大學(xué)畢業(yè)論文-數(shù)控加工中心自動換刀系統(tǒng)的研究外文翻譯

PAGE密級：JINGGANGSHAN外文翻譯題目數(shù)控加工中心自動換刀系統(tǒng)的研究學(xué)院機(jī)電工程學(xué)院專業(yè)機(jī)械設(shè)計(jì)制造及其自動化班級機(jī)制11(本1)學(xué)號姓名指導(dǎo)教師起訖時(shí)間2014.11——2015.5教務(wù)處印制PAGE1機(jī)電工程學(xué)院機(jī)械設(shè)計(jì)制造及其自動化專業(yè)外文翻譯井岡山大學(xué)外文翻譯用紙Machinery,2011,12(04)ResearchontheautomatictoolchangersystemofthemanchingcenterZHENGXin-wu,ZHANGMing-zhong,LIChun-mu,LIYin,CHENYong-ming(DepartmentofMechanical&ElectricalEngineering,XiamenUniversity,Xiamen361005,China)Abstract：Theautomatictoolchanger(ATC),whichincludesamagazine,atoolchangerandacontrolsystem,isoneofthekeycompomentsofthemachiningcenter(MC),GeneralissuesoftheATC,however,areitsslownessandlowstabilityduringtoolchangesandthecomplexityofcontrolsystemprogramming.Tosolvethoseproblems,onetypeofsoftwareanditsinternalPLCtechnologywereinverstigated.BasedonananalysisofthefundamentalstructureandoperatingprincipleoftheATCsystemandaresearchofthecontrolprocedureofthe“discwitharm”-typeATC,thePLCprogramandmacroprogramscombinedwithServoWorksCNCtechnologyweredeveloped.Finally,itwasshownthatnewlydesignedcontrolsystemcancompletethewholeprocessofchangingtoolsin4to6secondsontheYY-1060verticalMC.Theresultsindicatethattheprocessisrapid,accurateandreliableenoughtocompletelymeetthepracticalrequirements.Keywords:machiningcenter(MC);automatictoolchanger(ATC);programmablelogiccontroller(PLC)IntroductionUsingknifelibrary(MAG)automatictoolchangeisthewayoftoolchange,iswidelyusedinmachiningcenterindependentknifelibraryvastlyincreasesthestoragequantityofcuttingtool,whichhelpstoexpandthefunctionofmachinetool,andcanbewellisolatedinterferenceofvariouskindsoffactorsaffectingthemachiningaccuracy.Processingcenterofthelibrarytypesare:aknifedisctoollibraryandchaintoollibrary.Librarychangetoolwayaccordingtothepresenceofmanipulator,toolchangeprocessintoamanipulatortoolchangeandnomanipulatortoolchange.ThisstudyinordertoYY-1060verticalmachiningcenterisequippedwithDEX-A402disctoollibrarymanipulatorautomatictoolchangemechanismastheobject,studyofautomatictoolchanger(ATC)system.Programmablecontroller(PLC)isthecorepartofautomatictoolchangesystem.Atpresent,thedomesticcontroloftheautomatictoolchangemorethanthetraditionalPLC(hereinafterreferredtoashardPLC)andsinglechipmicrocomputer,suchasmitsubishiFXseriesPLC,SiemensS7-200seriesPLC,AT98C51microcontroller.HardPLCcontrolmethodwithoutspecialinstructionsofthetool,youneedtowritecomplexcutterPLCprogram,aswellassimplifytheprocessofncprogrammingbymacroprogram;Adoptsinglechipmicrocomputercontrolcircuitstructures,complex,thesystemstabilityislow,programmingcomplex.ThisresearchadoptstheLadderWorksisakindofbuilt-inPLCsystemsoftwarebasedonthetechnologyofServoWorkstype,canbebetweenCNCrapidinternalsignaltransmission.LibrarystructureandtoolchangemovementAutomatictoolchangemaincomponentsinclude:motor,CAM,toolpot,daolibrarymotor,cup,brake,pinecliproundtool,theoriginsignal,etc.DEX-A402automatictoolchangeisshowninfigure1.Fig.1.AutomatictoolchangeFig.2.SwordarmactionSwordarmactiondrivenbysteppingmotor,toolchangeactionpoints4stepstocomplete.Singleswordarmmotordirectionofrotation,throughtheautomatictoolchangemechanismofCAMmechanismtocontroltheswordarmandreversing,thedrivemodeimprovestheswordarmrotationAngleprecision,simplifythecontrolofthemotoratthesametime.Swordarmmovementofthespecificprocessasshowninfigure2.TransferinstructionsCNCprogramminginstructionbyT,Minstructionstocompletetheautomatictoolchangeaction,toolchangeinstructiondecodedbytheinternalsystem,thetargettool,andmacroinstruction,translatedintothecorrespondingbinarynumbersavedtothesystemspecifiedintheregister.ServoWorksPLCsystemTinstructiondecodertoF26,MinstructiondecodetoF10,userscanaccordingtotherequestofchangeknifeactionwritemacroprogramandPLCprogram.Tdirectivespecifiesthetool,completingthelibrarychoosetool,toollibraryrotationdirectionjudgmentanddeterminationofrotatinginterval;Mdirectivespecifiesthemacroprogram,accordingtotherequirementsintoolcompletespindlebacktozero,theZaxispointbacktochangethetool,thetoolarmrotatingdirection,locationandtoolcupupanddownmovement.3.1Thechoiceofcutter(T)Cuttingtoolchoiceistoollibraryspecifiedonthetooltochangethecutterlocation,theactionbytheTinstructionfunction.Automatictoolchanger(ATC)systembasedoninformationfromthepositionofthetoolstorageandTinstruction,accordingtothegivencommandandcontrolsystemdecidetheknifelibrarydirectionofrotation,therequirementsofthesteps,etc.,generally,thememorycanbeusedtomodelrandomcontrolandmechanicalcontrolintwoways.Correspondingtotheirrespectivemechanicalrandomcontroleverytoolset,usuallybetweenthespindleandthetoolstorage,toprovidetoolchange"middletoolset".Memorymodel,bycontrast,stochasticcontrolusingapointer,pointerpointsoutthatthepositionoftoollibraryrotation,eachknivesandtoolsetisnotalwaysone-to-onecorrespondence,thecontrolmodechangequicklyandreliable.Inaccordingtothemechanicalstructureofthetoolstoragechoicesintoolcontrolmode,thefollowingsystemofpointertoafloatswitchtoolway:bytheuserTdirectivespecifiesatool,afterdecodingsystem,foundinthefloatingofthepointertothememorynumbercorrespondingtothecuttingtool,thesystemusespecialinstructionROTBdirectionofrotationandrotationdistancejudgmenttheknife,toollibraryrotationtothetargetlocationchoicetoolfinishtool,M6instructionscompletedactioninthetool,thespecificprocessasshowninfigure3.Fig.3.Flowchartofchoosingtools3.2Transferinstructions(M)AuxiliaryMinstructiondecodingthroughthesystemtothePLC"rumet"point(internalrelay),userswritePLCprogramaccordingtotheactionrequirement.ATCauxiliaryMinstructionsincludeM6inknife,M19spindlepositioning,initializationM86toollibrary,etc.Machiningcenterlibrarychangeknifeprocessasshowninfigure4.Fig.4.InflowchartServoWorksCNCcanaccordingtotheneedsofuserscustomizetheG/M/S/Tmacrocallsimplifyncprogramming,commonlyusedmachinetoolmovementprogramcanbeintegratedintoacommand,suchasusingM06completethechangemovement.ThemacroprogramcancallwiththesameauxiliaryMinstructions.Withinthesystemtospecifyinstructionsstoredmobilestorageunitclassification,suchasG00,G01,G02G03instructionsstoredinthesystemvariablessuchas#4001.Macrocallsthemethodisasfollows:O9001G40G80#510=#4001#511=#4001#512=#4003#513=#1032AND256#514=#BIN[#513]（IF[#512EQ#514]GOTON1000）G90G30Z0M19M6G#510G#511N1000M99ThePLCprogramdevelopmentAutomatictoolchangethePLCprogrammainlyincludesthelibrarychoosetoolandswordarminapplication.ServoWorksPLCprogramaddressesare:machinetoolstothePLCinputsignal(X),PLCtotheinputsignal(Y)machinetools,CNCenginesignaltothePLCengine(F),PLCenginetotheCNCenginesignal(G),intermediaterelay(R),counter(C),thetimer(T),etc.Thefollowing"rumet"pointdescriptiontoolchangebyPLC.4.1LibrarychooseknifePLCprogramLadderWorksPLCbasedautomatictoolchangeorder(asshowninfigure3)are:tools,searchinstructionsDSCH,rotatingdirectionanddistancecalculationROTBCTR,libraryrotatingtoolcountinstructions.

