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湖南科技大學(xué)機(jī)械類(lèi)外文資料翻譯
Vertical Turning Center of NC
New SINUMERIK 802D CNC system on the use of more than 10 years of SKIQ16 CNC B Vertical Turning Center of NC, NC Machine Tool powerful features greatly broadened the scope of machining parts, and better ensuring the processing of parts the consistency and quality of products. This article was the second SINUMERIK NC application essay activities and the transformation of a prize-second prize.
KIQ16 CNC B Vertical Turning Center in the Czech HULIN companies in the 1990s manufacture, use FANUC-BASK 6T CNC system. Since the machine had been in use for more than 10 years, and the NC system upgrading, BASK 6T-FANUC CNC system has been shutdown, system board of aging, expensive spare parts. A new CNC machine tools to transform the system is imperative so that the machine can restore vitality, and give better play to the potential of machine tools.
Transformation programme development
The original full-featured machine, including spindle (table) and the rotation axis milling campaign, X, Z-axis coordinates of movement, 15 knives in a knife library systems, and such as the cooling system, hydraulic system, lubrication system , Paixie system functional machine. Spindle axis and milling by DC and DC motor speed regulator. X and Z-axis also coordinates by DC servo motor and DC servo governor. The knife used ordinary three-phase asynchronous AC motor from the five binary cam positioning. The mechanical part of the machine all good mechanical properties of stability, accuracy fair and normal hydraulic system, the part of the capital remain unchanged.
NC system and the replacement of electrical control part, by SIEMENS SINUMERIK 802D CNC system. X and Z axes and knives coordinates the servo drive system uses SIIMODRIVE 611UE variable frequency drive system and a FK7 servo motor, encoder pulse chosen as a location detection devices, digital servo drive system to achieve closed-loop control. And milling spindle axis drive system by the British company's 590 + Eurotherm Series DC motor speed control device. Machine control of other electrical lines, the replacement of electrical control devices to ensure that all kinds of machine control function and operation of the realization of the electrical control machine tools guarantee a long-term reliable work.
Apart from increasing MCP machine control panel, we must also re-designed machine operator panel with all types of machine function buttons and lights.
NC system and the servo drive system coordinates
SIEMENS SINUMERIK 802D CNC system is all CNC, PLC, HMI and communications tasks integration, is based on the NC system of PROFIBUS. Maintenance-free hardware integration PROFIBUS interface used to drive and I / O module and installed a speed of the operation panel. SINUMERIK 802D CNC control system X, Z axes and knives to the three figures into a spindle axis and. The machine used two I / O modules and machine operator panel PP72/48 MCP. TOOLBOX 802D use in PROGRAMMING TOOL PLC 802 software development PLC control procedures, call the subroutine library PLC SBR32 PLC-INI PLC initialization, SBR33 EMG-STOP exigency stop processing, transmission SBR34 MCP-802D machine control panel corresponding I / O status, NCK-SBR38 MCP MCP machine control panel signal, signal sent to the operation panel HMI NCK interface, SBR39 HANDWHL from the operation panel HMI in the machine coordinates or workpiece coordinate system selection hand wheel, SBR40 AXIS-CTL Feed spindle axis and enable control. The subroutine is the standard lathe control procedures, and so different from the actual situation of the machine, the digital knife-axis, an increase of the number of digital axis. In the machine control panel and feed axis and the spindle can control subroutine will be done in certain modifications. Vertical Turning Center unlike ordinary horizontal lathe, coordinates a different direction, it is also necessary to do subroutine amended accordingly.
