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中國地質(zhì)大學(xué)長城學(xué)院
本科畢業(yè)設(shè)計(jì)外文翻譯
系 別： 工程技術(shù)系
專 業(yè)：機(jī)械設(shè)計(jì)制造及其自動化
姓 名： 丁磊
學(xué) 號： 05208416
2012 年 3月 22日
On the development of machining production line
ABSTRACT
The machining production line at the rhythm of time, flexibility and progress, machining accuracy, integrated automation, reliability and utilization areas of progress and development are described. And its future development trends are analyzed and looking forward to.
Keywords: Flexible automation machining accuracy
?20 years beginning from the twentieth century, with the automobile, bearings, small motors and sewing machines and other industrial development, machinery manufacturing automatic production line began to appear, first appeared that the combination of machine automatic production line. Mechanical processing and manufacturing, there casting, forging, stamping, heat treatment, welding, machining and mechanical assembly automated line, also including the different types of processes, such as the blank manufacturing, processing, assembling, testing and packaging an integrated automatic lines.
Automatic production line of products should be large enough to yield; product design and process should be advanced, stable, reliable, and the long period of time remains basically unchanged. In a large, a large number of automatic production line can improve labor productivity, stability, and improve product quality, improve working conditions, reducing the production area, lower production costs, shorten production cycle to ensure the production of balanced, there has been a significant economic benefits.
1, machining production line development of
In automobiles, tractors, internal combustion engines and compressors and many other areas of industrial production, combination machine tool production line is still the high-volume machinery to achieve efficient, high-quality and economical production and processing of key equipment, but also an irreplaceable key processing equipment. Is for the combination of machine tool production line to illustrate the processing of domestic machinery production line development.
Modern portfolio of machine tool production line as the mechanical and electrical integration of product, which is the control, drive, measure, monitor, tools and mechanical components of a comprehensive reflection of technologies such as. China's traditional combination of machine tools automatic production line mainly uses the mechanical, electrical, gas, hydraulic control, in recent years with the numerical control technology, electronics technology, computer technology, the development of combined machine tool mechanical structure and control systems have also undergone enormous changes.
(1). Beat the time be further reduced. The early production line to achieve a short beat, often to be used or set side by side duplex two-way. Now mainly by shortening the basic time and auxiliary time to achieve. The main way to shorten the basic time is the introduction of new materials and novel tool knives, in order by improving the cutting speed and feed rate to shorten the basic time. Shorten the lead time is shorter, including auxiliary parts delivery, processing and rapid introduction of the module and processing module is converted to work by the fast-forward to the knife cut into the workpiece, after entering the time spent. At present, the accompanying high-speed conveyor clamps are commonly used in electro-hydraulic proportional valve control, or cycloid-driven conveyor device.
(2). Flexible rapid progress. The emergence of numerical control machine tool portfolio, not only completely changed the relay circuit from the past that a combination of machine tool control systems, but also so that the mechanical structure of modular machine tool components as well as common standards has occurred or is undergoing tremendous change. The traditional sense of the combination of machine tool rigidity automatic line and production line, also has a certain amount of flexibility. CNC machining modules from the combination of flexible machine tools and flexible automatic lines, and change through the application of numerical procedures for automatic tool changing, auto-replacement of multi-axle box and change the processing of travel, work cycle, cutting parameters and processing locations, in order to meet the changing varieties processing.
Coordinate processing module consists of a single station CNC sliding and spindle components (or multi-axle, including for multi-axle) component. Pairs of coordinate processing module consists of CNC Cross Slide and composition of spindle components, such as CNC milling module pairs of coordinates.
Multi-axis machining module is another important module, mainly for processing box and chuck workpieces flexible combination of machine tools and flexible automatic lines. Type of module has a variety of different structural forms, but basically can be divided into automatic processing module for box-type multi-axis, multi-axis turret processing module and multi-axis machining modules Rotary Table. Wrap Box modules can be specifically set up because of the multi-axle box to store large libraries of multi-axle, it can be used to process more different kinds of artifacts. The Rotary Table turret and multi-axis machining modules, due to the turret head and turning the table to allow a limited number of installed multi-axle, so this process can only achieve a limited variety of module processing.
