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1. Necessity of NC transformation of spinning machine:
There are hundreds of spinning machines in China, of which there are very few CNC machines. The vast majority of manufacturing and processing equipment in most manufacturing industries and enterprises are traditional machine tools, and most of them are old machine tools with service ages of more than 10 years, and their production equipment and technology are obsolete and backward. The products processed by this kind of equipment are generally poor in quality, low in quality, high in cost, and have a long delivery period. As a result, they lack competitiveness in the international and domestic markets, military products, and civilian products, directly affecting the products, markets, and benefits of a company. Affect the survival and development of the company. Therefore, the numerical control rate of the spinning machine must be greatly increased.
Because of the long use time of the old spinning machine, the discrete electronic components have been severely aged and the faults are frequent, and various mechanical and electronic components have no place to buy, resulting in difficulty in maintenance and some of them cannot be used normally. At present, many spinning machines perform manual profiling processing by hand. First, labor intensity is large and time is long. Second, the control level is relatively backward and the accuracy is relatively low. Therefore, the traditional manual operation method has poor processing consistency, low efficiency, and the processing quality cannot be guaranteed. Processing with numerical control technology has become an inevitable trend.
After the transformation of the numerical control spinning machine put into use, due to the system's flexible operation, easy to use, enhanced processing capabilities, suitable for the processing of more complex surface parts, improve production efficiency and ensure the processing accuracy.
2. Spinning machine numerical control transformation main content:
The first is to restore the original function, diagnose and recover the faulty part of the machine tool; the second is nc, add the numerical control system to the ordinary spinning machine, and transform it into the cnc machine tool; the third is the refurbishment to improve the accuracy, efficiency and Degree of automation, refurbishment of mechanical and electrical parts, re-assembly of mechanical parts, restoration of original precision; updating of cnc systems that do not meet production requirements with the latest cnc; and fourthly, technological updates or technological innovations to improve performance or Grade, or in order to use new technology, new technology, on the basis of the original to carry out large-scale technological updates or technological innovation, a substantial increase in the level and grade of the upgrading and transformation.
3. Reconstruction program:
In combination with actual production, depending on the process requirements and the degree to which the machine tool has been changed, different retrofit schemes can be used.
3.1 Mechanical transformation
A new CNC spinning machine is designed to achieve: high static and dynamic stiffness; small coefficient of friction between the pairs of movements, no gaps in transmission; large power; easy to operate and maintain. The above requirements shall be fulfilled as far as the CNC transformation of the machine tool is concerned. It cannot be said that connecting the numerical control device with the ordinary machine tool has reached the requirements of the numerical control machine tool, and the corresponding transformation of the main components is also required to achieve a certain design requirement in order to achieve the intended transformation.
3.1.1 Sliding rails
For CNC spinning machines, guide rails should not only have the general spinning machine's guiding accuracy and craftsmanship, but also have good friction and wear resistance, and reduce the dead zone caused by frictional resistance. At the same time, it must have sufficient rigidity to reduce the influence of rail deformation on machining accuracy, and reasonable guide rail protection and lubrication are needed.
3.1.2 Ball Screw
The choice of screw depends mainly on the precision requirements of the workpiece and drag torque requirements. The ball screw has low friction loss and high efficiency. Its transmission efficiency can be over 90%. It has high precision and long service life. The starting torque and the moment of movement are similar, which can reduce the motor starting torque. So it can meet the processing requirements of higher precision parts.
3.2 Spindle Drive Retrofit Selection
According to the spinning process requirements, the spindle is generally designed to stepless speed regulation.
For AC spindle motors, variable frequency speed control is used. Such as Siemens 6se70 vector control three-phase AC voltage source frequency control system, its speed and braking performance, high efficiency, high power factor and power saving effect, a wide range of applications and many other advantages are recognized at home and abroad. The most promising method of speed regulation.
For the DC spindle motor, if the Siemens 6ra70 full digital DC speed controller is used instead of the original one. 6ra70 is a three-phase AC power supply directly powered digital control device, small size, compact structure, used for DC motor armature and excitation power supply to complete the task of speed control. The advantage of this device is that it is equipped with a parameter setting unit itself, no other additional equipment is required to complete the parameter setting, and all the control, adjustment, monitoring and additional functions are realized by the microprocessor.
3.3 Numerical Control and Feed Drive System
Currently there are many manufacturers of CNC systems. Famous foreign companies such as German siemens company, France num company, Japanese fanuc company; domestic companies such as China Everest Company, Beijing Aerospace Machine Tool CNC System Group, Huazhong Numerical Control Company and Shenyang high-end CNC National Engineering Research Center.
When choosing the numerical control system, it is mainly selected according to the specific conditions such as the various precisions to be achieved after the NC transformation, the power of the drive motor, and the requirements of the user.
