防竄焊接滾輪架竄動檢測及防竄控制系統(tǒng)設計說明書[帶圖紙].doc

重慶理工大學畢業(yè)論文防竄焊接滾輪架：竄動檢測及防竄控制系統(tǒng)設計目錄摘要····························································································IAbstract···························································································II1.緒論··························································································11.1國內外焊接滾輪架發(fā)展現(xiàn)狀······················································11.2課題的研究內容及意義·······························································22.防竄焊接滾輪架系統(tǒng)的結構設計及工作原理···········································22.1系統(tǒng)的結構設計·······································································22.2系統(tǒng)的工作原理·······································································33.筒體軸向竄動的理論分析···································································33.1焊接過程中常出現(xiàn)的一些問題·····················································33.2軸向竄動的主要原因·································································43,3滾輪架簡體軸向竄動機理···························································53.4焊件不發(fā)生軸向竄動的充分條件··················································64.筒體軸向竄動的檢測、調節(jié)及執(zhí)行機構設計···········································74.1軸向竄動檢測··········································································74.2調節(jié)方式的選擇·······································································84.3調節(jié)執(zhí)行機構的調節(jié)原理···························································94.4升降裝置的選型·····································································105.系統(tǒng)控制部分················································································125.1系統(tǒng)硬件部分設計··································································125.1.1PLC控制器····································································125.1.2步進電機的計算與選型·····················································165.1.3步進電機驅動器的選用····················································215.1.4聯(lián)軸器的選擇································································225.1.5位移傳感器選型·····························································225.1.6限位開關選型································································235.1.7控制面板的設計·····························································235.2系統(tǒng)軟件部分設計··································································235.2.1防竄控制模式選擇··························································245.2.2主程序控制圖·································································255.2.3梯形圖程序···································································256.總結···························································································29參考文獻·························································································30文獻綜述·························································································31重慶理工大學畢業(yè)論文防竄焊接滾輪架：竄動檢測及防竄控制系統(tǒng)設計I摘要焊接滾輪架是在焊接生產中與焊接工序相配一種輔助裝置。在大厚壁、大型化、高容量、耐磨蝕的鍋爐、石油、化工壓力容器的焊接過程中，由于筒體的幾何形狀的不規(guī)則（偏離理想回轉體）和焊接滾輪架的制造安裝誤差等原因，筒體在滾輪架上轉動時，會不可避免的發(fā)生軸向竄動，從而影響環(huán)縫的焊接質量。本課題從理論上深入分析了筒體在焊接過程中產生軸向竄動的主要原因，分析了筒體軸向位移的調節(jié)機理，同時提出了采用螺旋升降裝置和步進電機傳動，用PLC控制器以脈沖控制的方式使步進電機精準的控制升降臺的上升和下降的位移。此防竄焊接控制系統(tǒng)有效地解決了窄間隙埋弧焊、內壁堆焊的問題，智能化控制焊接過程中出現(xiàn)的軸向竄動，此設計實現(xiàn)了精密化、大型化、數字化、智能化等優(yōu)點。