SIIMODRIVE 611UE variable frequency drive system is a function of the drive system can be configured with SINUMERIK 802D CNC system constitutes an ideal combination. SIIMODRIVE 611UE variable frequency drive system in the machine to meet the dynamic response and speed adjustment range and rotation accuracy characteristics of the requirement to use modular design can be optimized to best independent state. Debugging can drive on a PC using SimoCom U or use of the front of the driver modules for display and keyboard. SimoCom U can be set using drives and motors and power modules matching the basic parameters of actual under servo motor drive mechanical parts, the SIIMODRIVE 611UE speed controller for automatic optimization of the parameters; can monitor the operational status of drivers, including actual motor current and the actual torque.
axis milling spindle and drive system
And milling spindle axis drive system using the British company's 590 + Eurotherm Series DC motor speed control device. 590 + series of DC motor speed control device as supporting and control equipment installed in the standard box components and design. AC 380V control devices using the standard three-phase voltage, providing DC output voltage and current for the armature and exciting, applicable to DC Motor control and permanent magnet motor.
590 + series of DC motor speed device is used to achieve 32-bit microprocessor, has many advanced features: complex control algorithms; standard software modules and software configuration can control circuit integration of the serial link, and NC transmission devices or other communications systems, advanced to a process system.
Axis milling spindle motor and not replaced, the original analog volume control. The spindle motor and non-spindle between 1:1 Direct Connect, spindle SIEMENS installed on the 5000 line TTL pulse incremental encoder. SIIMODRIVE 611UE bus will address the biaxial 12 A feed channel module with the spindle, set a stack axis. Through the SINUMERIK 802D CNC system parameter settings, the use of SimoCom U driver debugging tools adjustment SIIMODRIVE 611UE bus configuration parameters and analog output, analog output interface for a given output spindle speed (± 10V), digital Output can be used to simulate the spindle control, WSG interface used to connect a spindle speed encoder feedback, and complete control of spindle configuration.
knife Library System
knife because the original system used for general motors, mechanical transmission ratio 1:360. The mechanical structure of special knives, knife disc in the vertical Z-axis ram, its direction and the B-axis rotation direction of the same. After transformation, using SIIMODRIVE 611UE and a variable frequency drive system FK7 servo motor, a knife to the NC coordinate axis, as increased pulse encoder position detection devices, digital servo drive system to achieve closed-loop control. The removal of the original five binary cam positioning mechanism. As the knife after the full gravity knives, knife the disk can not achieve balance gravity. Although the movement can knife precise positioning, but the reasons for the deviation of the actual location, location is still used after positioning coordinates movement pin inserted accurate positioning methods.
The special machine tool change process, with different vertical lathe general. PLC control ATC procedures are completed the following process: when the knife with X and Z-axis movement a safe place, Z axis, no knife, a machine tool relaxed state. PLC control manipulator out to promote vertical lathe tool to Z axis machine tool after the completion of that process finished with knives. Shirking knife, X and Z-axis movement a safe place, Z axis, a knife, a machine tool clamping state. PLC control mechanical hand outstretched, this tool to relax, manipulator driven vertical lathe tool retractable knife was back on, machine tool, knife disposal process is complete.
SINUMERIK 802D CNC system support for the use of M code or user calls T code cycle can be used for machine tool exchange. By setting parameters M activation code, the use of the procedure called M06 fixed exchange cycle enforcement tool. Procedures for the preparation of users cycle through each algorithm to determine the knife knife-axis (B-axis) rotation angle, use of the definition of M ATC activation PLC logic. PLC NC system will be "read to prohibit" buy-signal so that the cycle of a fixed stop. ATC will be mechanical movements M code with a custom implementation of decomposition, such as: M12 dumping knives, M13 with knives. ATC completed, the PLC will be "read prohibits" reset signal so that the fixed cycle continue. In the fixed cycle shown in the preparation of CNC system prompts on the screen to ATC by step.
Machine debugging
NC system connecting the various components after the completion of the installation, commissioning start PLC control procedures. Since the equipment is vertical lathe, unlike PLC subroutine library in the lathe applications, it must address the specific conditions of the machine to amend PLC subroutine.