DEX-A402toollibrarytoolingcapacityfor24,daolibrarytochoosethemainPLCprogramasshowninfigure5.ProgramR270storagetargettool,DSCHinstructioninD20of25theaddressofthestorageunittofindthesameastheR270content,andstoredintheR280;COspecifiesthetoolingcapacity,toollibraryROTBinstructionreal-timecomputingtargettoolR290andcurrenttoolcup,cuponC2,thestepdistanceanddirectionbetweentheR283fromstoragecloth,R203.6storagedirectionofrotation;C2countdonebyCRTinstruction,knifelibraryrotationdirectionR960.3decidedtoC2countsincreaseanddecrease,R200.4forsignalsofcount.4.2TheknifearminPLCprogramIntherotationofthePLCprogramtorealizetoolarmmotioncontrol.AutomatictoolchangethroughthemotordrivetheCAMarmmovementcontroltheknife,knifearmwithwheelbrakingsignalsandtheCAMsignalwheelbrakesignal,pinenippeddaosignals,theorigin,throughtheabovesignalsequencediagramwritebrakeposition.Position1correspondstotheoriginposition,position2correspondingtoolarmforward60degrees,position3correspondingknifearmisturned180degrees.ThisresearchaccordingtotheflowchartoftoolchangewrittenintoolPLCprogram,asshowninfigure6.Fig.5.LibrarychoosetoolapplicationFig6.InPLCprogram4.3StorageunitnumberswapsAutomatictoolchangerisarandomcontinuousprocess,thetoolchangeafterthecompletionoftheneedtomodifythecontentinthestorageunit,ensureaccuratetoolchangenexttime.Storageunittool,swaps,completethespindlecutternumberD20andpresentcorrespondingtool,toolcuponD+C2(20)exchange,throughtheintermediatestorageD18transition,specificimplementationwayasshowninfigure7.Fig.7.AccessunitknifeswapsXMOVinstructionstocompletethestorageunitdataread,write,readoperationonRW=0,RW=1toperformwriteoperations.TestLadderWorksconsoleisacollectionofPLCprogramcreating,editing,compilation,operationmonitoringanddebuggingofPLCcontrolplatform.LadderWorksPLCallsortsoffunctioninstructioniscomplete,theprogrammingmethodissimple,support"TXTformattextfiles.TheseprogramsarewritteninaccordancewiththerequirementsforLadderWorksPLCprogrammingcorrespondingstatementstable,saveto"TXT"inthedocument,compiledbytheLadderWorksconsoleandcompletethePLCprogramming.Asatoolofbuilt-inPLCsystemsoftwaretype,machinetooldistributionLadderWorksPLCsoftwareneedsspeciallyconfiguredwhenexternalI/OcommunicationmoduletoachievePLCcommunicatewithoutsideoftheactuator.ThisdesignUSEStheBECKHOFFcompanyEL1004asasignalinputmodule,EL2889asasignalinputmodule.

