X62W銑床主軸機械加工工藝規(guī)程與鉆床夾具設計(論文+DWG圖紙)
X62W銑床主軸機械加工工藝規(guī)程與鉆床夾具設計(論文+DWG圖紙),x62w,銑床,主軸,機械,加工,工藝,規(guī)程,鉆床,夾具,設計,論文,dwg,圖紙
無錫職業(yè)技術學院畢業(yè)設計調研報告
畢業(yè)設計調研報告
隨著工業(yè)設備自動化控制技術的發(fā)展，可編程控制器(PLC)在工業(yè)設備控制中的應用越來越廣泛。PLC控制系統(tǒng)的可靠性直接影響到企業(yè)的安全生產和經濟運行，系統(tǒng)的抗干擾能力是關系到整個系統(tǒng)可靠運行的關鍵。
Z30130X31型搖臂鉆床屬于大型立式鉆床，其傳統(tǒng)的控制方式是利用繼電器接觸器原理控制。由于利用繼電器接觸器控制系統(tǒng)比較復雜，難于操作；因此本次設計是將其改造成為利用PLC控制，這樣既可以提高生產效率，也可以增加其使用壽命。
首先通過對鉆床工作原理的了解，然后對PLC的硬件和軟件進行設計。根據(jù)鉆床的工作要求選擇合理的工作器件如：繼電器，接觸器等等，然后編寫相應的程序語句表并繪制梯形圖，再根據(jù)輸入輸出點數(shù)選擇PLC型號，輸入點數(shù)：22輸出點數(shù)：17，所以本次設計選擇FX2N-48MR型PLC并繪制硬件接線圖；最后對程序進行模擬調試。
自動化系統(tǒng)所使用的各種類型PLC中，有的是集中安裝在控制室，有的是安裝在生產現(xiàn)場和各電機設備上，它們大多處在強電電路和強電設備所形成的惡劣電磁環(huán)境中。要提高PLC控制系統(tǒng)可靠性，一方面要求PLC生產廠家提高設備的抗干擾能力，另一方面要求應用部門在工程設計、安裝施工和使用維護中引起高度重視，多方配合才能完善解決問題，有效地增強系統(tǒng)的抗干擾性能。影響PLC控制系統(tǒng)的干擾源與一般影響工業(yè)控制設備的干擾源一樣，大都產生在電流或電壓劇烈變化的部位，這些電荷劇烈移動的部位就是干擾源。
電磁干擾的主要來源
1．來自空間的輻射干擾?？臻g輻射電磁場(EMI)主要是由電力網絡、電氣設備的暫態(tài)過程、雷電、無線電廣播、電視、雷達、高頻感應加熱設備等產生的，通常稱為輻射干擾，其分布極為復雜。若PLC系統(tǒng)置于其射頻場內，就會受到輻射干擾，其影響主要通過兩條路徑：一是直接對PLC內部的輻射，由電路感應產生干擾；二是對PLC通信網絡的輻射，由通信線路感應引入干擾。輻射干擾與現(xiàn)場設備布置及設備所產生的電磁場大小特別是頻率有關，一般通過設置屏蔽電纜和PLC局部屏蔽及高壓泄放元件進行保護。
2．來自系統(tǒng)外引線的干擾。主要通過電源和信號線引入，通常稱為傳導干擾。這種干擾在我國工業(yè)現(xiàn)場較為嚴重，主要有下面三類：
第一類是來自電源的干擾。實踐證明，因電源引入的干擾造成PLC控制系統(tǒng)故障的情
況很多，筆者在某工程調試中遇到過，后更換隔離性能更高的PLC電源問題才得到解決。
PLC系統(tǒng)的正常供電電源均由電網供電，由于電網覆蓋范圍廣，它將受到所有空間電磁干擾而在線路上感應電壓和電流，尤其是電網內部的變化、開關操作浪涌、大型電力設備起停、交直流傳動裝置引起的諧波、電網短路暫態(tài)沖擊等，都通過輸電線路傳到電源原邊。PLC電源通常采用隔離電源，但因其機構及制造工藝等因素使其隔離性并不理想。實際上，由于分布參數(shù)特別是分布電容的存在，絕對隔離是不可能的。
第二類是來自信號線引入的干擾。與PLC控制系統(tǒng)連接的各類信號傳輸線，除了傳輸有效的各類信息之外，總會有外部干擾信號侵入。此干擾主要有兩種途徑：一是通過變送器供電電源或共用信號儀表的供電電源串入的電網干擾，這往往被忽視；二是信號線受空間電磁輻射感應的干擾，即信號線上的外部感應干擾，這種往往非常嚴重。
由信號引入的干擾會引起I/O信號工作異常和測量精度大大降低，嚴重時將引起元器件損傷。對于隔離性能差的系統(tǒng)，還將導致信號間互相干擾，引起共地系統(tǒng)總線回流，造成邏輯數(shù)據(jù)變化、誤動和死機。PLC控制系統(tǒng)因信號引入干擾造成I/O模件損壞數(shù)相當嚴重，由此引起系統(tǒng)故障的情況也很多。