Set the knife for B-axis, and the standard procedures only X and Z axis, and the need to increase the B-axis in the MCP plus or minus adding B-axis direction to move the button, the need for SBR34, SBR38, SBR40 such as subroutine. Because it is vertical lathe, X, Z-axis direction to move the plus or minus key MCP and set different standards also needs to be revised. According to MCP on the machine need to design user-defined keys, such as hydraulic launch, hydraulic stop, relax beams, and light beams locking design MCP and machine operator panels PLC control procedures and debugging features to achieve. Fully tested by the use of the subroutine library of subroutines to ensure that the subroutine with the functions of PLC control procedures linked, are correct. Alarm users edit PLC design, machine parameters provided by setting the properties of each alarm. Machine set basic parameters include: PROFIBUS bus configuration, positioning servo drive module, the spindle axis position control and coordinate enable ratio and transmission parameters.
In the machine undergone a series of adjustments, NC Machine Tools has basically can be in normal operation. But to make the whole system into the best running state, but also a system parameter optimization work.
When the normal operation of the system as a whole, should also coordinate axis corresponding parameters such as optimal adjustment, such as: speed, gain, and the acceleration of the control parameters, in order to enable access to the best system of the state. In the normal operation of machine tools, machine tools should also mechanical parts, such as the vertical axis, the reverse gap, transmission precision measurement adjustments, the mechanical system to the best. Of course, the mechanical adjustments, should also fine-tune system parameters to enable the machine running in the best condition. When the part of the adjustment after the end of the machine through mechanical precision measurement, CNC machine tools needed for the position control system for precision compensation. Reverse clearance compensation for position feedback encoder mounted on the lead screw drive-head, although the slowdown in bins eliminate mechanical part of the reverse gap, but the reverse itself leadscrew gap still exists, the value of the corresponding input system parameters, each reverse operation, the system of compensation. Because long-term use of the leadscrew wear, the location of the leadscrew pitch and will have a nominal value error, to improve positioning accuracy, the system parameters compensation.
According to the production needs of users with the process of transforming machine tools, from SINUMERIK 802D CNC system for the analysis, design and implementation. At present, against the machine mechanical, electrical, various aspects of the system transformation, installation, commissioning work has been completed, samples were processed fully achieve the desired results. Machine Tool has been transformed into normal use, the progressive completion of a number of machining tasks. From the use of the machine running the state, the modified machine compared with the original machine, greatly enhancing the functionality, a high degree of automation. NC powerful features greatly broadened the scope of machining parts. Better guarantee the consistency of the parts processing, and product quality. At the same time a high degree of automation has greatly reduced the labor intensity operations workers, but in the operation of the overall quality of workers has also put forward higher requirements.
From the machine operable, compact structure reasonable, displays, switches and indicator of the layout more suitable for the use of operators. At the same time increased by a small handheld unit operations, in order to operate in different state of the operation of a more appropriate choice of location. The hoisting of the entire operating system using TFT LCD, the window menu-operation, not only to reduce the operation buttons, but more simple and easy operation.
After transformation, the machine can be maintained and enhanced. NC system for monitoring the work of the state control components and fault and displayed on the monitor in a timely manner, while PLC control applications, so that the whole machine tool control systems greatly simplify the circuit. All this makes machine fault detection and maintenance more convenient and rapid. Secondly, the need to be tested, liquid injection, fuel components are arranged in operation or maintenance staff accessible areas, which will help the day-to-day maintenance.
After transformation, the machine reliability greatly improved. NC system, servo control systems, such as the various components of the system are highly integrated computer control system, which makes the whole machine tool control system itself has a high reliability. Design and Application of PLC, succeeded in bringing all of the control to the harmonization greatly simplifies the machine control circuit and the necessary components, and more conducive to improving the reliability of the whole system. The completion of the machine tool, not only for users to expand the scope of the processing machine, but also save a lot of money. The success of this transformation for the future transformation of the machine has accumulated a wealth of experience.