In addition to the variety of CNC machining modules, the robot and servo-driven machine tools and jigs is also a flexible combination of flexible automatic lines are important components. Particularly in the flexible automatic line, is now more widespread use of an empty shelf gantry robot automatic loading and unloading of workpieces, for workpiece transfer bits or flip. For the handling of different workpieces can be automatic line-side gripper library in order to achieve the automatic gripper change. Fixture is equipped with servo drives, to adapt to different workpiece ethnic automatic workpiece clamping.
(3). Increasing machining accuracy. In order to meet users workpiece machining accuracy of the high demand, in addition to further enhance the spindle parts,boring bar, fixtures (including the boring mode) the accuracy of a new special tool to optimize machining processes using tool size measurement and control system and control of machine tool and The thermal deformation of the workpiece and a series of measures, the present, the hollow taper shank tools (HSK), and the process of statistical quality control (SPC) application has become the automatic line to enhance and monitor the machining accuracy of a new and important technical means. Tool is a hollow taper shank radial (cone) and axial (face) Positioning of the innovative two-way tool, its advantages are high bending stiffness, torsional stiffness and high repeatability. SPC is based on process capability for monitoring the quality of workpiece machining methods. At present, the automatic line of such quality assurance systems being used more and more of the entire production process for continuous monitoring of processing quality.
(4). Reliability and efficiency continue to improve and improve. To improve process reliability, availability and quality of workpieces, using the process of monitoring equipment to its constituent functions, processes and workpiece quality control, in order to quickly identify faults and rapid fault diagnosis and early warning process deviation, so that operators and maintenance personnel to intervene in a timely manner in order to shorten the debug cycle facilities, reduce equipment downtime and avoid the processing quality of bias.
Fault Diagnosis Technology for knowledge-based fault diagnosis techniques, can produce automatic line running all the fault diagnosis (but not limited to diagnosis of the most frequently occurring failure), to determine the position and the reasons for failure, which won for the rapid troubleshooting time, thus significantly reducing debugging time and the automatic line downtime.
At present, the automatic line of control technology has been focused on control mode shift toward decentralized control mode. Based on this new control model studies have shown that a decentralized control system than a centralized control systems can be cost savings. This is mainly due to distributed control systems can reduce cabling costs (using the bus system) to reduce the electrical maintenance and repair costs (due to increased transparency), eliminating the need for control of the counter frame (distributed control system, control cabinet directly to set up the automatic line processing station on), and no need to set focus on the cooling devices. In addition, the overall configuration of distributed control system as simple and beneficial to speed up the automatic line put into operation, and because at a glance the structure of configuration, fault in the production is very easy to determine the site of failure. Finally, the distributed control system is also modular and standardized help to reduce costs and increase transparency.
2, machining production line trends
As market competition intensifies and the increase in demand for products, high-precision, high productivity, flexible, multi-variety, short cycle, numerical control machine tools and automatic lines were combined impact of the traditional combination of machine tool production line, therefore, the development of modular machine tool production line idea must be to improve the combination of machining precision, modular machine tool flexibility, reliability, and combined portfolio of machine tool technology, complete sets of machines as the main direction.
Machine tool equipment, high-speed and ultra-high-speed machining technology, the key is to improve the machine tool spindle speed and feed rate. Complex, multi-functional, multi-axis was also optimistic about the prospect of Control. In the increasingly integrated components, at the same time reduce the number of processing the shape is increasingly complex. Control multi-axis machine tools and equipment for processing of complex shape of the workpiece. In addition, the shortening of product life cycle also requires machine tools can readily adjust and adapt to new changes, to meet the processing needs of a wide variety of products even more crucial, however, is that modern communications technology in machine tools and equipment in the application of information and communication technology enables the introduction of modern to further enhance the degree of automation of machine tools, the operator via the Web or mobile phones to remotely program the machine changes to the status of the operation to monitor and accumulate the relevant data; through the network to the remote equipment maintenance and inspection, to provide after-sales service. In advanced countries, our country in these areas there is a considerable gap between, so China's machine tool production line combined high-speed, high precision, flexible, modular, adjustable variable, arbitrary, and processing of the application of communications technology will be the future direction of development.