第三類是來自接地系統(tǒng)混亂的干擾。接地是提高電子設備電磁兼容性(EMC)的有效手段之一，正確的接地既能抑制電磁干擾的影響，又能抑制設備向外發(fā)出干擾；而錯誤的接地反而會引入嚴重的干擾信號，使PLC系統(tǒng)無法正常工作。 PLC控制系統(tǒng)的地線包括系統(tǒng)地、屏蔽地、交流地和保護地等，接地系統(tǒng)混亂對PLC系統(tǒng)的干擾主要是各個接地點電位分布不均，不同接地點間存在地電位差，引起地環(huán)路電流，影響系統(tǒng)正常工作。例如電纜屏蔽層必須一點接地，如果電纜屏蔽層兩端A、B都接地，就存在地電位差，有電流流過屏蔽層。當發(fā)生異常狀態(tài)如雷擊時，地線電流將更大。
此外，屏蔽層、接地線和大地可能構成閉合環(huán)路，在變化磁場的作用下，屏蔽層內會出現(xiàn)感應電流，通過屏蔽層與芯線之間的耦合，干擾信號回路。若系統(tǒng)地與其它接地處理混亂，所產生的地環(huán)流就可能在地線上產生不等電位分布，影響PLC內邏輯電路和模擬電路的正常工作。PLC工作的邏輯電壓干擾容限較低，邏輯地電位的分布干擾容易影響PLC的邏輯運算和數(shù)據(jù)存貯，造成數(shù)據(jù)混亂、程序跑飛或死機。模擬地電位的分布將導致測量精度下降，引起對信號測控的嚴重失真和誤動作。
3．來自PLC系統(tǒng)內部的干擾。主要由系統(tǒng)內部元器件及電路間的相互電磁輻射產生，如邏輯電路相互輻射、模擬地與邏輯地的相互影響及元器件間的相互不匹配使用等。這都屬于PLC制造廠家對系統(tǒng)內部進行電磁兼容設計的內容，比較復雜，作為應用部門無法改變，可不必過多考慮，但要選擇具有較多應用實績或經過考驗的系統(tǒng)。
抗干擾設計
為了保證系統(tǒng)在工業(yè)電磁環(huán)境中免受或減少內外電磁干擾，必須從設計階段開始便采取三個方面抑制措施：抑制干擾源、切斷或衰減電磁干擾的傳播途徑、提高裝置和系統(tǒng)的抗干擾能力。這三點就是抑制電磁干擾的基本原則。
PLC控制系統(tǒng)的抗干擾是一個系統(tǒng)工程，要求制造單位設計生產出具有較強抗干擾能力的產品，且有賴于使用部門在工程設計、安裝施工和運行維護中予以全面考慮，并結合具體情況進行綜合設計，才能保證系統(tǒng)的電磁兼容性和運行可靠性。進行具體工程的抗干擾設計時，應主要注意以下兩個方面。
1．設備選型。
在選擇設備時，首先要選擇有較高抗干擾能力的產品，其包括了電磁兼容性，尤其是抗外部干擾能力，如采用浮地技術、隔離性能好的PLC系統(tǒng)；其次還應了解生產廠家給出的抗干擾指標，如共模抑制比、差模抑制比、耐壓能力、允許在多大電場強度和多高頻率的磁場強度環(huán)境中工作等；另外是靠考查其在類似工作中的應用實績。
在選擇國外進口產品要注意，我國是采用220V高內阻電網制式，而歐美地區(qū)是110V低內阻電網。由于我國電網內阻大，零點電位漂移大，地電位變化大，工業(yè)企業(yè)現(xiàn)場的電磁干擾至少要比歐美地區(qū)高4倍以上，對系統(tǒng)抗干擾性能要求更高。在國外能正常工作的PLC產品在國內工業(yè)就不一定能可靠運行，這就要在采用國外產品時，按我國的標準(GB/T13926)合理選擇。
2．綜合抗干擾設計。主要考慮來自系統(tǒng)外部的幾種抑制措施，內容包括：對PLC系統(tǒng)及外引線進行屏蔽以防空間輻射電磁干擾；對外引線進行隔離、濾波，特別是動力電纜應分層布置，以防通過外引線引入傳導電磁干擾；正確設計接地點和接地裝置，完善接地系統(tǒng)。另外還必須利用軟件手段，進一步提高系統(tǒng)的安全可靠性。
主要抗干擾措施
1．采用性能優(yōu)良的電源，抑制電網引入的干擾。
在PLC控制系統(tǒng)中，電源占有極重要的地位。電網干擾串入PLC控制系統(tǒng)主要通過PLC系統(tǒng)的供電電源(如CPU電源、I/O電源等)、變送器供電電源和與PLC系統(tǒng)具有直接電氣連接的儀表供電電源等耦合進入的?，F(xiàn)在對于PLC系統(tǒng)供電的電源，一般都采用隔離性能較好的電源，而對于變送器供電電源以及和PLC系統(tǒng)有直接電氣連接的儀表供電電源，并沒受到足夠的重視。雖然采取了一定的隔離措施，但普遍還不夠，主要是使用的隔離變壓器分布參數(shù)大，抑制干擾能力差，經電源耦合而串入共模干擾、差模干擾。所以對于變送器和共用信號儀表供電應選擇分布電容小、抑制帶大(如采用多次隔離和屏蔽及漏感技術)的配電器，以減少PLC系統(tǒng)的干擾。
此外，為保證電網饋電不中斷，可采用在線式不間斷供電電源(UPS)供電，提高供電的安全可靠性。而且UPS還具有較強的干擾隔離性能，是一種PLC控制系統(tǒng)的理想電源。
2．正確選擇電纜的和實施敷設。
為了減少動力電纜尤其是變頻裝置饋電電纜的輻射電磁干擾，筆者在某工程中采用了銅帶鎧裝屏蔽電力電纜，降低了動力線產生的電磁干擾，該工程投產后取得了滿意的效果。