FinallythisstudywilldesigntheautomatictoolchangethePLCprogramandthemacroprogramapplicationinYY-1060machiningcenter,verifytheaccuracyandreliabilityoftheprogram.Opensystem,inmanualprogrammingmodel(MDI)underthedispatch1tooltotoolchangeposition,initializationoftoollibrary,thenselectuseTcommandspecifiedwithinthescopeofthecuttingtool.Verifiedthesystemautomaticallycalculatestheshortesttoollibraryrotatingpathmethodasshownintable1.Table1KnifelibraryrotatingpathiscalculatedWhenthespecifiedtargettool,beyondthecuttingtool,thesystemerror.Aftermanydebugging,completetheclosestcutterreplacement(libraryrotatingatool)need4s,thefarthestdistanceintool(libraryrotating12knife)need6s.Experimentalresultsshowthatthedesignedsysteminourstudyrandomlychoosetoolaccuratetoolchangeprocess,nodisorderlyknifephenomenon,toolchangemotionstability,canwellsatisfytheprocessingcenterautomatictoolchangerofquickness,accuracyandstabilityrequirements.ConclusionComparedwiththetraditionalautomatictoolchangecontrolsystem,basedonthetechnologyofServoWorksLadderWorksPLCbuilt-insoftwaretype,withautomatictoolchangededicatedcontrolinstruction,greatlysimplifiestheprogrammingofncmachiningcentertoolchangesystemandmaintenancedifficulty.Atthesametime,thetechnologyandCNCtechnologycanquicklyandaccuratelyfinishthetoolchangeprocess.WiththedevelopmentofpuresoftwareCNCtechnology,thecontrolmethodwillbewidelyused.References[1]ZhanShuLiu.Machiningcenterstructure,maintenanceanddebugging[M].Beijing:ChinaMachinePress,2003.[2]ChangJiDeng,GuanLianJiang.BasedonthePLCautomaticallychooseknifeknifeapplicationanddevelopment[J].Journalofcombinationmachinetoolsandautomaticprocessingtechnology,2010(6):53-56.[3]GUjian,NIUYun-yan.ResearchontheStructureandPLCControlofaNewAutomaticToolChanger[C]//2011InternationalConferenceonConsumerElectronics,CommunicationsandNetworks.United[4]ZHANGLian-zhong,WANGLI.MachiningCenterAutomaticATCAnalysisandResearh[C]//3rdInternationalConferenceonIndustrialEngineering.UnitedStates;IEEEComputerSociety,2010;355-358.