Among the newly developed products is a long aluminum abutment model Q7, on which two φ3.7×1.65 flat-bottom blind holes are to be machined. Due to the high precision and large batch volumes, it is not possible to use traditional drilling dies in drilling machines. On the processing, it is also difficult to process on the traditional milling machine. To this end, we designed and manufactured a machine for the processing of such products - general-purpose CNC milling and milling machines.
I. System Overview The control part adopts PLC and is equipped with man-machine interface for program parameter modification, setting, and running status display monitoring. The contents of the man-machine interface can be set programmatically. The three axes are all digital AC servo systems. Each axis servo motor drives the ball screw through the coupling to move the workbench equipped with the linear guideway and the spindle milling head. The positioning is accurate and the speed is fast. The spindle milling head is controlled by the inverter. According to the tool and the workpiece and the feed amount, the spindle can be set to a reasonable speed, and its start and stop can be set in the program. Each axis is equipped with a two-terminal limit sensor and an origin sensor. Both cooling and lubrication also have anomaly detection. Alarm messages are displayed at the alarm lamp and the man-machine interface. In order to facilitate the debugging and overhauling, all operations are equipped with manual functions, such as manual axis speed, spindle high and low speed rotation, cutting fluid and lubrication switch. Although the overall machine tool is semi-closed-loop control, as long as options, assembly, programming and operation are reasonable, accuracy and stability can still meet the requirements of use.
Second, the hardware configuration PLC Yongyong FBS-40MCT selected, this type of machine has a high cost, small size, strong features, 24 inputs, including 16 high-speed counters, frequency up to 120K, 16 points output, including 4-axis stepping or servo output is integrated inside, the output frequency can reach 120K, it is very convenient to use, the wiring is simple and convenient. Programming software WinProladder is known as a ladder diagram master, easy to learn and easy to use and powerful, editing, monitoring, debugging and other operations are very easy to use, buttons, mouse and online real-time instruction function query and operating instructions, so that editing, input efficiency.
Contact allocation: take the Z-phase signal of the servo motor of each axis as the origin switch, and tap it at several high-speed input points to use the interrupt to return to the machine's origin. The rest of the limit switches, operation switches, liquid level detection and other conventional contacts can be In order, access. The three-axis servomotors of X, Y, and Z are connected to the servo output points of the first three axes. The high and low speeds of the spindle, cooling, and alarms are connected to the remaining output points.
X, Y, and Z3 axis servo systems all use the same, Hollysys ES series full digital AC servo drive 0040E-CBCEE-02, and 60 series small inertia servo motor 60CB040C-2DE6E. The servo system has relatively complete functions, such as energy consumption braking, electronic gear, automatic acceleration and deceleration, etc., with a variety of pulse train input, protection functions are also more complete, undervoltage, overvoltage, overcurrent, overload, stall, stall , location error, abnormal encoder and so on. In this device, connected to the PLC by open collector drive, the maximum pulse input frequency is 200K, servo ON, Z-phase signals, etc. are also connected accordingly.
The frequency converter selects Fuling's DZB70B0015L2A, the specification is single-phase 1500W, 400Hz, there are many paces for editing use. Due to infrequent speed change during normal use, the speed adjustment setting is not derived, but is only adjusted on the inverter operation panel, two speeds are set, high speed is used for machining, and low speed is used for tool setting. Adjust the relevant parameters and the spindle to match, such as the fundamental frequency, base pressure, operating frequency upper limit, carrier frequency, etc., and modify the corresponding jumper.
The spindle does not use the traditional method, but according to the processing needs, the electric spindle used by the engraving machine is adopted. The ADX80-24Z/1 type of Anyang Lebitai is small in size, low in noise, and only 80mm in diameter, which makes the entire spindle box easy The overall seal can effectively prevent the debris from being splashed on the Z-axis screw and the guide rail to cause damage, and also make the headstock look beautiful. Its maximum speed is 24,000 rpm, giving a suitable margin for normal operating speeds of 6000-14,000 rpm. The man-machine interface selects the human-machine electronic general-purpose programmable text display MD204L, it may monitor or revise the numerical value and the state of the PLC internal register or the relay in the form of the text or the indicator lamp and so on.
Third, the software design first checks whether the manual switch is valid after power-on, if the manual switch is effective, the manual operation of each manual control switch is performed. If the manual switch is ineffective, the zero point return program is started, and the axes return to the machine zero point, and then return to the Z axis and then return to the other two axes. When all the axes are returned to the original point, the next step can be performed. If there is no change in the tool, fixture and workpiece program, it can be reset to the tool preparation state without tool setting. If tool setting is required, open the tool setting switch and start the tool setting program. The three axes are set to the tool to find the workpiece origin. Use the manual axis shift switch to move each axis as quickly as possible, so that the three surfaces of the workpiece touch the tool rotating at a low speed and they just touch it. After that, press OK on the tool to confirm, and then enter the tool offset. After the program is processed, the workpiece origin will be programmed as 0 point. According to the 0 point, the tool path will be calculated according to the drawing, and the operator will be clear in thinking and editing operations. simple. The operator edits the user program and can edit the tool path, that is, the coordinates of each axis, the moving speed, and the number of cycles in the cycle processing. After programming or when using the current program, it is reset to the ready state: Each axis moves to the initial position—a suitable position. When the loading and unloading of the workpiece is convenient and it is not easy to touch the tool, the workpiece is loaded, and the machining can be started by pressing the spindle. Operation, coolant is on, and each axis moves according to programmed coordinates. When the machining is completed, the machine tool is reset, that is, each axis moves to the initial position, the spindle stops, and cooling is turned off. At this time, the workpiece can be removed to complete the machining process.