不同類型的信號分別由不同電纜傳輸，信號電纜應按傳輸信號種類分層敷設，嚴禁用同一電纜的不同導線同時傳送動力電源和信號，避免信號線與動力電纜靠近平行敷設，以減少電磁干擾。
3．硬件濾波及軟件抗干擾措施。
信號在接入計算機前，在信號線與地間并接電容，以減少共模干擾；在信號兩極間加裝濾波器可減少差模干擾。
由于電磁干擾的復雜性，要根本消除干擾影響是不可能的，因此在PLC控制系統(tǒng)的軟件設計和組態(tài)時，還應在軟件方面進行抗干擾處理，進一步提高系統(tǒng)的可靠性。常用的一些提高軟件結構可靠性的措施包括：數(shù)字濾波和工頻整形采樣，可有效消除周期性干擾；定時校正參考點電位，并采用動態(tài)零點，可防止電位漂移；采用信息冗余技術，設計相應的軟件標志位；采用間接跳轉，設置軟件保護等。
4．正確選擇接地點，完善接地系統(tǒng)。
接地的目的通常有兩個，一為了安全，二是為了抑制干擾。完善的接地系統(tǒng)是PLC控制系統(tǒng)抗電磁干擾的重要措施之一。
系統(tǒng)接地有浮地、直接接地和電容接地三種方式。對PLC控制系統(tǒng)而言，它屬高速低電平控制裝置，應采用直接接地方式。由于信號電纜分布電容和輸入裝置濾波等的影響，裝置之間的信號交換頻率一般都低于1MHz，所以PLC控制系統(tǒng)接地線采用一點接地和串聯(lián)一點接地方式。集中布置的PLC系統(tǒng)適于并聯(lián)一點接地方式，各裝置的柜體中心接地點以單獨的接地線引向接地極。如果裝置間距較大，應采用串聯(lián)一點接地方式，用一根大截面銅母線(或絕緣電纜)連接各裝置的柜體中心接地點，然后將接地母線直接連接接地極。接地線采用截面大于22mm2的銅導線，總母線使用截面大于60mm2的銅排。接地極的接地電阻小于2Ω，接地極最好埋在距建筑物10～15m遠處，而且PLC系統(tǒng)接地點必須與強電設備接地點相距10m以上。
信號源接地時，屏蔽層應在信號側接地；不接地時，應在PLC側接地；信號線中間有接頭時，屏蔽層應牢固連接并進行絕緣處理，一定要避免多點接地。多個測點信號的屏蔽雙絞線與多芯對絞總屏蔽電纜連接時，各屏蔽層應相互連接好，并經絕緣處理，選擇適當?shù)慕拥靥巻吸c接地。
本文小結
PLC控制系統(tǒng)的干擾是一個十分復雜的問題，因此在抗干擾設計中應綜合考慮各方面的因素，合理有效地抑制干擾，對有些干擾情況還需做具體分析，采取對癥下藥的方法，才能夠使PLC控制系統(tǒng)正常工作,保證工業(yè)設備安全高效運行。
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外文翻譯資料
Air operated moves the carrier vehicle and the PLC control
Air operated namely uses the air pump and the air valve control air current, the positive governing barometric pressure and the current capacity, enable the air to have the vibration.
The programmable controller (PLC) is taken the microprocessor as the core, collection computer technology, the automated control technology in a body one new industry control system. PLC has used the model computer structure, mainly includes CPU, RAM, ROM and the input/ Output connection electric circuit and so on. If regards as PLC a system, this system is composed by the input variable -PLC- output variable, the exterior each kind of switching signal, the simulated signal, the sensor examine the signal took PLC the input variable, they input after the PLC exterior post to the internal register in, after the PLC interior logic operation or other each kind of operation, processing delivers the output terminal, they are the PLC output variable, carries on each kind of control by these output variables to the auxiliary equipment.
The PLC control system adopts generally easy to understand and to grasp trapezoidal chart language and face industry control simple instruction. The image is direct-viewing, is based on the field bus technology, opens completely, and uses the advanced software and hardware technology. The PLC control has the structure simply nimble, the anti-jamming ability strong, safe reliable, installs the convenience, the failure rate lowly, the maintenance is simple, large scale saves the use cost the characteristic, can satisfy each kind of center small scale process control, the smooth logic control and the data acquisition duty demand, widely has used in gradually in the industry control system, including domain and so on metallurgy, mining industry, machinery, light industry, has provided the powerful tool for the industrial automation.
The control engineering in the near future to will use in the logical equipment which programmed the process and the machinery controls carrying on an investigation, although the computer and computer technology already provided the infinite control for each kind of control to be possible, but PLC still was a important part. In this investigation, it will surpass half number of people to expand its PLC in the future 12 months the investment. It will surpass 40% person in the future investment many in the past 12 months. The PLC application scope is extremely widespread. In this 300 individual participation investigation, majority of PLC all uses in the machinery control, the process control follows closely after that, then is the movement control, the batch control and the diagnosis. The majority uses in directly the factory level (54%), uses in OEM is 25%, two all is 17%.