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湖南科技大學(xué)本科生畢業(yè)設(shè)計(jì)（論文）
湖 南 科 技 大 學(xué)
英文文獻(xiàn)翻譯
學(xué) 生 姓 名： 楊 靖
學(xué) 院： 機(jī)電工程學(xué)院
專(zhuān)業(yè)及班級(jí)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 五班
學(xué) 號(hào)： 1103010506
指導(dǎo)教師： 時(shí) 彧
2015年 5 月 11 日
湖南科技大學(xué)機(jī)械類(lèi)外文資料翻譯
數(shù)控立式車(chē)削中心數(shù)控化改造
用新型SINUMERIK 802D數(shù)控系統(tǒng)對(duì)使用10多年的SKIQ16 CNC B數(shù)控立式車(chē)削中心進(jìn)行數(shù)控化改造，機(jī)床強(qiáng)大的數(shù)控功能極大地拓寬了機(jī)床加工零件的范圍，更好地保證了零件加工的一致性和產(chǎn)品質(zhì)量。本文獲第二屆SINUMERIK 數(shù)控應(yīng)用與改造有獎(jiǎng)?wù)魑幕顒?dòng)二等獎(jiǎng)。
KIQ16 CNC B數(shù)控立式車(chē)削中心是捷克HULIN公司于上世紀(jì)90年代制造，采用FANUC-BASK 6T數(shù)控系統(tǒng)。由于該機(jī)床已經(jīng)使用10余年，加之?dāng)?shù)控系統(tǒng)更新?lián)Q代，F(xiàn)ANUC-BASK 6T數(shù)控系統(tǒng)早已停產(chǎn)，系統(tǒng)板件老化，備件昂貴。采用新型數(shù)控系統(tǒng)對(duì)該機(jī)床進(jìn)行改造勢(shì)在必行，這樣可使該機(jī)床重新煥發(fā)活力，更好地發(fā)揮機(jī)床的潛力。
改造方案的制定
該機(jī)床原有功能齊全，包括主軸(工作臺(tái))和銑磨軸的旋轉(zhuǎn)運(yùn)動(dòng)、X、Z軸坐標(biāo)運(yùn)動(dòng)、15個(gè)刀位的刀庫(kù)系統(tǒng)，還有諸如冷卻系統(tǒng)、液壓系統(tǒng)、潤(rùn)滑系統(tǒng)、排屑系統(tǒng)等機(jī)床功能。主軸和銑磨軸采用直流電動(dòng)機(jī)及直流調(diào)速器。X、Z軸坐標(biāo)也采用直流伺服電機(jī)及直流伺服調(diào)速器。刀庫(kù)采用普通三相異步交流電動(dòng)機(jī)，由5位二進(jìn)制凸輪定位。該機(jī)床的機(jī)械部分各方面機(jī)械性能良好穩(wěn)定、精度尚可、液壓系統(tǒng)工作正常，因此上述部分基本保持不變。
數(shù)控改造更換數(shù)控系統(tǒng)和電氣控制部分，采用SIEMENS SINUMERIK 802D數(shù)控系統(tǒng)。X、Z軸和刀庫(kù)坐標(biāo)伺服驅(qū)動(dòng)系統(tǒng)采用SIIMODRIVE 611UE變頻驅(qū)動(dòng)系統(tǒng)和1FK7伺服電機(jī)，選用脈沖編碼器作為位置檢測(cè)元件，達(dá)到數(shù)字伺服驅(qū)動(dòng)系統(tǒng)閉環(huán)控制。主軸和銑磨軸驅(qū)動(dòng)系統(tǒng)采用英國(guó)Eurotherm公司的590+系列直流電動(dòng)機(jī)調(diào)速裝置。改造機(jī)床其他電氣控制線路，更換電氣控制元件，保證機(jī)床各種控制功能和操作的實(shí)現(xiàn)，保證機(jī)床電氣控制部分長(zhǎng)期可靠工作。