[5]Mitsubishi.CNCEZMotion-NCE60PLCprogrammingManual[Z].Mitsubishi,2002.[6]YinLi.Puresoftwareofopennumericalcontrolsystemresearchandreferenceonthemachiningcenter[D].Xiamen:xiamenuniversityschoolofphysicalandmechanicalandelectrical,2009.[7]DENGChang-qi,LIBin.TheApplicationandDevelopmentofAutomaticToolSelectioninToolMagazinebasedonPLC[C]//2010InternationalConferenceonManufacturingEngineeringandAutomation,ICMEA2010.Germany:TransTechPublications,2010:1959-1962.[8]SofeServoSystemINC.ServoWorksCNCLadderWorksPLCUser’sManual[Z].SoftServoSystemInc,2006.機(jī)械，2011，12（04）數(shù)控加工中心自動換刀系統(tǒng)的研究鄭新武，章明眾，李春木，李寅，陳永明（廈門大學(xué)機(jī)電工程系，福建廈門361005）摘要：自動換刀系統(tǒng)（ATC）包括刀庫機(jī)構(gòu)、換刀機(jī)構(gòu)以及控制系統(tǒng)3個(gè)部分，是加工中心的重要組件之一。為了解決數(shù)控加工中心自動換刀速度慢、穩(wěn)定性低及控制系統(tǒng)編程復(fù)雜等問題，將一種軟件式內(nèi)置PLC技術(shù)應(yīng)用于自動換刀系統(tǒng)中。在分析自動換刀系統(tǒng)的基本結(jié)構(gòu)、工作原理以及研究圓盤刀臂式自動換刀系統(tǒng)的控制流程的基礎(chǔ)上，結(jié)合ServoWorksCNC技術(shù)，開發(fā)了適用于各種自動換刀機(jī)構(gòu)的PLC程序以及宏程序。最后，將所開發(fā)的控制系統(tǒng)應(yīng)用于YY-1060立式加工中心，其在4s-6s內(nèi)可完成整個(gè)換刀過程。研究結(jié)果表明，換刀過程快捷、準(zhǔn)確、可靠，完全能夠滿足使用的要求。關(guān)鍵詞：加工中心；自動換刀；可編程邏輯控制器1.引言利用刀庫(MAG)實(shí)現(xiàn)自動換刀是目前加工中心大量使用的換刀方式,獨(dú)立的刀庫大大增加了刀具的存儲數(shù)量,有利于擴(kuò)大機(jī)床的功能,并能較好地隔離各種影響加工精度因素的干擾。加工中心的常用刀庫類型有：盤式刀庫和鏈?zhǔn)降稁?。刀庫換刀方式按照換刀過程有無機(jī)械手參與，分成有機(jī)械手換刀和無機(jī)械手換刀。本研究以YY-1060立式加工中心裝備的DEX-A402盤式刀庫有機(jī)械手自動換刀機(jī)構(gòu)為對象，對自動換刀系統(tǒng)(ATC)進(jìn)行研究。可編程控制器（PLC）是自動換刀系統(tǒng)的核心部分。目前，國內(nèi)對自動換刀機(jī)構(gòu)的控制多采用傳統(tǒng)PLC（簡稱硬PLC）及單片機(jī)，如三菱FX系列的PLC控制、西門子S7-200系列PLC、AT98C51單片機(jī)。硬PLC控制方法沒有專用的選刀指令，需要編寫復(fù)雜的選刀PLC程序，同時(shí)無法通過宏程序簡化數(shù)控編程過程；采單片機(jī)控制電路搭建復(fù)雜，系統(tǒng)穩(wěn)定性較低，編程復(fù)雜。本研究采用的LadderWorks是一種基于ServoWorks技術(shù)的軟件式內(nèi)置PLC系統(tǒng)，可與CNC之間進(jìn)行內(nèi)部的信號的快速傳輸。2.庫的結(jié)構(gòu)及換刀動作自動換刀機(jī)構(gòu)主要構(gòu)成包括：刀臂電機(jī)、凸輪、刀臂、刀庫電機(jī)、刀杯、剎車、松夾刀、原點(diǎn)訊號輪等。