From the above discussion we can see that China's current production lines machining time in the rhythm, flexibility and progress, machining accuracy, integrated automation, reliability and utilization, and other aspects of the great progress and development. Control technology is also from the centralized control mode shift toward decentralized control mode. The future will be high speed, high precision, flexibility, and digital direction.
淺談機(jī)械加工生產(chǎn)線發(fā)展?fàn)顩r
摘 要
對機(jī)械加工生產(chǎn)線在節(jié)拍時間、柔性化進(jìn)展、加工精度、綜合自動化程度、可靠性和利用率等方面的進(jìn)步和發(fā)展進(jìn)行了闡述。并對其未來發(fā)展趨勢進(jìn)行了分析、展望。
關(guān)鍵詞：柔性化； 自動化； 加工精度
從二十世紀(jì)20年代開始，隨著汽車、滾動軸承、小型電動機(jī)和縫紉機(jī)等工業(yè)發(fā)展，機(jī)械加工制造中開始出現(xiàn)自動線，最早出現(xiàn)的是組合機(jī)床自動線。機(jī)械加工制造業(yè)中有鑄造、鍛造、沖壓、熱處理、焊接、切削加工和機(jī)械裝配等自動線，也有包括不同性質(zhì)的工序，如毛坯制造、加工、裝配、檢驗(yàn)和包裝等的綜合自動線。采用自動線進(jìn)行生產(chǎn)的產(chǎn)品應(yīng)有足夠大的產(chǎn)量；產(chǎn)品設(shè)計(jì)和工藝應(yīng)先進(jìn)、穩(wěn)定、可靠，并在較長時間內(nèi)保持基本不變。在大批、大量生產(chǎn)中采用自動線能提高勞動生產(chǎn)率，穩(wěn)定和提高產(chǎn)品質(zhì)量，改善勞動條件，縮減生產(chǎn)占地面積，降低生產(chǎn)成本，縮短生產(chǎn)周期，保證生產(chǎn)均衡性，有顯著的經(jīng)濟(jì)效益。
1 機(jī)械加工生產(chǎn)線的發(fā)展?fàn)顩r
在汽車、拖拉機(jī)、內(nèi)燃機(jī)和壓縮機(jī)等許多工業(yè)生產(chǎn)領(lǐng)域，組合機(jī)床生產(chǎn)線仍是大批量機(jī)械產(chǎn)品實(shí)現(xiàn)高效、高質(zhì)量和經(jīng)濟(jì)性生產(chǎn)加工的關(guān)鍵裝備，也是不可替代的主要加工設(shè)備。現(xiàn)針對組合機(jī)床生產(chǎn)線來說明一下國內(nèi)機(jī)械加工生產(chǎn)線的發(fā)展情況。
現(xiàn)代組合機(jī)床生產(chǎn)線作為機(jī)電一體化產(chǎn)品，它是控制、驅(qū)動、測量、監(jiān)控、刀具和機(jī)械組件等技術(shù)的綜合反映。我國傳統(tǒng)的組合機(jī)床自動線主要采用機(jī)、電、氣、液壓控制，近年來隨著數(shù)控技術(shù)、電子技術(shù)、計(jì)算機(jī)技術(shù)等的發(fā)展，組合機(jī)床的機(jī)械結(jié)構(gòu)和控制系統(tǒng)也發(fā)生了翻天覆地的變化。