除增加MCP機(jī)床控制面板外，還要重新設(shè)計(jì)機(jī)床操作面板，具有各種機(jī)床功能按鈕和指示燈。
數(shù)控系統(tǒng)和坐標(biāo)伺服驅(qū)動(dòng)系統(tǒng)
SIEMENS SINUMERIK 802D數(shù)控系統(tǒng)是將所有CNC、PLC、HMI和通訊任務(wù)集成，是基于PROFIBUS總線的數(shù)控系統(tǒng)。免維護(hù)硬件集成PROFIBUS接口用于驅(qū)動(dòng)和I/O模塊并具有速裝結(jié)構(gòu)的操作面板。SINUMERIK 802D數(shù)控系統(tǒng)控制X、Z軸和刀庫(kù)三個(gè)數(shù)字進(jìn)給軸和一個(gè)主軸。該機(jī)床采用二塊I/O模塊PP72/48和機(jī)床操作面板MCP。利用TOOLBOX 802D中PROGRAMMING TOOL PLC 802軟件編寫(xiě)PLC控制程序，調(diào)用PLC子程序庫(kù)中的SBR32 PLC-INI PLC初始化、SBR33 EMG-STOP 急停處理、SBR34 MCP-802D 傳送機(jī)床控制面板對(duì)應(yīng)I/O狀態(tài)、SBR38 MCP-NCK 機(jī)床控制面板MCP信號(hào)、操作面板HMI信號(hào)送至NCK接口、SBR39 HANDWHL 由操作面板HMI在機(jī)床坐標(biāo)系或工件坐標(biāo)系選擇手輪、SBR40 AXIS-CTL 進(jìn)給軸和主軸使能控制。由于子程序是標(biāo)準(zhǔn)的車(chē)床控制程序，這樣與該機(jī)床實(shí)際情況不同，刀庫(kù)采用數(shù)字軸控制，增加了數(shù)字軸的數(shù)量。在機(jī)床控制面板和進(jìn)給軸和主軸使能控制等子程序中都要做一定的修改。立式車(chē)削中心有別于一般的臥式車(chē)床，所以坐標(biāo)方向也有所不同，還需要子程序做相應(yīng)的修改。
SIIMODRIVE 611UE變頻驅(qū)動(dòng)系統(tǒng)是一種功能可配置的驅(qū)動(dòng)系統(tǒng)，與SINUMERIK 802D數(shù)控系統(tǒng)構(gòu)成理想的組合。SIIMODRIVE 611UE變頻驅(qū)動(dòng)系統(tǒng)滿(mǎn)足機(jī)床在動(dòng)態(tài)響應(yīng)、速度調(diào)整范圍和旋轉(zhuǎn)精度特征等方面的要求，采用模塊化設(shè)計(jì)可獨(dú)立優(yōu)化至最佳狀態(tài)。驅(qū)動(dòng)調(diào)試可在PC機(jī)上利用SimoCom U進(jìn)行或利用驅(qū)動(dòng)模塊前端的顯示器和鍵盤(pán)進(jìn)行。利用SimoCom U可設(shè)定驅(qū)動(dòng)器與電動(dòng)機(jī)和功率模塊匹配的基本參數(shù)；可根據(jù)伺服電機(jī)實(shí)際拖動(dòng)的機(jī)械部件，對(duì)SIIMODRIVE 611UE速度控制器的參數(shù)進(jìn)行自動(dòng)優(yōu)化；可監(jiān)控驅(qū)動(dòng)器的運(yùn)行狀態(tài)包括電動(dòng)機(jī)實(shí)際電流和實(shí)際扭矩。
主軸和銑磨軸驅(qū)動(dòng)系統(tǒng)