Workpiece processing flow chart shown in Figure 3, to Q7 products as an example, the first time clamping the workpiece 15 pieces, then there are 30 φ3.7 flat bottom blind hole needs processing, tool selection φ3.7 2 edge Tungsten steel end mill, drilling, drilling depth of 1.65mm. In the ready state, the fixture is fixed on the workbench, and after the start, the spindle rotates. When the spindle is about to reach the rated speed, the X and Y axes are simultaneously turned to the first machining station, which is the first hole. The X, Y workpiece coordinate values, at this point the coolant is turned on, Z-axis quickly fell to the processing area, that is, the end face of the milling cutter is about to touch the workpiece processing surface, and quickly began to drill with slow working speed. When the machining depth reaches the set depth (1.65mm), the Z-axis drives the milling cutter to lift quickly. The lifted height is that the end face of the milling cutter can not touch the workpiece and the leveling device in the horizontal direction. After the counter is incremented, the program performs a comparison operation to determine whether the machining is completed. If not, the X and Y axes continue to move to the next machining station, and then repeat the Z axis down machining operation. If the machining is finished, the production counter counts up, the spindle stops, and the coolant is turned off. At the same time, a 5s sound and light report is issued to remind the operator that each axis moves to the initial position: Z axis to the top; X axis to the left; Y axis To the outside. After unloading the tyres, one machining cycle is completed, and the tyres are loaded and the tyres are started again for the next round of machining.
Fourth, some of the emphasis on electrical measures 1. The main circuit installed leakage circuit breakers, the appropriate circuits are installed in the appropriate circuit breakers.
2. Power supply filters are added to the power supply of PLC and servo system respectively.
3. All DC relay coils are connected with anti-peak diodes. The AC contactor coils are connected to the RC circuit.
4. Lubrication and spindle cooling are equipped with a low level alarm.
5. Use shielded cables for servo control lines and man-machine interface communication lines, and keep them away from the power line.
6. Route the cable inside the drag chain, use a flex-resistant flexible cable, and try to increase the bending radius of the drag chain.
7. The inverter maintains a certain distance from the PLC and servo drives.
I. System Overview The control part adopts PLC and is equipped with man-machine interface for program parameter modification, setting, and running status display monitoring. The contents of the man-machine interface can be set programmatically. The three axes are all digital AC servo systems. Each axis servo motor drives the ball screw through the coupling to move the workbench equipped with the linear guideway and the spindle milling head. The positioning is accurate and the speed is fast. The spindle milling head is controlled by the inverter. According to the tool and the workpiece and the feed amount, the spindle can be set to a reasonable speed, and its start and stop can be set in the program. Each axis is equipped with a two-terminal limit sensor and an origin sensor. Both cooling and lubrication also have anomaly detection. Alarm messages are displayed at the alarm lamp and the man-machine interface. In order to facilitate the debugging and overhauling, all operations are equipped with manual functions, such as manual axis speed, spindle high and low speed rotation, cutting fluid and lubrication switch. Although the overall machine tool is semi-closed-loop control, as long as options, assembly, programming and operation are reasonable, accuracy and stability can still meet the requirements of use.
Second, the hardware configuration PLC Yongyong FBS-40MCT selected, this type of machine has a high cost, small size, strong features, 24 inputs, including 16 high-speed counters, frequency up to 120K, 16 points output, including 4-axis stepping or servo output is integrated inside, the output frequency can reach 120K, it is very convenient to use, the wiring is simple and convenient. Programming software WinProladder is known as a ladder diagram master, easy to learn and easy to use and powerful, editing, monitoring, debugging and other operations are very easy to use, buttons, mouse and online real-time instruction function query and operating instructions, so that editing, input efficiency.
Contact allocation: take the Z-phase signal of the servo motor of each axis as the origin switch, and tap it at several high-speed input points to use the interrupt to return to the machine's origin. The rest of the limit switches, operation switches, liquid level detection and other conventional contacts can be In order, access. The three-axis servomotors of X, Y, and Z are connected to the servo output points of the first three axes. The high and low speeds of the spindle, cooling, and alarms are connected to the remaining output points.
X, Y, and Z3 axis servo systems all use the same, Hollysys ES series full digital AC servo drive 0040E-CBCEE-02, and 60 series small inertia servo motor 60CB040C-2DE6E. The servo system has relatively complete functions, such as energy consumption braking, electronic gear, automatic acceleration and deceleration, etc., with a variety of pulse train input, protection functions are also more complete, undervoltage, overvoltage, overcurrent, overload, stall, stall , location error, abnormal encoder and so on. In this device, connected to the PLC by open collector drive, the maximum pulse input frequency is 200K, servo ON, Z-phase signals, etc. are also connected accordingly.