1.1節(jié)拍時間進(jìn)一步縮短。早期的生產(chǎn)線要實(shí)現(xiàn)短的節(jié)拍，往往要采用并列的雙工位或設(shè)置雙線的辦法?，F(xiàn)在主要是通過縮短基本時間和輔助時間來實(shí)現(xiàn)的?？s短基本時間的主要途徑是采用新的刀具材料和新穎刀具，以通過提高切削速度和進(jìn)給速度來縮短基本時間?？s短輔助時間主要是縮短包括工件輸送、加工模塊快速引進(jìn)以及加工模塊由快進(jìn)轉(zhuǎn)換為工進(jìn)后至刀具切入工件所花的時間。目前，隨行夾具高速輸送裝置常用的有電液比例閥控制的或擺線驅(qū)動的輸送裝置。
1.2柔性化進(jìn)展迅速。數(shù)控組合機(jī)床的出現(xiàn)，不僅完全改變了過去那種由繼電器電路組成的組合機(jī)床的控制系統(tǒng)，而且也使組合機(jī)床機(jī)械結(jié)構(gòu)乃至通用部件標(biāo)準(zhǔn)發(fā)生了或正在發(fā)生著巨大的變化。傳統(tǒng)意義上的組合機(jī)床剛性自動線和生產(chǎn)線，也具有了一定的柔性。由數(shù)控加工模塊組成的柔性組合機(jī)床和柔性自動線，可通過應(yīng)用和改變數(shù)控程序來實(shí)現(xiàn)自動換刀、自動更換多軸箱和改變加工行程、工作循環(huán)、切削參數(shù)以及加工位置等，以適應(yīng)變型品種的加工。
單坐標(biāo)加工模塊由數(shù)控滑臺和主軸部件（或多軸箱，包括可換多軸箱）組成。雙坐標(biāo)加工模塊由數(shù)控十字滑臺和主軸部件組成，例如數(shù)控雙坐標(biāo)銑削模塊。
多軸加工模塊是又一種重要模塊，主要用于加工箱體和盤類工件的柔性組合機(jī)床和柔性自動線。這類模塊有多種不同的結(jié)構(gòu)形式，但基本上可分為自動換箱式多軸加工模塊、轉(zhuǎn)塔式多軸加工模塊和回轉(zhuǎn)工作臺式多軸加工模塊。自動換箱式模塊由于可在專門設(shè)置的多軸箱庫中儲存較多的多軸箱，故可用來加工較多不同品種的工件。而轉(zhuǎn)塔式和回轉(zhuǎn)工作臺式多軸加工模塊，由于在轉(zhuǎn)塔頭和回轉(zhuǎn)工作臺上允許裝的多軸箱數(shù)量有限，所以這種加工模塊只能實(shí)現(xiàn)有限品種的加工。
除上述各種CNC加工模塊外，機(jī)器人和伺服驅(qū)動的夾具也是柔性組合機(jī)床和柔性自動線的重要部件。特別在柔性自動線上，目前已較普遍地采用龍門式空架機(jī)器人進(jìn)行工件的自動上下料，用于工件的轉(zhuǎn)位或翻轉(zhuǎn)。為搬運(yùn)不同的工件，可在自動線旁設(shè)置手爪庫，以實(shí)現(xiàn)手爪的自動更換。夾具配備伺服驅(qū)動裝置，以適應(yīng)工件族內(nèi)不同工件的自動夾緊。
1.3加工精度日益提高。為了滿足用戶對工件加工精度的高要求，除了進(jìn)一步提高主軸部件、鏜桿、夾具（包括鏜模）的精度，采用新的專用刀具，優(yōu)化切削工藝過程，采用刀具尺寸測量控制系統(tǒng)和控制機(jī)床及工件的熱變形等一系列措施外，目前，空心工具錐柄（HSK）和過程統(tǒng)計(jì)質(zhì)量控制（SPC）的應(yīng)用已成為自動線提高和監(jiān)控加工精度的新的重要技術(shù)手段?？招墓ぞ咤F柄是一種采用徑向（錐面）和軸向（端面）雙向定位的新穎工具，其優(yōu)點(diǎn)是具有較高的抗彎剛度、扭轉(zhuǎn)剛度和很高的重復(fù)精度。SPC 是基于工序能力的用于監(jiān)控工件加工質(zhì)量的一種方法。目前，在自動線上這種質(zhì)量保證系統(tǒng)愈來愈多地被用來對整個生產(chǎn)過程中的加工質(zhì)量進(jìn)行連續(xù)監(jiān)控。