主軸和銑磨軸驅(qū)動(dòng)系統(tǒng)采用英國(guó)Eurotherm公司的590+系列直流電動(dòng)機(jī)調(diào)速裝置。590+系列直流電動(dòng)機(jī)調(diào)速裝置是作為與配套控制設(shè)備安裝在標(biāo)準(zhǔn)箱內(nèi)的部件而設(shè)計(jì)的。控制裝置使用AC 380V的三相標(biāo)準(zhǔn)電壓，提供直流輸出電壓和電流，用于電樞和勵(lì)磁，適用于直流他激電動(dòng)機(jī)和永磁電動(dòng)機(jī)控制。
590+系列直流電動(dòng)機(jī)調(diào)速裝置是采用32位微處理器實(shí)現(xiàn)，具有許多先進(jìn)的性能：復(fù)雜的控制算法；標(biāo)準(zhǔn)軟件模塊與可組態(tài)的軟件控制電路相結(jié)合；通過(guò)串行線路，可與其他傳動(dòng)裝置或數(shù)控系統(tǒng)通訊，能構(gòu)成先進(jìn)的過(guò)程系統(tǒng)。
主軸和銑磨軸電動(dòng)機(jī)沒(méi)有更換，采用原來(lái)的模擬量控制。主軸電動(dòng)機(jī)與主軸之間非1：1直連，主軸上安裝SIEMENS 5000線的TTL脈沖增量編碼器。將SIIMODRIVE 611UE的總線地址為12的雙軸模塊A進(jìn)給通道攜帶主軸，設(shè)定一個(gè)疊加軸。通過(guò)對(duì)SINUMERIK 802D數(shù)控系統(tǒng)參數(shù)設(shè)定，使用SimoCom U驅(qū)動(dòng)調(diào)試工具軟件調(diào)整SIIMODRIVE 611UE參數(shù)并配置總線模擬量輸出，模擬量輸出接口用于輸出主軸速度給定（±10V），數(shù)字量輸出用于模擬主軸使能控制，WSG接口用于連接主軸編碼器作為速度反饋，完成主軸控制配置。
刀庫(kù)系統(tǒng)
由于刀庫(kù)系統(tǒng)原來(lái)采用普通電動(dòng)機(jī)，機(jī)械傳動(dòng)比1：360。刀庫(kù)機(jī)械結(jié)構(gòu)特殊，圓盤(pán)刀庫(kù)豎直位于Z軸滑枕后，其旋轉(zhuǎn)方向與B軸方向相同。改造后采用SIIMODRIVE 611UE變頻驅(qū)動(dòng)系統(tǒng)和1FK7伺服電動(dòng)機(jī)，將刀庫(kù)改為數(shù)控坐標(biāo)軸，增加脈沖編碼器作為位置檢測(cè)元件，達(dá)到數(shù)字伺服驅(qū)動(dòng)系統(tǒng)閉環(huán)控制。拆除原有的5位二進(jìn)制凸輪定位機(jī)構(gòu)。由于刀庫(kù)裝滿(mǎn)刀具后的重力作用，刀庫(kù)圓盤(pán)無(wú)法達(dá)到重力平衡。雖然刀庫(kù)運(yùn)動(dòng)可以精確定位，但是上述原因?qū)е缕鋵?shí)際定位出現(xiàn)偏差，所以仍然采用坐標(biāo)運(yùn)動(dòng)定位后定位銷(xiāo)插入的準(zhǔn)確定位方法。
該機(jī)床換刀過(guò)程特殊，不同與一般的立式車(chē)床。PLC控制程序完成以下?lián)Q刀過(guò)程：裝刀時(shí)X、Z軸運(yùn)動(dòng)安全位置，Z軸上無(wú)刀，機(jī)床處于刀具放松狀態(tài)。PLC控制機(jī)械手伸出，推動(dòng)立車(chē)刀架到Z軸上完成后刀具夾緊，即裝刀過(guò)程完畢。卸刀時(shí)X、Z軸運(yùn)動(dòng)安全位置，Z軸上有刀，機(jī)床處于刀具夾緊狀態(tài)。PLC控制機(jī)械手伸出，此時(shí)刀具放松，機(jī)械手縮回帶動(dòng)立車(chē)刀架回到刀盤(pán)上后，刀具夾緊，即卸刀過(guò)程完畢。
