurable machine tools. For example, Shinno and Ito proposed a methodology for generating the structural configuration of machine tools. They decomposed the machine tool structures into simple geometric forms: e.g. boxes, cylinders, etc. Yan and Chen [21], [1] extended this work to the machining center structural design. [12] adapted Ito’s method for modular machine tool synthesis and developed a method for enumerating machine tool modules. Paradis and Khosla [15] determined the modular assembly configuration which is optimally suited to perform a specific task. On the systems front, Rogers and Bottaci [16] discussed the significance of reconfigurable manufacturing systems, and Owen et al. [13] developed a modular reconfigurable manufacturing system synthesis program for educational purposes. In our work, traditional methods of motion representation and topology (i.e. screw theory, graph theory, etc.) are employed to capture the characteristics of RMTs. These mathematical schemes are used for topological synthesis, function-decomposition, and mapping procedures; details can be found in [9]. Figure 1 B.Task clarification The design of an RMT begins with task clarification, which entails analyzing the cutter location data to determine the set of functions which are necessary to accomplish the desired kinematic motions. There are three steps. First, graphs are generated which abstractly representation Position Feed Spindle Coolant t1 t2 t3 t4 t5 t6 t7 t8 Fig. 3. High-level operation sequence, showing causal dependencies and concurrencies. This abstract representation of the sequence of operations is derived from the CL data, and will be used to design the sequencing control the motions. These graphs are then decomposed into functions, and finally the functions are mapped onto machine modules which exist in the library. A graph representation of the machine tool structure allows for systematic enumeration of alternate configurations and also provides a method of identification of nonisomorphic graphs. The graph representation is also used for bookkeeping to assign machine modules to the graph elements. A graph consists of a set of vertices connected together by edges. In using a graph as an abstract representation of a machine tool structure, we define two different types of vertices: type 0 and type 1. A vertex represents a physical object with two ports; each port represents the location on the object where it can be attached to a neighboring object. A type 0 vertex has input and output ports that are in-line with respect to each other, whereas a type 1 vertex has input and output ports that are perpendicular to each other. Machining tasks are also classified as type 0 or type 1, depending on whether the tool is parallel or perpendicular to the workpiece. C. Module selection Commercially available modules are selected from the module library for each of the functions (structural as well as kinematic) that were mapped to the graph in the task clarification stage. The data stored for each module in the library includes the homogenous transformation matrix representing its kinematic or structural function, the twist vector supplemented by range of motion information, a compliance matrix representing the module stiffness, module connectivity information, and power requirements (for active modules such as spindles and slides). The first step in module selection is to compare the homogeneous transformation matrices of the modules with the task requirement matrix such that when appropriate modules are selected to meet the task requirements, the product of all module matrices should be equal to the desired task matrix: T = T1· T2 · · · Tn. Again, there may be many possible choices of modules for a given structural configuration. Figure 6 shows how different slides, spindles, and structural elements can be assembled according to the graph of Figure 4. A slide module, with its CAD model and transformation matrix, is shown in Figure 7. It is capable of one direction of linear motion, indicated by the ~1 variable in its transformation matrix. Its