1.4可靠性和利用率不斷改善和提高。為提高加工過程的可靠性、利用率和工件的加工質(zhì)量，采用過程監(jiān)控，對其各組成設(shè)備的功能、加工過程和工件加工質(zhì)量進(jìn)行監(jiān)控，以便快速識別故障、快速進(jìn)行故障診斷和早期預(yù)報(bào)加工偏差，使操作人員和維修人員能及時地進(jìn)行干預(yù)，以縮短設(shè)備調(diào)試周期、減少設(shè)備停機(jī)時間和避免加工質(zhì)量偏差。
故障診斷技術(shù)中的基于知識的故障診斷技術(shù)，可對自動線運(yùn)行中產(chǎn)生的所有故障進(jìn)行診斷（而不是局限于診斷最常出現(xiàn)的故障），確定故障部位及其原因，這為迅速排除故障贏得了時間，從而顯著地縮短自動線的調(diào)試時間和停機(jī)時間。
當(dāng)前，自動線的控制技術(shù)已由集中控制方式轉(zhuǎn)向分散控制方式。根據(jù)對這種新的控制模式的研究表明，采用分散控制系統(tǒng)要比采用集中控制系統(tǒng)可節(jié)省費(fèi)用。這主要是由于分散控制系統(tǒng)可減少電纜敷設(shè)費(fèi)用（采用總線系統(tǒng)）、減少電氣保養(yǎng)維修費(fèi)（由于提高了透明度）、省去控制柜臺架（分散控制系統(tǒng)的控制柜直接設(shè)置在自動線的加工工位上）和無需設(shè)置集中冷卻裝置等。此外，這種分散控制系統(tǒng)由于總體配置簡單，有利于加快自動線的投入運(yùn)行，并由于一目了然的結(jié)構(gòu)配置，在產(chǎn)生故障時很容易確定故障的部位。最后，分散控制系統(tǒng)的模塊化和標(biāo)準(zhǔn)化也有利于降低成本和提高透明度。
2 機(jī)械加工生產(chǎn)線的發(fā)展趨勢
隨著市場競爭的加劇和對產(chǎn)品需求的提高，高精度、高生產(chǎn)率、柔性化、多品種、短周期、數(shù)控組合機(jī)床及其自動線正在沖擊著傳統(tǒng)的組合機(jī)床生產(chǎn)線，因此，組合機(jī)床生產(chǎn)線的發(fā)展思路必須是以提高組合機(jī)床加工精度、組合機(jī)床柔性、組合機(jī)床工作可靠性和組合機(jī)床技術(shù)的成套性為主攻方向。
機(jī)床裝備的高速和超高速加工技術(shù)的關(guān)鍵是提高機(jī)床的主軸轉(zhuǎn)速和進(jìn)給速度。復(fù)合、多功能、多軸化控制的前景亦被看好。在零部件一體化程度不斷提高、數(shù)量減少的同時，加工的形狀卻日益復(fù)雜。多軸化控制的機(jī)床裝備適合加工形狀復(fù)雜的工件。另外，產(chǎn)品周期的縮短也要求加工機(jī)床能夠隨時調(diào)整和適應(yīng)新的變化，滿足各種各樣產(chǎn)品的加工需求然而更關(guān)鍵的是 現(xiàn)代 通信技術(shù)在機(jī)床裝備中的應(yīng)用，信息通信技術(shù)的引進(jìn)使得現(xiàn)代機(jī)床的自動化程度進(jìn)一步提高，操作者可以通過 網(wǎng)絡(luò) 或手機(jī)對機(jī)床的程序進(jìn)行遠(yuǎn)程修改，對運(yùn)轉(zhuǎn)狀況進(jìn)行監(jiān)控并積累有關(guān)數(shù)據(jù)；通過網(wǎng)絡(luò)對遠(yuǎn)程的設(shè)備進(jìn)行維修和檢查、提供售后服務(wù)等。在這些方面我國就先進(jìn)國家還有相當(dāng)大的差距，因此我國組合機(jī)床生產(chǎn)線高速度、高精度、柔性化、模塊化、可調(diào)可變、任意加工性以及通信技術(shù)的應(yīng)用將是今后的發(fā)展方向。
從以上論述可以看出我國目前的機(jī)械加工生產(chǎn)線在節(jié)拍時間、柔性化進(jìn)展、加工精度、綜合自動化程度、可靠性和利用率等方面都有了長足的進(jìn)步和發(fā)展?？刂萍夹g(shù)也由集中控制方式轉(zhuǎn)向分散控制方式。未來將向高速、高精、柔性及數(shù)字方向發(fā)展。