DEX-A402自動換刀機(jī)構(gòu)如圖1所示。圖1自動換刀機(jī)構(gòu)圖2刀臂動作刀臂動作由步進(jìn)電機(jī)驅(qū)動，換刀動作分4各步驟完成。刀臂電機(jī)單方向旋轉(zhuǎn)，通過自動換刀機(jī)構(gòu)中的凸輪機(jī)構(gòu)控制刀臂的正反轉(zhuǎn)，該驅(qū)動方式提高了刀臂旋轉(zhuǎn)角度的精度，同時(shí)簡化了電機(jī)的控制。刀臂運(yùn)動的具體流程如圖2所示。3.換刀指令數(shù)控編程通過T指令、M指令完成自動換刀動作，換刀指令經(jīng)系統(tǒng)內(nèi)部譯碼，將目標(biāo)刀號、宏指令號譯為相對應(yīng)的二進(jìn)制數(shù)保存到系統(tǒng)指定的寄存器。ServoWorksPLC系統(tǒng)中T指令譯碼到F26，M指令譯碼到F10，用戶可根據(jù)換刀動作要求編寫宏程序以及PLC程序。T指令指定目標(biāo)刀號，完成刀庫選刀、刀庫旋轉(zhuǎn)方向的判斷以及旋轉(zhuǎn)步距的確定；M指令指定宏程序號，根據(jù)換刀要求完成主軸回零，Z軸回?fù)Q刀點(diǎn)，刀臂旋轉(zhuǎn)方向、位置以及刀杯上下等動作。3.1刀具的選擇（T指令）刀具的選擇是把刀庫上指定的刀具轉(zhuǎn)到換刀位置，該動作由T功能指令實(shí)現(xiàn)。自動換刀系統(tǒng)（ATC）根據(jù)來自刀庫的位置信息和T指令，按照給出的命令，控制系統(tǒng)決定刀庫的旋轉(zhuǎn)方向、要求的步數(shù)等，通?？刹捎糜洃浤Ｊ诫S機(jī)控制和機(jī)械隨機(jī)控制兩種方式。機(jī)械隨機(jī)控制每把刀對應(yīng)各自的刀套，通常在主軸和刀庫之間，以“中間刀套”提供換刀。相比而言，記憶模式隨機(jī)控制采用指針方式，指針指出了刀庫旋轉(zhuǎn)的位置，每把刀具和刀套不總是一一對應(yīng)，該控制方式換刀迅速、可靠。一般根據(jù)刀庫的機(jī)械結(jié)構(gòu)選擇換刀的控制方式，以下介紹一種浮動指針系統(tǒng)的換刀方式：用戶通過T指令指定刀號，系統(tǒng)譯碼后，在浮動指針指向的內(nèi)存中找到對應(yīng)刀具號，采用系統(tǒng)專用指令ROTB判斷刀庫旋轉(zhuǎn)方向及旋轉(zhuǎn)距離，刀庫旋轉(zhuǎn)到目標(biāo)刀具位置完成選刀動作，M6指令完成換刀動作，具體流程如圖3所示。圖3選刀流程圖3．2換刀指令（M指令）輔助M指令通過系統(tǒng)譯碼到PLC中R點(diǎn)（內(nèi)部繼電器），用戶根據(jù)動作要求編寫PLC程序。ATC的輔助M指令主要有：M6換刀，M19主軸定位，M86刀庫初始化等。加工中心刀庫換刀流程如圖4所示。圖4換刀流程圖ServoWorksCNC可以根據(jù)用戶的需求自定義G/M/S/T宏調(diào)用簡化數(shù)控編程，常用機(jī)床運(yùn)動程序可集成到一個(gè)指令中，如使用M06完成整個(gè)換刀動作。宏程序可以同名調(diào)用輔助M指令。系統(tǒng)內(nèi)部指定存儲單元分類儲存移動指令，如G00、G01、G02G03等指令存儲在系統(tǒng)變量#4001。宏指令調(diào)用方法如下：O9001G40G80#510=#4001#511=#4001#512=#4003#513=#1032AND256#514=#BIN[#513]（IF[#512EQ#514]GOTON1000）G90G30Z0M19M6G#510G#511N1000M994.PLC程序開發(fā)自動換刀PLC程序主要包括刀庫選刀程序及刀臂換倒程序。ServoWorksPLC程序的地址有：機(jī)床到PLC的輸入信號（X），PLC到機(jī)床的輸入信號（Y），CNC引擎到PLC引擎的信號（F），PLC引擎到CNC引擎的信號（G），中間繼電器（R），計(jì)數(shù)器（C），計(jì)時(shí)器（T）等。下面通過PLC的R點(diǎn)描述換刀動作。4.1刀庫選刀PLC的程序基于LadderWorksPLC的自動換刀指令（如圖3所示）主要有：刀具號搜索指令DSCH、旋轉(zhuǎn)方向和距離計(jì)算指令ROTB、刀庫旋轉(zhuǎn)刀位計(jì)數(shù)