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多功能組合機(jī)床時(shí)代摘要:組合機(jī)床加工中心可使加工制造業(yè)適應(yīng)不斷變化的需求,有效利用勞動力資源,并在全球范圍的市場上更具競爭力。關(guān)鍵字:組合機(jī)床對于多功能組合機(jī)床,工業(yè)領(lǐng)域內(nèi)有很多稱呼來形容它,如“多任務(wù)處理裝置”、“多功能機(jī)床”、“多程序生產(chǎn)系統(tǒng)”等,它確實(shí)可稱為加工領(lǐng)域的新星,可降低成本,簡化配置,并一直保持在美國本土生產(chǎn)。過去只有使用多機(jī)操作才能完成的任務(wù),現(xiàn)在可以集中到一臺機(jī)床上加工完成。由于市場需求的不斷變化,產(chǎn)品的生命周期在不斷縮短,今天的市場更加強(qiáng)烈需求多任務(wù)處理裝置概念。在整個(gè)生產(chǎn)環(huán)境中推行精益管理時(shí),沒有比把零件加工集中到一臺機(jī)器上完成更精一些傳統(tǒng)的制造業(yè)廠商認(rèn)為多功能組合機(jī)床過于復(fù)雜,很難找到合適的操作人員也就不足為奇了。在一些勞動力市場,要找到能夠?qū)Χ噍S組合機(jī)床加工中心進(jìn)行手工編程的人是不太可能的事。但資料顯示,解決方案可有兩個(gè),一個(gè)是現(xiàn)代多功能組合機(jī)床的直覺式技術(shù),另一個(gè)是針對金屬加工基本原理及在生產(chǎn)車間現(xiàn)場有關(guān)新機(jī)床使用中難題創(chuàng)新解決方面的培訓(xùn)。直覺式技術(shù)控制設(shè)備采用“帶走熱量”式設(shè)計(jì),有床身、鋼制直線滾動導(dǎo)軌、鋼制轉(zhuǎn)塔刀架、設(shè)備上使用的不同材料,所有這些組合到一起建造成一臺機(jī)床。這些都與導(dǎo)熱系數(shù)、體積膨脹相關(guān)。所有不同尺寸的東西都會以不同的速度生長。由于這個(gè)原因,需要制造熱友好機(jī)床,以便知道發(fā)熱的薄弱點(diǎn)在哪里,可以通過合理的機(jī)床設(shè)計(jì)來補(bǔ)償。元件是全程運(yùn)動。機(jī)床滑動產(chǎn)生摩擦并轉(zhuǎn)化為熱。切削加工產(chǎn)生的熱屑掉到不同地方,在整個(gè)過程中冷卻液會混合在其中。在切削刀具上會持續(xù)出現(xiàn)很多不同的溫度區(qū)域,所以也會有很多東西對熱穩(wěn)定性產(chǎn)生影響。切削刀具技術(shù)把多功能組合機(jī)床變成了具備銑削和切削能力的“全能機(jī)器”。據(jù)資料介紹,最顯著的特點(diǎn)是這些機(jī)床整體上更具直覺性。防撞保護(hù)技術(shù)已經(jīng)非常成熟,在某些情況下,即使采用手動操作模式,也能避免碰撞的發(fā)生。由于控制軟件有很好的直覺性,用戶操作友好程度也在不斷提高。相信多功能組合機(jī)床會以其生存能力遍布于更多不同的加工現(xiàn)場。離線編程優(yōu)化和NC自動控制系統(tǒng)的形成已經(jīng)使這一技術(shù)更容易接受,因此當(dāng)將程序用在機(jī)床上時(shí),不必花很多時(shí)間去調(diào)整程序和確認(rèn)某一元件沒有問題。如果一個(gè)零件需要配備上下兩個(gè)轉(zhuǎn)塔刀架同時(shí)進(jìn)行粗加工,這種情況下編程是比較困難的,因?yàn)樗枰獌蓚€(gè)轉(zhuǎn)塔刀架同時(shí)進(jìn)刀。AdMac系統(tǒng)可以實(shí)現(xiàn)對這些同時(shí)進(jìn)刀的刀架的自動編程,并能使正確的主軸速度、正確的進(jìn)給速度等所有參數(shù)實(shí)現(xiàn)同步。Okuma公司的防撞系統(tǒng)設(shè)計(jì)基于實(shí)際加工工況的防撞模擬,因此,如果操作者安裝了錯(cuò)誤的刀具或設(shè)定了錯(cuò)誤的參數(shù),控制系統(tǒng)會檢測出來并阻止機(jī)床進(jìn)入加工狀態(tài),通過與西門子公司合作,INDEX公司現(xiàn)在可以提供3D模式的“虛擬機(jī)床”,按照某一特定型號的機(jī)床定制。結(jié)果表明,模擬加工出來的成品零件不只是與實(shí)際成品相似,簡直就是一對一的拷貝。直覺式控制界面、模擬以及其他軟件技術(shù)進(jìn)步,更多的生產(chǎn)車間向多功能組合機(jī)床敞開了大門,但如果沒有相應(yīng)的知識培訓(xùn)和解決問題的創(chuàng)造力,制造商也很難體會到和充分利用先進(jìn)機(jī)床柔順性方面的優(yōu)勢。對機(jī)器所做的工作越多,機(jī)器就會越復(fù)雜,也相應(yīng)地需要具備更強(qiáng)技能的人才能操縱它。假如一個(gè)機(jī)械師過去一天操作3臺機(jī)床,那么現(xiàn)在他有這樣一臺多功能的機(jī)床,就可以生產(chǎn)出更多的零件。