The frequency converter selects Fuling's DZB70B0015L2A, the specification is single-phase 1500W, 400Hz, there are many paces for editing use. Due to infrequent speed change during normal use, the speed adjustment setting is not derived, but is only adjusted on the inverter operation panel, two speeds are set, high speed is used for machining, and low speed is used for tool setting. Adjust the relevant parameters and the spindle to match, such as the fundamental frequency, base pressure, operating frequency upper limit, carrier frequency, etc., and modify the corresponding jumper.
The spindle does not use the traditional method, but according to the processing needs, the electric spindle used by the engraving machine is adopted. The ADX80-24Z/1 type of Anyang Lebitai is small in size, low in noise, and only 80mm in diameter, which makes the entire spindle box easy The overall seal can effectively prevent the debris from being splashed on the Z-axis screw and the guide rail to cause damage, and also make the headstock look beautiful. Its maximum speed is 24,000 rpm, giving a suitable margin for normal operating speeds of 6000-14,000 rpm. The man-machine interface selects the human-machine electronic general-purpose programmable text display MD204L, it may monitor or revise the numerical value and the state of the PLC internal register or the relay in the form of the text or the indicator lamp and so on.
Third, the software design first checks whether the manual switch is valid after power-on, if the manual switch is effective, the manual operation of each manual control switch is performed. If the manual switch is ineffective, the zero point return program is started, and the axes return to the machine zero point, and then return to the Z axis and then return to the other two axes. When all the axes are returned to the original point, the next step can be performed. If there is no change in the tool, fixture and workpiece program, it can be reset to the tool preparation state without tool setting. If tool setting is required, open the tool setting switch and start the tool setting program. The three axes are set to the tool to find the workpiece origin. Use the manual axis shift switch to move each axis as quickly as possible, so that the three surfaces of the workpiece touch the tool rotating at a low speed and they just touch it. After that, press OK on the tool to confirm, and then enter the tool offset. After the program is processed, the workpiece origin will be programmed as 0 point. According to the 0 point, the tool path will be calculated according to the drawing, and the operator will be clear in thinking and editing operations. simple. The operator edits the user program and can edit the tool path, that is, the coordinates of each axis, the moving speed, and the number of cycles in the cycle processing. After programming or when using the current program, it is reset to the ready state: Each axis moves to the initial position—a suitable position. When the loading and unloading of the workpiece is convenient and it is not easy to touch the tool, the workpiece is loaded, and the machining can be started by pressing the spindle. Operation, coolant is on, and each axis moves according to programmed coordinates. When the machining is completed, the machine tool is reset, that is, each axis moves to the initial position, the spindle stops, and cooling is turned off. At this time, the workpiece can be removed to complete the machining process.
Workpiece processing flow chart shown in Figure 3, to Q7 products as an example, the first time clamping the workpiece 15 pieces, then there are 30 φ3.7 flat bottom blind hole needs processing, tool selection φ3.7 2 edge Tungsten steel end mill, drilling, drilling depth of 1.65mm. In the ready state, the fixture is fixed on the workbench, and after the start, the spindle rotates. When the spindle is about to reach the rated speed, the X and Y axes are simultaneously turned to the first machining station, which is the first hole. The X, Y workpiece coordinate values, at this point the coolant is turned on, Z-axis quickly fell to the processing area, that is, the end face of the milling cutter is about to touch the workpiece processing surface, and quickly began to drill with slow working speed. When the machining depth reaches the set depth (1.65mm), the Z-axis drives the milling cutter to lift quickly. The lifted height is that the end face of the milling cutter can not touch the workpiece and the leveling device in the horizontal direction. After the counter is incremented, the program performs a comparison operation to determine whether the machining is completed. If not, the X and Y axes continue to move to the next machining station, and then repeat the Z axis down machining operation. If the machining is finished, the production counter counts up, the spindle stops, and the coolant is turned off. At the same time, a 5s sound and light report is issued to remind the operator that each axis moves to the initial position: Z axis to the top; X axis to the left; Y axis To the outside. After unloading the tyres, one machining cycle is completed, and the tyres are loaded and the tyres are started again for the next round of machining.
Fourth, some of the emphasis on electrical measures 1. The main circuit installed leakage circuit breakers, the appropriate circuits are installed in the appropriate circuit breakers.
2. Power supply filters are added to the power supply of PLC and servo system respectively.
3. All DC relay coils are connected with anti-peak diodes. The AC contactor coils are connected to the RC circuit.
4. Lubrication and spindle cooling are equipped with a low level alarm.
5. Use shielded cables for servo control lines and man-machine interface communication lines, and keep them away from the power line.
6. Route the cable inside the drag chain, use a flex-resistant flexible cable, and try to increase the bending radius of the drag chain.
7. The inverter maintains a certain distance from the PLC and servo drives.
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