3.3.1 AC/DC servo motor dragging, semi-closed loop control system of encoder feedback
The semi-closed-loop system detection element is mounted on the intermediate transmission and indirectly measures the position of the actuator. It can only compensate for the errors of some components inside the system loop. Therefore, its accuracy is lower than that of the closed-loop system, but its structure and debugging are simpler than the closed-loop system. Such as Siemens 1ft5, 1ft6 AC servo motor, stable and reliable, good servo performance.
3.3.2 Asynchronous Motor or DC Motor Dragging, Grating Measurement Feedback Loop Control System
The difference between this system and the open-loop system is that the actual position feedback signal measured by a position detection device such as a grating is compared with a given value at any time, and the difference between the two is amplified and transformed to drive the actuator. Closed-loop feed systems are more complex in structure than open-loop feed systems, have higher costs, and are more difficult to design and debug than open-loop systems. However, it is possible to obtain a higher accuracy than the open-loop feed system, and the characteristic index of the drive power is greater.
3.3.3 Closed Loop Control System for Servo Valve/Servo Cylinder and Grating Measurement Feedback
When the stroke is short and the rotary pressure demand is large, the closed loop control system composed of servo valve and servo cylinder is a good choice.
4. Main steps of NC transformation of machine tools:
4.1 Determination of reconstruction plan
After the feasibility analysis of the transformation is passed, the modification plan can be determined for the current situation of the process and the machine tool, which generally includes:
4.1.1 Combination of Mechanical Repair and Electrical Modification
In general, machine tools that require electrical modifications need to be mechanically repaired. The integrity of the mechanical properties is the basis for successful electrical transformation.
4.1.2 First Part After Whole
When determining the transformation steps, the whole electrical part transformation should be divided into several subsystems first, such as the numerical control system, measurement system, spindle, feed system, panel control and strong power, etc. jobs.
4.1.3 Select System According to Use Conditions
For the use of the environment, temperature, humidity, dust, power, light, and even no other conditions such as rodent damage, this choice of electrical system protection performance, anti-jamming performance, self-cooling performance, air filtration performance, etc. can provide the correct basis , so that the transformed electrical system has a reliable use guarantee.
4.1.4 Determination of transformation scope
Sometimes the transformation of the CNC machine tool electrical system does not necessarily include all of the machine's electrical system. It should be determined based on scientific determination and analysis.
4.2 Technical preparation for transformation
Whether the technical preparations before the transformation are sufficient or not largely determines the success of the transformation. Technical preparation includes:
4.2.1 Preparation of Mechanical Parts
Measurements, calculations, designs, drawings, parts production, etc. of large-scale mechanical remodeling that must be carried out in order to cooperate with the electrical transformation should be completed in advance.
4.2.2 Digestion of old system electrical data
Only by fully digesting the old system's electrical data can we understand the previous design ideas and better complete the convergence and transformation of the old and new systems.
4.2.3 Digestion of new system electrical data
The new system has many new features and new technologies. Therefore, you should familiarize yourself with the technical materials before the renovation, including system principle descriptions, circuit diagrams, plc ladder diagrams and texts, installation and commissioning instructions, user manuals, and programming manuals.
4.2.4 Conversion Design of New and Old System Interfaces
Global transformation, should be designed mechanical and electrical conversion interface, operation panel control and configuration, interconnection part of the contact, etc., requires the operation and maintenance of convenient and reasonable, the line goes to smooth, less connection points, strong and weak electrical interference is small, with a suitable margin and so on. For partial reconstruction, it is also necessary to consider performance matching, voltage polarity and size transformation, installation location, and digital-to-analog conversion of the old and new systems.
4.2.5 Determination of Commissioning Steps
The commissioning work involves mechanical, hydraulic, electrical and debugging steps can be from simple to complex, from small to large, from the outside to the inside, but also after partial global, first subsystem after the entire system.
4.2.6 Determination of Acceptance Criteria
The acceptance criteria is the assessment of the new system and must be established in a practical and realistic manner.
4.3 Implementation of the transformation
After the preparations are ready, you can enter the implementation phase of the transformation. The contents of the implementation phase are divided into chronological order:
4.3.1 Full maintenance of the original machine
After long-term use of the machine tool, there will be problems in mechanical, hydraulic, lubrication, and cleanliness to varying degrees, so the first comprehensive maintenance. Secondly, it should record the geometric accuracy and dimensional accuracy of the machine tool before it is changed. This can not only guide the transformation of the work of reference, but also at the end of the transformation for comparative analysis.
4.3.2 Optimal adjustment of retained electrical parts
If the electrical system is partially modified, the reserved electrical parts should be maintained and optimized. Such as replacement of parts of high-voltage parts, maintenance of motors, drying and insulation of transformers, cleaning of pollution, cleaning of ventilation cooling devices, optimization of servo drive devices, update of aging wire and cable, fastening of connectors, etc. .
4.3.2 Demolition of the original system
The removal of the original system must be carried out carefully against the original drawings, and markings should be made on the drawings in a timely manner to prevent omission or over-demolition (partial transformation). In the process of demolition, some defects in the design of new systems will also be found and should be promptly added and amended.