SINUMERIK 802D數(shù)控系統(tǒng)支持利用M代碼或T代碼調(diào)用用戶(hù)循環(huán)，可用于機(jī)床刀具交換。通過(guò)設(shè)置參數(shù)激活M代碼，利用程序段中的M06調(diào)用固定循環(huán)程序執(zhí)行刀具交換。編寫(xiě)用戶(hù)循環(huán)程序，通過(guò)算法確定每個(gè)刀位刀庫(kù)軸（B軸）的旋轉(zhuǎn)角度，利用自定義M代碼啟動(dòng)PLC換刀邏輯。PLC將數(shù)控系統(tǒng)“讀入禁止”信號(hào)置位，使該固定循環(huán)停止。將換刀機(jī)械動(dòng)作用自定義M代碼分解執(zhí)行，例如：M12卸刀、M13裝刀等。換刀完成后，PLC將“讀入禁止”信號(hào)復(fù)位，使該固定循環(huán)繼續(xù)執(zhí)行。在固定循環(huán)中編寫(xiě)信息顯示在數(shù)控系統(tǒng)屏幕上提示操作者換刀所進(jìn)行的步驟。
機(jī)床調(diào)試
數(shù)控系統(tǒng)的各個(gè)部件安裝連接完成后，開(kāi)始調(diào)試PLC控制程序。由于該設(shè)備是立式車(chē)床，不同于PLC子程序庫(kù)中的車(chē)床應(yīng)用程序，所以必須針對(duì)該機(jī)床的具體情況修改PLC子程序。
將刀庫(kù)設(shè)為B軸，而原標(biāo)準(zhǔn)程序只有X、Z軸，需要增加B軸和在MCP上添加B軸正負(fù)方向點(diǎn)動(dòng)鍵，需要對(duì)SBR34、SBR38、SBR40等子程序。由于是立式車(chē)床，X、Z軸正負(fù)方向點(diǎn)動(dòng)鍵與MCP標(biāo)準(zhǔn)設(shè)置不同也需要修改。根據(jù)機(jī)床需要設(shè)計(jì)MCP上用戶(hù)自定義鍵，如液壓?jiǎn)?dòng)、液壓停止、橫梁放松、橫梁鎖緊及指示燈，設(shè)計(jì)MCP和機(jī)床操作面板的PLC控制程序并且調(diào)試功能實(shí)現(xiàn)。全面測(cè)試所使用的子程序庫(kù)的子程序，確保子程序的功能在與PLC控制程序聯(lián)結(jié)在一起時(shí)正確無(wú)誤。編輯設(shè)計(jì)PLC用戶(hù)報(bào)警，通過(guò)設(shè)定機(jī)床參數(shù)規(guī)定每個(gè)報(bào)警的屬性。設(shè)定機(jī)床基本參數(shù)包括：PROFIBUS總線配置、伺服驅(qū)動(dòng)器模塊定位、主軸和坐標(biāo)軸位置控制使能以及傳動(dòng)系統(tǒng)參數(shù)配比。
在對(duì)機(jī)床進(jìn)行了一系列調(diào)整后，數(shù)控機(jī)床已基本可以正常運(yùn)行。但要使整個(gè)系統(tǒng)進(jìn)入最佳運(yùn)行狀態(tài)，還應(yīng)進(jìn)行系統(tǒng)參數(shù)優(yōu)化等工作。
當(dāng)整個(gè)系統(tǒng)運(yùn)行正常后，還應(yīng)對(duì)相應(yīng)的坐標(biāo)軸等參數(shù)優(yōu)化調(diào)整，如：速度、增益、加速度及各項(xiàng)監(jiān)控參數(shù)等，以使系統(tǒng)進(jìn)入最佳工作狀態(tài)。在機(jī)床正常運(yùn)行后，還應(yīng)對(duì)機(jī)床機(jī)械部分，如各軸垂直度、反向間隙、傳動(dòng)系統(tǒng)精度等進(jìn)行測(cè)量調(diào)整，使機(jī)械系統(tǒng)達(dá)到最佳。當(dāng)然，機(jī)械調(diào)整后，還應(yīng)對(duì)系統(tǒng)參數(shù)進(jìn)行微調(diào)，以使機(jī)床運(yùn)行在最佳狀態(tài)。