不僅提高了生產效率而且確保批量生產過程中焊接質量的穩(wěn)定性，節(jié)省因竄動進行人工調節(jié)的時間，減少勞動力，提高焊接的精度和質量，降低成本。關鍵詞:竄動理論分析竄動檢測調節(jié)執(zhí)行機構硬件部分設計軟件部分設計重慶理工大學畢業(yè)論文防竄焊接滾輪架：竄動檢測及防竄控制系統(tǒng)設計IIAbstractWeldingrollerbedisintheweldingproductionandweldingprocesstomatchanauxiliarydeviceTheWeldingandProductioninthebigThick-Cliff、TheLarge-Scale、High-Content、Endure-AblationofthepressurevesseloftheBoiler、Oil、chemical,becauseofreasonoftheabnormityofgeometry-formofthecylinder(departureidealgyrationobject)andtheerrorofthemanufacture-installation,thecylinderwheelontherollerbed,inevitablyitwilloccuraxialdrifting,sothataffecttheweldingquality.Thistopicofcylinderwereanalyzedtheoreticallyintheweldingprocesstoproduceaxialchannelingmove,themainreasonoftheregulationmechanismofcylinderaxialdisplacementareanalyzed,atthesametimeputsforwardadoptingspiralliftinggearandstepmotordriving,PLCcontrollertocontrolbymeansofpulsetomakeprecisesteppermotorcontroldisplacementoftheriseandfalloftheliftingplatform.Theantichannelingweldingcontrolsystemcaneffectivelysolvethenarrowgapsubmergedarcwelding,theweldingproblem,intelligentcontrolintheweldingprocessoftheaxialchannelingmove,thisdesignimplementsthemotors,large-scale,digitalandintelligentadvantages.Notonlyimprovestheproductionefficiencyandensurethestabilityofweldingqualityinmassproductionprocess,saveforchannelingmanuallyadjusttime,reducethelaborforce,improvetheaccuracyofweldingandquality,reducecosts.Keywords:DynamicanalysisTheaxialdynamicdetectionAdjusttheactuatorThehardwarepartofthedesignSoftwarepartdesign重慶理工大學畢業(yè)論文防竄焊接滾輪架：竄動檢測及防竄控制系統(tǒng)設計11緒論1.1國內外焊接滾輪架發(fā)展現(xiàn)狀近年來，隨著我國改革開放進程的深化，隨著中外合作合作生產和引進技術生產的機械產品日益增多，促進了我國焊接結構用量的迅速增加。尤其是為滿足我國石油、化工、交通、能源等工業(yè)的迅猛發(fā)展，大厚壁、大型化、高容量、耐磨蝕、耐動載的鍋爐、石油、化工壓力容器的用量更是日益增加，其接頭的焊接質量要求也越來越高，并且在實際生產中要求有較高的生產效率。防竄焊接滾輪架就是在上述焊接生產中與焊接工序相配合，有利于實現(xiàn)焊接生產機械化，自動化，有利于提高裝配焊接質量，促使焊接生產效率提高的一種輔助裝置和設備。焊接滾輪架是借助主動滾輪與焊件之間的摩接力帶動焊件旋轉的變位機械。在筒形工件內外環(huán)縫的焊接中，組合式焊接滾輪架逐漸取代長軸式、固定式等焊接滾輪架，獲得了廣泛的應用，但如何合理的控制其焊接時的軸向竄動及主動輪的轉速仍值得分析。組臺式焊接滾輪架主要由主動輪座、從動輪座、支架三部分組成。支架相當于機座，輪座坐在其上對工件起支承作用，其中主動輪座還起驅動作用。這三部分自成獨立單元，人們可利用其數量的協(xié)調變化組合成能驅動各種長度、各種直徑、不同重量筒形工件的焊接滾輪架。但是，作為標準組臺，是由兩個支架和四個輪座組成的，其中至少有一個輪座是主動輪座。我國在1990年頒布的焊接滾輪架的行業(yè)標準（ZBJ/T33003-1990）中規(guī)定：主動滾輪的圓周速度應在6－60m/h范圍內無級可調，速度波動量按不同的焊接工藝要求，要低于±5％±10％，滾輪轉速應穩(wěn)定、均勻，不允許有爬行現(xiàn)象。按GB150規(guī)定制造的筒體類工件在防軸向竄動滾輪架上進行焊接時，在整個焊接過程中允許工件的軸向竄動量為±3mm。國外于20世紀80年代中期推出的防止焊件軸向竄動焊接滾輪架，能將焊件的竄動量控制在±2mm以內。我國近年來也有個別工廠生產過防竄動滾輪架，但在實用性和可靠性方面，與國外產品相比還存在著差距。國外在80年代初期研制開發(fā)了一種防止工件軸向竄動的焊接滾輪架。如瑞典伊薩（ESAB）、意大利安莎多（ANSALDO）和英國（BODE）公司等都推重慶理工大學畢業(yè)論文防竄焊接滾輪架：竄動檢測及防竄控制系統(tǒng)設計2出了這種產品。國外所研制的防軸向竄動焊接滾輪架與國內常規(guī)的焊接滾輪架相比，增加了一套高可靠度的軸向位移自動調節(jié)系統(tǒng)。在焊接過程中能同步調節(jié)筒體的姿態(tài)，使焊接過程可靠實施，大大提高了生產效率，同時可得到高質量的焊接接頭。相比國外，我國防軸竄焊接滾輪架的研制還處于初始階段，據調查，至今國內尚無正式廠家能夠制造抽比較成熟的產品，生產中主要是依靠引進國外的設備，如蘭州石油化工機械廠、哈爾濱鍋爐廠、齊齊哈爾第一重型機械廠等，都是從國外引進的防軸向竄動的焊接滾輪架。這樣，一方面要花費大量的外匯，另一方面也遠遠不能滿足國內日益增長的焊接生產需要。1.2課題的研究內容及意義本課題主要研究的內容是：①深入分析出現(xiàn)竄動的原因以及竄動機理；②設計防竄滾輪架控制系統(tǒng)（包括控制部分軟硬件、梯形圖、電氣原理）；焊接滾輪架的軸向竄動問題一直是各大企業(yè)及各使用者所關心的重要問題，本課題能從理論上有效的解決焊接滾輪架在焊接過程中出現(xiàn)軸向竄動的問題，提高焊縫的精度和質量；同時也提高我自己在這方面的知識。2防竄焊接滾輪架系統(tǒng)的結構設計及工作原理2.1系統(tǒng)的結構設計防竄滾輪架系統(tǒng)主要由驅動滾輪架，從動滾輪架，調節(jié)裝置，電氣控制系統(tǒng)，PLC，步進電機等組成。主動滾輪架的滾輪旋轉采用交流變頻電機驅動、變頻調速，具有調速范圍寬，轉動平滑性好等特點；從動滾輪架裝置是由底座、滾輪、滾輪座、防竄滾輪裝置等組成，其底座固定；防竄滾輪裝置由從動滾輪裝置和升降機構組成，升降機構包括蝸輪絲桿升降機構、升降限位開關等。采用步進電機驅動升降機的升降，根據位移傳感器檢測到的工件軸向竄動信號，自動糾正工件的軸向竄動。主要用于管道、容器、鍋爐、油罐等重型圓筒形工件的裝配與焊接。若對從動滾輪的高度做適當的調整后還可進行錐體、分段不等徑回轉體的裝配與焊接。