4.3.3 Reasonably Arrange the New System Location and Cabling
According to the new system design drawings, reasonable new system configuration, including the box fixed, panel placement, line direction and fixed, adjust the position of components, sealing and necessary decoration. Ensure that the wiring process specification, wire diameter is correct, correct, reliable and beautiful.
4.3.4 Commissioning
Commissioning must be done in accordance with pre-determined steps and requirements. Debugging staff records at any time to find and solve problems. During the debugging, firstly test the safety protection system sensitivity to prevent the accidents of personnel and equipment; the motion coordinate carriages are in the center position of the full stroke; if they can carry out the no-load test, they shall be loaded after the no-load; if they can simulate the test, they will be simulated first; Can be manual, first automatically after the manual.
4.4 Acceptance Work and Training
The acceptance work shall be engaged by the relevant personnel to participate in the inspection and shall be carried out according to the established acceptance criteria. The contents include:
4.4.1 Acceptance of Machine Tool Mechanical Performance
After mechanical repair and transformation and comprehensive maintenance, the mechanical properties of the machine tool should meet the requirements and the geometric accuracy should be within the specified range.
4.4.2 Acceptance of Electrical Control Functions and Control Accuracy
The various functions of the electrical control must be normal, sensitive and reliable. Control accuracy is controlled by the use of standard measuring instruments (such as laser interferometers, coordinate measuring instruments, etc.) to within the accuracy range. At the same time, it should also be compared with the various functions and accuracy of the machine before the transformation to obtain the quantitative index difference.
4.4.3 Acceptance of Specimen
Specimen can accept machine tool stiffness, force, motion trajectory, and associated actions.
4.4.4 Acceptance of drawings and data
After the transformation of the machine tool, the drawings (including schematics, configuration drawings, wiring diagrams, ladder diagrams, etc.), data (including various types of manuals), and transformation files (including various records before and after the reconstruction) shall be collected and arranged in a timely manner. Archive. Maintaining complete, effective and continuous data is very important for the stable operation of the equipment in the future.
4.4.5 Technical training for operators and programmers
5. Transformation effect
Compared with the transformation of other machine tools, the numerical control transformation of spinning machines is still relatively small. The general criteria for the evaluation of NC transformation are the low investment, short payback period, and high return on investment; in particular, certain spinning machines for military products cannot be purchased from foreign countries. If so, the delivery time and prices are unacceptable. Some CNC transformation of spinning machines will achieve great social and economic benefits.
As in 1995, Anshan High-Pressure Vessel Factory reconstructed two spinner closing machine production lines. It has been in operation for 7 years and still operates normally. It is well received by users.
6. The advantages and disadvantages of CNC transformation
6.1 Reducing the investment amount and delivery time
Compared with the purchase of a new spinning machine, it can generally save 60% to 80% of the cost. In particular, the cost savings of a large spinning machine are particularly obvious.
6.2 Stable and reliable mechanical performance, limited structure
The basic parts such as the existing bed used are heavy and strong cast parts, not the kind of welded parts, and the machine tools after the transformation are good in rigidity and stable in performance. However, due to the limitations of the original mechanical structure, it is not appropriate to make a breakthrough transformation.
6.3 familiar with the equipment, easy operation and maintenance
When buying a new device, you do not know whether the new device can meet its processing requirements. Modification is not the case, and the bed's processing capability can be accurately known. In addition, due to the use for many years, the operator has already understood the characteristics of the machine tool, and the training time is short and effective in operation and maintenance. Once the modified machine is installed, full-load operation can be realized.
6.4 can make full use of existing conditions
You can make full use of existing foundations without having to rebuild your foundation as you would if you purchased new equipment. At the same time the core mold and peripheral tooling can also be reused. The cost of general spinning tooling accounts for about 10% of the total cost of the machine tool.
6.5 can use the latest control technology
According to the development speed of technological innovation, the automation level and efficiency of spinning machine can be improved in time, and the quality and grade of equipment can be improved.
7. Conclusion
1) The technological transformation of the spinning machine, after the system is designed, installed and adjusted, it can reach the specified technical specifications, and the operation can be stable and reliable.
2) The system software has added many special functions to facilitate the user's programming and expand the scope of the spinning process.
3) Carry out the cnc technical transformation to the spinning machine, the feed system accuracy can be improved compared to the original; for the spinning machine modified with the AC servo technology, the feed drive system adopts the AC servo motor, the performance is reliable, and the precision is more stable.
4) The technical innovation of the cnc technology for spinning presses has obvious social and economic benefits.
Due to the continuous advancement of machine tools and technology, machine tool transformation is an "eternal" topic. China's machine tool transformation industry has also moved from the old industry to a new industry dominated by numerical control technology. At present, the purchase of a large-scale numerical control spinning machine is very expensive, so it provides a certain market for the CNC transformation of the old equipment.