更為重要的是,他可以借助軟件的幫助使生產(chǎn)效率更高,對于轉(zhuǎn)換加工零件的準(zhǔn)備,也可以編制加工工藝計(jì)劃。因?yàn)楦鼡Q零件需要降下3個(gè)主軸,因此在更換零件之前,車間應(yīng)加工盡可能多的零件。對于多功能機(jī)床,轉(zhuǎn)換零件速度非??欤a(chǎn)批次間隔時(shí)間更短,庫存更低,生產(chǎn)效率更高。能夠充分利用多功能機(jī)床的一些車間,很快就會發(fā)現(xiàn)崗位功能的統(tǒng)一。現(xiàn)在,一個(gè)車間可以只用一個(gè)操作人員、一個(gè)調(diào)整工和一個(gè)編程師,將來這3項(xiàng)工作完全可以由一個(gè)人來做。傳統(tǒng)崗位描述中機(jī)械師將過渡成為一個(gè)調(diào)整工程師,如果該工程師還熟悉零件加工編程,那就更理想了。對于這樣的轉(zhuǎn)換,培訓(xùn)就比較簡單了,只要培訓(xùn)1個(gè)人就行,而不是3個(gè)人。從長遠(yuǎn)觀點(diǎn)看,這將提供給人們更高的崗位滿意度。當(dāng)調(diào)整工程師負(fù)責(zé)加工編程并且親自關(guān)注零件加工的整個(gè)過程時(shí),他就完全成了這個(gè)零件的主宰者。除此之外,還應(yīng)該在刀具選擇和編程方面做更多的努力,要使任何型號的多功能組合機(jī)床都成功,車間需要配備熟練的機(jī)械師,有能力并靈活地完成多種操作。因此,橫向培訓(xùn)比過去任何時(shí)候都重要了。把銑削和車削加工視為不同學(xué)科的觀點(diǎn)一去不復(fù)返了。對于編程人員來說,這是屬于他們的時(shí)代。對于會編程的人員,懂機(jī)床并控制它,這是他們能力的體現(xiàn)。刀具選擇大多數(shù)人不會將轎車輪胎裝到跑車上,但加工刀具就發(fā)生了這樣的情況。刀具應(yīng)與新機(jī)床相匹配,可以想像在新機(jī)床上重復(fù)使用舊刀具對生產(chǎn)效率的影響。為匹配多功能組合機(jī)床,新刀具和刀具適配器技術(shù)已經(jīng)被開發(fā)出來。目前工業(yè)領(lǐng)域正在研制開發(fā)的加工刀具,可以在同一刀架上完成車削、鏜削和鉆削加工,只是加工時(shí)相對于工件的角度有所不同而已。加工操作上的差別甚至都混淆不清了。新的加工刀具可以完成銑削和車削。動化技術(shù)(機(jī)床)是本世紀(jì)以來發(fā)展極迅速和影響極大的科學(xué)技術(shù)之一?,F(xiàn)代自動化技術(shù)是一種完全新型的生產(chǎn)力,是直接創(chuàng)造社會財(cái)富的主要手段之一,對人類的生產(chǎn)活動和物質(zhì)文明起著極大的推動作用。因此,自動化技術(shù)受到世界各國的廣泛重視和越來越多的應(yīng)用。

機(jī)械自動化(機(jī)床),主要指在機(jī)械制造業(yè)中應(yīng)用自動化技術(shù),實(shí)現(xiàn)加工對象的連續(xù)自動生產(chǎn),實(shí)現(xiàn)優(yōu)化有效的自動生產(chǎn)過程,加快生產(chǎn)投入物的加工變換和流動速度。機(jī)械自動化技術(shù)的應(yīng)用與發(fā)展,是機(jī)械制造業(yè)技術(shù)改造、技術(shù)進(jìn)步的主要手段和技術(shù)發(fā)展的主要方向。機(jī)械自動化的技術(shù)水準(zhǔn),不僅影響整個(gè)機(jī)械制造業(yè)的發(fā)展,而且對國民經(jīng)濟(jì)各部門的技術(shù)進(jìn)步有很大的直接影響。因此,發(fā)展我國的機(jī)械制造業(yè)自動化技術(shù),符合我國社會主義的基本原則,符合我國現(xiàn)代生產(chǎn)的發(fā)展規(guī)律。

如何發(fā)展我國的機(jī)械自動化技術(shù)(機(jī)床),這里有個(gè)技術(shù)政策問題,應(yīng)實(shí)事求是,一切從我國的具體國情出發(fā),做好各項(xiàng)基礎(chǔ)工作,走中國的機(jī)械自動化技術(shù)發(fā)展之路。

國內(nèi)外的工業(yè)發(fā)展史告訴我們,實(shí)現(xiàn)機(jī)械自動化是一個(gè)由低級到高級、由簡單到復(fù)雜、由不完善到完善的發(fā)展過程。當(dāng)機(jī)器的操作采用自動控制器后,生產(chǎn)方式才從機(jī)械化逐步過渡到機(jī)械控制(傳統(tǒng))自動化、數(shù)字控制自動化、計(jì)算機(jī)控制自動化。只有建立了自動化工廠后,生產(chǎn)過程才能全盤自動化,才能使生產(chǎn)率全面提高,達(dá)到自動化的高級理想階段。