當(dāng)各部分的調(diào)整結(jié)束后，通過(guò)對(duì)機(jī)床機(jī)械精度的測(cè)量，還需對(duì)數(shù)控機(jī)床的位控系統(tǒng)進(jìn)行精度補(bǔ)償。反向間隙補(bǔ)償由于位置反饋編碼器裝在傳動(dòng)絲杠的端頭，雖然消除了減速箱等機(jī)械傳動(dòng)部分的反向間隙，但絲杠本身的反向間隙仍然存在，可將該值輸入系統(tǒng)相應(yīng)參數(shù)，每次反向運(yùn)行時(shí)，系統(tǒng)自動(dòng)補(bǔ)償。由于絲杠長(zhǎng)期使用中的磨損，絲杠各位置的螺距與標(biāo)稱(chēng)值會(huì)有一定誤差，為提高定位精度，通過(guò)系統(tǒng)參數(shù)進(jìn)行補(bǔ)償。
根據(jù)用戶(hù)生產(chǎn)的需求，結(jié)合機(jī)床改造過(guò)程，對(duì)由SINUMERIK 802D數(shù)控系統(tǒng)進(jìn)行了分析、設(shè)計(jì)及實(shí)施。目前，針對(duì)該機(jī)床的機(jī)械、電氣、系統(tǒng)各個(gè)方面的改造、安裝、調(diào)試工作已經(jīng)完成，樣件加工完全達(dá)到預(yù)期效果。改造后機(jī)床已投入正常使用，陸續(xù)完成了多項(xiàng)零件加工任務(wù)。從整個(gè)機(jī)床的使用、運(yùn)行狀態(tài)來(lái)看，改造后機(jī)床與原機(jī)床相比，功能的極大增強(qiáng)、自動(dòng)化程度很高。 強(qiáng)大的數(shù)控功能極大地拓寬了機(jī)床加工零件的范圍。更好地保證了零件加工的一致性和產(chǎn)品質(zhì)量。同時(shí)高度的自動(dòng)化也大大降低了操作工人的勞動(dòng)強(qiáng)度，但對(duì)操作工人的綜合素質(zhì)又提出了更高的要求。
從機(jī)床的可操作性來(lái)看，結(jié)構(gòu)緊湊合理，顯示器、各種開(kāi)關(guān)和指示燈布局更適合操作人員的使用。同時(shí)增加了一個(gè)小型的手持操作單元，以便于操作人員在不同的狀態(tài)下選擇更合適的操作位置。整個(gè)懸掛操作系統(tǒng)采用TFT液晶顯示器，窗口菜單式操作方式，不但減少了操作按鈕，而且操作更為簡(jiǎn)單容易。
改造后的機(jī)床增強(qiáng)了可維修性。數(shù)控系統(tǒng)可監(jiān)控各控制部件的工作狀態(tài)及故障，并及時(shí)在顯示器上顯示，同時(shí)PLC控制的應(yīng)用，使整個(gè)機(jī)床控制系統(tǒng)線路大為簡(jiǎn)化。所有這些都使機(jī)床故障檢測(cè)和維修更為方便、迅速。其次，需經(jīng)常進(jìn)行檢測(cè)、注液、加油的部件均布置于操作或維修人員容易接近的地方，利于日常的保養(yǎng)維護(hù)。
改造后的機(jī)床可靠性大為提高。數(shù)控系統(tǒng)、伺服系統(tǒng)等控制系統(tǒng)的各個(gè)組成部分均是高度集成的微機(jī)控制系統(tǒng)，這使得整個(gè)機(jī)床控制系統(tǒng)本身就具有較高的可靠性。PLC的設(shè)計(jì)應(yīng)用，成功地使各個(gè)控制部分達(dá)到了協(xié)調(diào)統(tǒng)一，極大地簡(jiǎn)化了機(jī)床控制線路及所需元器件，更有利于提高整個(gè)系統(tǒng)的可靠性。 該機(jī)床改造的完成，不但為用戶(hù)擴(kuò)大了該機(jī)床的加工范圍，也節(jié)約了大筆資金。本次改造的成功也為今后的機(jī)床改造工作積累了大量的經(jīng)驗(yàn)。
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