7.2.4 Technical training of operation and programming personnel After the transformation of the electrical system of the machine tool, it will inevitably bring new requirements to the operation and programming personnel. Therefore, it is very important to train the operators and programmers in the new system knowledge in advance, otherwise it will affect the transformation of the machine tool into production. The training content should generally include the new operator panel configuration, function, indication meaning; the functional scope of the new system, the method of use and the difference with the old system; maintenance requirements; programming standards and automation programming. The focus is on understanding and working with the operating instructions and programming instructions.
7.2.5 Determination of commissioning procedures and acceptance criteria After the transformation of the new electrical system, how to commission and determine reasonable acceptance criteria is also an important part of the technical preparation work. The commissioning work involves mechanical, hydraulic, electrical, control, sensing, etc., so it must be carried out by the project leader and other personnel. The debugging steps can be from simple to complex, from small to large, from outside to inside, or first and then global, first subsystem and then complete system. The acceptance criteria are the assessment of the new system. It must be realistic when it is formulated. The standards that are too high or too low will have a negative impact on the transformation work. Once the standard is determined, it cannot be easily modified because it involves all aspects of the entire transformation work.
7.3. After the implementation of the transformation is ready, you can enter the implementation phase of the transformation. The content of the implementation phase is divided into chronological order:
7.3.1 Comprehensive maintenance of the original machine tool After long-term use, the machine tool will have defects in mechanical, hydraulic, lubrication, cleaning, etc., so the first step is to carry out comprehensive maintenance. Secondly, the geometric accuracy and dimensional accuracy of the machine tool should be measured before the change. This can not only guide and reference the transformation work, but also can be used for comparative analysis at the end of the transformation.
7.3.2 Optimized adjustment of the retained electrical part If the electrical system is partially modified, the maintenance and optimization of the reserved electrical part shall be carried out. Such as the replacement of parts in the strong electric part, the maintenance of the motor, the drying insulation of the transformer, the cleaning of the pollution, the cleaning of the ventilation cooling device, the optimization of the servo drive, the renewal of the aging wire and cable, the fastening of the connector, etc. . Only a fine optimization of the retained electrical parts can ensure that the modified machine has a lower failure rate.
7.3.3 Demolition of the original system The original system must be carefully carried out according to the original drawings, and marked on the drawings in time to prevent omission or over-disassembly (under partial modification). In the process of dismantling, some defects in the design of new systems will also be found. They should be supplemented and corrected in time. The removed systems and parts should be classified and properly kept in case of unsuccessful transformation or partial failure. There are certain use values ​​that can be used as spare parts for other machine tools. Don't be too big and big, throw it away.
7.3.4 Reasonable Arrangement of New System Location and Wiring According to the new system design drawings, the new system configuration is reasonably carried out, including box fixing, panel placement, line orientation and fixing, adjustment of component position, sealing and necessary decoration. The work of connection must be clearly defined, and some people should review and inspect to ensure that the connection process specifications, wire diameter are correct, correct, reliable and beautiful.
7.3.5 Commissioning and commissioning must be carried out in accordance with predetermined steps and requirements. The commissioning staff should be calm and record at any time in order to discover and solve problems. In the commissioning, first try to protect the sensitivity of the system to prevent accidents of people and equipment. The debugging site must be cleaned up and free of unnecessary items; each motion coordinate carriage is at the center of the full stroke; it can be loaded with no load test, first loaded after no load; can simulate the test, first simulate and then move; can be manual, first manual After automatic.
7.4. Acceptance and post-work acceptance work should involve relevant personnel to participate and carry out according to the established acceptance criteria. The post-reform work is also very important, it is conducive to the improvement of the project's technical level and the equipment to put into production as soon as possible. Acceptance and post work include:
7.4.1 Mechanical performance acceptance of machine tools After mechanical repair and modification and comprehensive maintenance, the mechanical properties of the machine tools should meet the requirements, and the geometric accuracy should be within the specified range.
7.4.2 Electrical control function and control accuracy Acceptance The functions of electrical control must be normal, sensitive and reliable. Control accuracy The function of the application itself (such as step size) is checked against standard measuring instruments (such as laser interferometers, coordinate measuring instruments, etc.) to within the accuracy range. At the same time, it should be compared with the functions and precision of the machine tool before the transformation, and the quantitative index difference can be obtained.
7.4.3 The test acceptance of the test piece can be carried out with reference to the standards of CNC machine tool cutting test pieces at home and abroad, and the test can be carried out with the help of qualified operators and programmers. The specimen cutting can accept the machine tool stiffness, cutting force, noise, motion trajectory, associated movements, etc. It is generally not appropriate to use the product parts for the test piece.