In the industrial production assembly line, must move frequently the transmission belt A on goods to conveyer belt B on. If direct artificially is engaged in this kind of duplicated work, arid, tasteless also labor intensity big, is easy to cause operates worker's weariness, appears the mistake. But uses the air operated manipulator carries on the transporting according to the stipulation movement and the rule, may achieve fast, accurate, is convenient, big reduces the labor intensity, enhances the production the automat city. Air operated manipulator this kind of orderly movement, uses PLC to carry on the control, and may facilitate realization.
The robot sets an example the integration of machinery intelligence equipment. flows in the automated system in the manufacture and the thing to act the strong character. But the standard industry robot only is has certain degrees of freedom an intelligent electromechanical device. Isolation robot in the actual operating mode is not any application value. only then according to factor and so on work content, work piece form, quality, contour characteristic and size matches to the robot by the auxiliary machinery installment like hand fingernail which adapts, it only then can become the practical production equipment. air operated not only is 1.th robot main drive type is quick-moving requesting machinist terminal execution quick-moving, the structure simple, the control maintenance convenient, the cost to be low, Moreover the flexible transformation quick. and has the versatile assembly and the transporting and so on "ascends when puts", the transmission movement work, uses air operated, or air operated combines with other transmission control technologies further increases its movement precision and the flexibility relatively fixed. Moreover the movement is frequent, the duplicated strong center low power operating mode in the work space scope limited, working routine, and uses the air operated modular organization unit the combination to realize the machinist work, can manifest the air operated technical effective substitution manpower operation realization production process Taiwan physics and chemistry and the automated characteristic and the superiority. Is can be fast to the air operated machinist's basic request, accurately ascend to put requests them with transporting thing. To have the high accuracy, the rapid reaction, the certain bearing capacity, the enough working space and the nimble degree of freedom and in the free position all can characteristic and so on automatic positioning. Designs the air operated machinist's principle is: Full analysis work object (work piece) the work specification, and draws up the most reasonable work working procedure and the craft. And satisfies the system function request and the environmental condition; explicit: The work piece structure shape and the materials behavior, the pointing accuracy request. capture, time the transporting stress characteristic, the size and the quality parameter and so on, thus further determines to the machinist structure and the operating control request; The as far as possible designation standard module, the simplification design manufacture process. Pay attention to both versatility and special-purpose, and can realize the flexible transformation and the programming control.
The air operated hand fingernail is the present machinist transports, the assembly class machinist in particular in captures in the technology to apply most universal way. it to be possible to realize bidirectional captures, voluntarily to the center, moreover the redundant precision high. Capture the strength to be constant. and may conveniently match meets each kind of jig. The air operated hand fingernail is direct connection between the machinist and of the work object, the careful analysis, chooses the good air operated hand fingernail to relate directly to machinist's operating performance. In the actual movement, the hand fingernail supports on both sides the strength to be supposed to guarantee is bigger than all static and the dynamic strength sum total. The PLC procedure movement way is circulates the scanning way, but the non- order carries out the way; therefore any manipulator satisfies after its condition namely starts the movement. Between various is parallel. The machinist is the multi-degrees of freedom open the type series structure. But changes the system request speed high control area broad precision unceasingly in spatial and the time dynamics parameter along with its configuration high, the traditional single degree of freedom organization control technology is far cannot satisfy this kind of controlled member to be good because of the air operated machinist cancels much to the multistage localization control, the pursue target point pointing accuracy and multiple spindle at the same time cooperates weakly to have the foreword movement control, but little requests the high path precision, thus simplified to the control system request.
The material mode of transport has the multipurpose function which may grasp may attract; The pneumatic system electromagnetism cross valve selects the afflux board collection attire method, reduced has taken the space; The PLC control has, is on foot automatic and so on the many kinds of work way. Because the pneumatic actuator has is angry the source easy to operate, does not pollute the environment, the movement nimbly rapid, the job safety reliable, the operation service is simple. And is suitable for under the adverse circumstance characteristic and so on work, thus in the ramming processing, casts and the compression casting and so on virulent or the high temperature environment is mean industry, on the engine bed, the yummy treats, the measuring appliance and in the light industry profession small work and so on components transportation and automatic assembly, food packing and the transportation, the electronic products transportation, automatic peg grafting, process and so on ammunition in production automation is widely applied. Therefore. The pneumatic actuator is one kind easy to promote popularly realizes the industrial automation application technology. The pneumatic system application caused the various countries industrial field to take generally.