database entry, shown in Table I, stores not only its transformation matrix but also the manufacturer name, model number, initial position, power level, and motion data. The twist vector is augmented by information on the minimum, initial, and maximum displacement of the module. TABLE I Database information and documentation for the machine module shown in Figure 7. Manufacturer SUHNER Model Name UA 35-AC Initial Position 1 0 0 0 2 0 1 0 0 3 6 6 0 0 1 100 4 0 0 0 1 5 7 7 Twist vector ￡ 0 0 0 0 1 0 ¤T Range of motion ￡ -155 0 155 ¤ Max. force 5500N Compliance matrix, Etc. Power requirements, Connectivity information, . . . (a) V6 machine (b) V8 machine Fig. 2. Reconfigurable machine tool designs for the two different parts. D. Evaluation Once a set of kinematically-feasible modules have been selected, the resulting machine design must be evaluated. The criteria for evaluation of the reconfigurable machine tools synthesized by the above systematic procedure include the work envelope, the number of degrees of freedom, the number of modules used, and the dynamic stiffness. The number of kinematic degrees of freedom of the machine tool must be kept to a minimum required to meet the requirements, both to reduce the actuation power and minimize the chain of errors. Machine tool designs which are generated using this methodology for the example parts of Figure 1 are shown in Figure 8. The resulting designs must be evaluated with respect to the expected accuracy. The stiffness of the entire machine tool, one of the most important factors in performance, is estimated based on the module compliance matrices and the connection method. III. Control Design As the machine is built from modular elements, so is the control. In this work, we focus on the logic control for sequencing and coordination of the machine modules; a discrete-event system formalism is used [6]. There is one control module associated with each active machine module; we refer to these as machine control modules. In the machine design, there are passive elements which connect the active elements together. In the control design, there must also be“glue” modules which connect the machine control modules. The overall architecture of the control system for an RMT is shown in Figure 9.The structure is similar for either of the two machines shown in Figure 8; for the V8 machine, there is no Y -axis control module. As shown, the machine control modules are at the lowest level; these interact directly with the mechanical system. Three modules handle the mode switching logic. In this section, we briefly describe each of these types of control modules as well as their interaction and coordination. A. Machine control modules Each machine control module has a well-defined interface specification: it accepts discrete-event commands from a given set, and returns discrete-event responses from a given set. Within the control module will be all of the continuousvariable control, such as servo control for axes. This continuous control is designed using standard PID algorithms and the axis parameters such as inertia, power, lead screw pitch, which come from the machine module definition. In addition, each machine control module will contain controls for any machine services associated with the machine module, such as lubrication or coolant. Thus, each machine control module is a self-contained controller for the machine module it accompanies, and can be designed and tested independently of the rest of the machine. Fig.10.Slide Controller The design of a machine control module must be done only once for each machine module in the library. Whenever the machine module is used in a machine design, the control module can be used in the associated control design. The control module may be used independently, with its own processing power, I/O and a network connection to the rest of the control system, or it may be used as a piece of the overall machine controller which is implemented in a centralized fashion. B. Operation sequence The operation sequence module is defined from the high level sequence extracted