7.4.4 Drawings and data acceptance After the transformation of the machine tool, the drawings (including schematics, configuration drawings, wiring diagrams, ladder diagrams, etc.), materials (including various instructions), and reconstruction files (including before and after the transformation) should be timely Records) summary, collation, and handover. Keeping the data complete, effective and continuous is very important for the stable operation of the equipment in the future.
7.4.5 Summary and improvement should be summarized in time after each transformation, which is beneficial to improve the technical level of technicians and to the technological progress of the whole enterprise.
Eight, several examples of numerical control transformation 1. Transforming X53 milling machine with SIEMENS 810M In 1998, the company invested 200,000 yuan to carry out X, Y for one of the company's X53 milling machines with Siemens 810M CNC system and 611A AC servo drive system. Z three-axis CNC transformation; retaining the original spindle system and cooling system; the modified three-axis mechanically uses a roller screw and gear transmission mechanism. The whole transformation work includes mechanical design, electrical design, PLC program preparation and debugging, machine tool overhaul, and finally the installation and commissioning of the whole machine. After the milling machine is modified, the effective stroke X/Y/Z axis is 880/270/280 mm; the maximum speed X/Y/Z axis is 5000/1500/800 mm/min; the manual speed X/Y/Z axis respectively It is 3000/1000/500 mm/min; the machining accuracy of the machine is ±0.001mm. The three-coordinate linkage of the machine tool can complete the processing of various complex curves or surfaces.
2. Reforming the C6140 lathe with GSK980T and stepping drive system In 1999, the company invested 80,000 yuan, using the GSK980T CNC system produced by Guangzhou CNC Equipment Factory and the DY3 hybrid stepping drive unit on the X of the company's extended C6140 lathe. The Z axis is modified; the original spindle system and cooling system are retained; the modified two shafts are mechanically equipped with a roller screw and a timing belt transmission mechanism. The entire transformation work includes mechanical design, electrical design, machine tool overhaul and installation and commissioning of the whole machine. After the lathe is modified, the effective stroke X/Z axis is 390/1400 mm; the maximum speed X/Z axis is 1200/3000 mm/min; the manual speed is 400mm/min; the manual fast X/Z axis is 1200 respectively. /3000 mm/min; the minimum moving unit of the machine is 0.001 mm.
3. Renovation of C6140 lathe with GSK980T and AC servo drive system in 2000, using GSK980T CNC system, DA98 AC servo unit and 4-station automatic tool holder produced by Guangzhou CNC Equipment Factory for a C6140 lathe X and Z of the motor factory. The shaft is numerically modified; the original spindle system and cooling system are retained; the modified two shafts are mechanically equipped with a roller screw and a timing belt transmission mechanism. The entire transformation work includes mechanical design, electrical design, machine tool overhaul and installation and commissioning of the whole machine. After the lathe is modified, the effective stroke X/Z axis is 390/730 mm; the maximum speed X/Z axis is 1200/3000 mm/min; the manual speed is 400mm/min; the manual fast X/Z axis is 1200 respectively. /3000 mm/min; the minimum moving unit of the machine is 0.001 mm.
4. Transforming X53 milling machine with SIEMENS 802S In 2000, the company invested 120,000 yuan to carry out X, Y and Z three-axis NC transformation of another X53 milling machine with Siemens 802S CNC system and stepping drive system. The original spindle system and cooling system are retained; the modified three-axis mechanically uses a roller screw and a gear transmission mechanism. The entire transformation work includes mechanical design, electrical design, machine tool overhaul, and finally the installation and commissioning of the whole machine. After the milling machine is modified, the effective stroke X/Y/Z axis is 630/240/280 mm; the maximum speed X/Y/Z axis is 3000/1000/600 mm/min; manual feed speed X/Y/Z The axes are 2000/800/500 mm/min respectively; the minimum moving unit is 0.001 mm.
Nine, problems and suggestions in the NC transformation After the numerical control transformation work of several machine tools, it is found that there are also many problems in the work, mainly in:
First, the responsibilities of various departments and developers are unclear and the organization is confusing, which seriously affects the progress of the transformation;
Second, most of the work processes and plans formulated are based on experience and are not reasonable;
Third, the training work of the relevant personnel is not in place, resulting in the problem that the process personnel will not be programmed after the machine tool transformation, and the operator is not skilled in the operation of the machine tool.
To sum up the above questions, there are several suggestions:
First, the responsibilities of the employees responsible for the transformation are clear, the rewards and punishments are clear, and the enthusiasm of the employees is fully mobilized;
The second is to train a group of high-quality application and maintenance personnel, and send personnel to go out to study and learn advanced technology;
Third, we must pay attention to the technical training of users to use and maintain the CNC system, and establish a library of CNC technology resources at home and abroad.
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