Most uses the programmable controller at present as the pneumatic system control device (PLC). The programmable foreword controller is take the microprocessor as a foundation, comprehensive computer technology, the automatic control technology and the communication technology but develop one kind new, general automatic control device, in the practical application, the control system is very easy to realize. Is generally by is controlled the equipment the sequence of operation and the technological requirement, constitutes the labor step of condition table, forms the trapezoidal chart, again establishes the PLC instruction.
The material transporting system moves the air cylinder, the replacement onset and retreat air cylinder by about, rises and falls the air cylinder, clamps the hand or the vacuum cup, the material block, the sensor, the column guide rail, the support, the foundation, the microswitch and so on is composed.Clamps the hand either the vacuum cup may grip or hold the material block, the capture material part uses the clamp type and the adsorption type two forms, selects the different form, may complete the work piece separately the capture and the adsorption, adapts the different type material transporting.Clamps the hand to use the electro-magnet to attract gathers with separates the way clamp material.Clamps the hand or the sucker in rises and falls the air cylinder under the function to be possible to reciprocate; Clamps the hand or the vacuum cup together with rises and falls the air cylinder to move the air cylinder in about under the function to be possible to control along the column guide rail moves; In under the replacement onset and retreat air cylinder function the material block back initial position, for the next action cycle preparation, realizes the circulation.This system can realize a material in plane transporting.Operates the kneading board to install in the electrically controlled box, is separates with the test installation main body.The PLC programmable controller, the solenoid valve, the vacuum generator and so on lays aside in the electrically controlled box. About the material transporting system has moves, reciprocated and to the material clamp and the relaxation, pushes the material onset and retreat function, may realize on foot, and so on automatically under the PLC control many kinds of working.After moreover, the material is clamped the hand transporting completes, for satisfies continuously acts the need, but also must ship this material the zero point position, will supply the next time to transport the need.The system may complete each working is as follows.On foot: May realize the rise, the drop, the left shift, the right lateral, the clamp, the relaxation, pushes the material to enter, to push the material to draw back and so on eight kind of spots to move the operation; Continuously: After presses down “the start” the button, clamps the hand to start from the zero point position continuously to carry out the transporting material.Material transporting system realization movement: The drop -> stresses the material -> rise -> right lateral -> to drop -> the loose material -> to rise again -> the left shift -> to push the material again to enter -> pushes the material to draw back.In this system, we only realize a material cyclic action, therefore returns to the zero point after the manipulator, must drive back the homing position the material.May realize the single acting under the PLC control, act continuously the working.On after the system the electricity, according to turns the choice through revolving is the single acting or the gearing, if is the single acting carries out the single acting procedure, otherwise carries out the gearing procedure.Single acting working: To clamps hand each movement using the button alone to carry on the control.Continuously: Presses down the start button, clamps the hand to start from the zero point, according to the working procedure autocycle work, until presses down the pause button, clamps the hand after to complete last cyclical the work, returns to the zero point, auto-stop. Can realize the material autocycle transporting based on the PLC control material transporting system.This system both may use clamps the hand clamp material, and may use the vacuum cup adsorption material, has the multiple functions function; The pneumatic system electromagnetism cross valve uses the afflux board containerization, reduced has taken the space; May realize the single acting and the gearing two execution way under the PLC control, completes the material the transporting. Regarding small and medium-sized enterprise, as a result of fund and technical limit, not impossible disposable equipment integrity control system, like DCS system.But PLC is the general controller. Standard building block system hardware architecture, modular software design.May according to the control area be possible to be possible small, to be possible greatly Jan Kefan, to use the general IBM labor to control machine or the compatible machine, the necessary commercialization on position monitoring software package or hangs on the corresponding workstation, realizes functions and so on equipment operation, return route control, picture demonstration, nimble simple, saves the investment.Therefore, as the foundation process control system may constitute one kind take PLC the complete product which is advantageous for the user to organize voluntarily.
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