from the cutter location data shown in Figure 3. C. Modular control structure The user interface control module interacts with the user through a set of pushbuttons to turn the control system on and off, switch between control modes, and single-step through the operation sequence. Its main functions are to pass the user commands through to the rest of the controller, and to display the current state of the machine to the user. IV. Conclusions and Future Work Historically, machine tool design has been experience based. In this research, we described a mathematical basis for synthesis and evaluation of Reconfigurable Machine Tools and their associated controllers. This research work has addressed both the generation of machine tool configurations and modular control design. The systematic design process begins with the machining requirements. The presented methodology for synthesis of machine tools allows a library of machine modules to be precompiled and stored in a database, self-contained with controllers and ready to be used in any machine design. The methodology also ensures that all kinematically viable and distinctly different configurations are systematically enumerated to reduce the chance of missing a good design. We have already developed a Java-based program which automates the machine design process; we are currently incorporating the control design procedure within the existing framework. The authors would like to acknowledge the support and invaluable feedback from the industrial members of the ERC who have participated in this project. 中文譯文 組合機床與控制設計 摘要——在本文中，我們描述一個系統(tǒng)的設計程序的可重構機床及其控制系統(tǒng)。為設計的出發(fā)點是一組操作，必須在一個給定的部分或部分家庭進行。這些操作被分解成一組的功能，機器必須執(zhí)行的功能映射到機器模塊，每一個都有一個相關聯(lián)的機器控制模塊。一旦機器構造的一組模塊，電機控制模塊連接。操作順序控制模型?模塊，用戶接口控制模塊，模式切換邏輯，完成控制設計。集成的機械和控制設計的機床的可重構性進行了詳細的描述。 Ⅰ引言 在當今競爭激烈的市場，制造系統(tǒng)必須快速響應不斷變化的客戶需求和產品生命周期逐漸減少。傳統(tǒng)的傳輸線是專為大批量的生產，在一個固定的自動化模式操作，因此不能很容易地容納在產品設計上的變化。另一方面，傳統(tǒng)的數控系統(tǒng)的“柔性”制造系統(tǒng)提供廣義柔度但通常是緩慢的和前?沉思的因為他們不是任何特定產品或一類產品的優(yōu)化。 ? 在密歇根大學的努力，旨在發(fā)展理論和可重構制造系統(tǒng)的使能技術。而每一次新的部分是需要從頭開始建立一個加工系統(tǒng)，現有的系統(tǒng)可以重新配置，以產生新的部分。在本文中，我們描述了如何一體機和控制設計策略能夠使機床能夠迅速和容易地配置和重新配置。 為了提供準確的功能和容量，需要處理的零件族，RMTs設計圍繞一個給定的零件族。給定一組要執(zhí)行的操作，可以通過安裝合適的機器RMTs模塊配置。在圖書館，每個有源模塊與控制模塊。當我?裝配機械模塊，控制模塊將被連接的機器將準備就緒。廣泛的和耗時的專用控制系統(tǒng)的設計不需要。第二部分介紹了機器的設計，從一組基本的機械模塊。 ? 支持這項研究部分由NSF-ERC連接在一個明確的時尚，和第三部分的?文士如何控制同樣是由控制模塊里?圖書館。這種模塊化施工機械和控制允許多層次的可重構性描述在第四章本文的結論的描述未來的工作在第五部分。 Ⅱ機械設計 在密歇根大學對制造系統(tǒng)的配置正在進行的工作的一部分地址從起動問題（或部分家庭）的描述和提取的加工操作需要產生部分（的）。的操作是根據公差組合，執(zhí)行順序，和所需的時間周期的系統(tǒng)，與意向每個操作“集群”可以在一個單一的機床生產。使用集群是為凸輪塔帽上的V6和V8氣缸頭，如圖1所示的一套孔鉆。對可重構機床設計過程的輸入是由工藝師生成此操作?化集群的刀位數據。數據包括定位和鉆井資料。 RMT設計過程分為三個主要階段：任務澄清，模塊的選擇，評價。一個簡短的文獻回顧后，這三個階段將在本節(jié)概述。 A：相關研究 由于可重構加工系統(tǒng)中一個相對較新的概念，是很少的，如果任何，對可重構機床設計文獻。然而，組合機床已在市場上幾年，一些已發(fā)表的文章在模塊化機器人，模塊化的機器和裝配有可重構機床設計的一些相關。例如，Shinno和Ito提出了一種方法，用于生成機床的結構配置。他們的機床結構分解成簡單的幾何形式：如盒，圓筒，等。燕、陳[ 21 ]，[ 1 ]擴展這項工作的加工中心結構設計。[ 12 ]適用于組合機床的合成和ITO的方法開發(fā)一個枚舉機床模塊的方法。Paradis和Khosla [ 15 ]確定模塊化組件的配置是最適合執(zhí)行特定的任務。在系統(tǒng)前，羅杰斯和Bottaci [ 16 ]討論了可重構制造系統(tǒng)的意義，和歐文等人。[ 13 ]開發(fā)的模塊化可重構制造系統(tǒng)綜合程序用于教育目的。 在我們的工作中，傳統(tǒng)的運動表示和拓撲方法（即螺旋理論，圖論，等）被用于捕獲的皮膚的特點。這些數學方法用于拓撲合成，功能分解，和繪圖程序；細節(jié)中可以找到[ 9 ]。 圖1 B：任務說明 一個機床設計從任務澄清，這需要對刀具位置數據來確定所需要的函數集來完成所需的運動運動。有三個步驟。首先，圖表生成抽象表示。 Position Feed Spindle Coolant t1 t2 t3 t4 t5 t6 t7 t8 圖3 這樣的操作序列的抽象表示來自CL數據，將被用來設計順序控制的動作。這些圖被分解為功能，和最后的功能映射到機床模塊中存在的圖書館。 該機床結構的圖形表示允許備用配置系統(tǒng)的枚舉，還提供了一種的不同構的圖形識別方法。圖表示也用于簿記分配機模塊的圖形元素。一個圖包括一組由邊緣連接在一起的頂點。在使用圖形作為機床結構的抽象表示，我們定義了頂點的兩種不同的類型：0型和1型。一個頂點表示的物理對象的兩個端口，每個端口的位置；代表的對象，它可以連接到一個相鄰的對象。0型頂點有輸入和輸出端口，尊重對方在線，而1型頂點具有輸入和輸出端口，互相垂直的。加工任務也分為0型或1型，這取決于該工具是平行或垂直于工件。 C.模塊的選擇 市售的模塊，從模塊庫中選為每個函數（結構以及運動），映射到任務澄清階段圖。在圖書館的每個模塊存儲的數據包括齊次變換矩陣表示其運動或結構功能，扭曲矢量輔以運動信息的范圍，代表剛柔度矩陣模塊，模塊的連接信息，和功率要求（有源模塊如主軸和幻燈片）。 在模塊選擇的第一步是要比較的齊次變換矩陣的模塊與任務需求矩陣，在適當的時候選擇模塊以滿足任務的要求，所有模塊矩陣的乘積應等于所需的任務矩陣：T = T1 T2????TN，可能有一個給定的結構的模塊配置許多可能的選擇。圖6顯示不同的幻燈片，主軸的結構元素，并可按圖4組裝。 滑動模塊，其CAD模型轉化為?矩陣，如圖7所示。它能夠線性運動的一個方向，通過它的變換矩陣的~ 1變量表示。它的數據庫條目，見表1，不僅存儲其變換矩陣，而且制造商的名稱，型號，初始位置，功率電平，和運動數據。扭曲向量是增加了信息的最小值，初始模塊的最大位移。 表1 組合機床的數據庫信息和文件在圖7中顯示出來 Manufacturer SUHNER Model Name UA 35-AC Initial Position 1 0 0 0 2 0 1 0