機(jī)械自動化技術(shù)從本世紀(jì)20年代首先在機(jī)械制造冷加工大批量生產(chǎn)過程中開始發(fā)展應(yīng)用,60年代后為適應(yīng)市場的需求和變化,為增強(qiáng)機(jī)械制造業(yè)對市場靈活快速反應(yīng)的能力,開始建立可變性自動化生產(chǎn)系統(tǒng),即圍繞計(jì)算機(jī)技術(shù)的柔性自動化。它是在制造系統(tǒng)不變或變化較小的情況下,機(jī)器設(shè)備或生產(chǎn)管理過程通過自動檢測、信息處理、分析判斷自動地實(shí)現(xiàn)預(yù)期的操作或某種過程,并能夠自動地從制造一種零件轉(zhuǎn)換到制造另一種不同的零件。社會實(shí)踐證明,這種定義下的制造系統(tǒng)自動化與當(dāng)代大多數(shù)企業(yè)的實(shí)際不相容。當(dāng)代社會還沒有在科學(xué)技術(shù)、物質(zhì)和人員方面準(zhǔn)備好實(shí)現(xiàn)這一自動化的條件,硬要這么做只會事倍功半。這種情況對于離散生產(chǎn)方式的機(jī)械制造業(yè)也不例外,難度會更大些。80年代國際上出現(xiàn)了開始采用計(jì)算機(jī)集成制造系統(tǒng)CIMS(ComputerIntegratedManufacturing),柔性自動化生產(chǎn)模式也有這種情況。初期犆犐犕犛以信息集成為重點(diǎn),以較高的自動化程度為特征,但在實(shí)現(xiàn)過程中遇到了困難。鑒于實(shí)現(xiàn)計(jì)算機(jī)集成制造系統(tǒng)的全盤自動化所需的巨額投入(一個(gè)全盤自動化工廠耗資數(shù)百億美元,柔性制造系統(tǒng)一般價(jià)格為600~2500萬美元),所承擔(dān)的巨大風(fēng)險(xiǎn),加之技術(shù)上的難度與可靠性等問題,世界工業(yè)發(fā)達(dá)國家已開始“碰壁轉(zhuǎn)產(chǎn)”,轉(zhuǎn)而注重信息集成的效果,追求低成本自動化LCA(LowCostAutomation)的企業(yè)組織結(jié)構(gòu)和運(yùn)行方式。組合機(jī)床未來的發(fā)展將更多地使用調(diào)速電動機(jī)和滾珠絲杠等傳動,以簡化結(jié)構(gòu)、縮短生產(chǎn)節(jié)拍;采用數(shù)字控制系統(tǒng)和主軸箱、夾具自動更換系統(tǒng),以提高工藝可調(diào)性。Multi-purposeaggregatemachine-tooltimeSummary:Theaggregatemachine-toolmachiningcentermaycausethedemandwhichtheprocessingmanufacturingindustryadaptschangesunceasingly,usesthepooloflaborpowereffectively,andhasthecompetitivepoweringlobalscale'smarket.Keyword:MakethelatheupRegardingthemulti-purposeaggregatemachine-tools,intheindustrialfieldhasmanynamestodescribeit,like“themultitaskinginstallment”,“themulti-purposeenginebeds”,“themulti-procedureproductionsystem”andsoon,itmaybecalledtheprocessingdomaintrulythenova,mayreducethecost,thesimplifieddisposition,andhasmaintainedintheUSterritoryproduces.Inthepastonlythenusedthedutywhichmanymachineoperationscouldcomplete,nowmayconcentratetoanenginebedonprocessescompletes.Asaresultofmarketdemand'sunceasingchange,theproductlifecycleisreducingunceasingly,today'smarketmoreintensedemandmultitaskinginstallmentconcept.Carriesoutthefineprofitmanagementwhentheentireproductionenvironment,comparedtohavingnotconcentratedthecomponentsprocessingtoamachineoncompletesafinerprofit.Sometradition'smanufacturingindustrymanufacturerthoughtthatthemulti-purposeaggregatemachine-toolsaretoocomplex,verydifficulttofindtheappropriateoperatorsalsothedifficultprobleminnovatesonthespotontheinsufficiencyforthemetalworkingbasicprincipleandintheProductionworkshoprelatednewenginebedusesolutionaspecttraining.IntuitiontypetechnicalcontrolTheequipmentuse“carriesoffthequantityofheat”thetypedesign,hasdifferentmaterialwhichthelathebed,thesteelinessstraightlinerollingguide,onthesteelinessrevolvingtoolboxsaddle,theequipmentuses,allthesecombinemakeanenginebedtogether.Thesewiththethermalconductivity,thevolumeexpansionarerelated.Alldifferentsize'sthingcanbythedifferentspeedgrowth.Asaresultofthisreason,needstomakethehotfriendlyenginebed,withtheaimofknowinggivesoffheattheweakpointinwhere,cancompensatethroughthereasonableenginebeddesign.Thepartistheentirejourneymovement.Theenginebedglideproducesrubsandtransformhotly.Themachiningproducesthehotfilingsfalltothedifferentplace,therefrigerantcanmixintheentireprocessinwhich.Willpresentthedifferenttemperatureprovincecontinuallyonthecuttingtool,willthereforealsohavemanythingstohavetheinfluencetothethermostability.Thecuttingtooltechnologyturnedthemulti-purposeaggregatemachine-toolshashadthemillingandcuttingpower“theversatilemachine”.Accordingtothematerialintroducedthatthemostremarkablecharacteristicisintheseenginebedwholehastheintuition.Theanti-collisionpreservationtechnologywasalreadymature,incertaincircumstances,evenifusesthemanualoperationpattern,canalsoavoidtheoccurrencewhichcollides.Becausethecontrolsoftwarehastheverygoodintuition,theuseroperationfriendlydegreeunceasinglyisalsoenhancing.Believethemulti-purposeaggregatemachine-toolsbyitssurvivabilityworld-wideinthemoredifferentprocessingscenes.Theoff-lineprogrammingoptimizationandtheNCautomaticcontrolsystem'sformationalreadymadethistechnologytobeeasiertoaccept,whenthereforeusestheprocedurewhentheenginebed,doesnotneedtospendmanytimetune-upprocedureandconfirmedthatsomepartdoesnothavethequestion.Ifcomponentsneedtoprovidethehighandlowtworevolvingtoolboxsaddlesimultaneouslytocarryontheroughmachining,inthiskindofsituationtheprogrammingisquitedifficult,becauseitneedstworevolvingtoolboxsaddlesalsotofeed.TheAdMacsystemmayrealizetoolrest'sautomaticprogrammingwhichsimultaneouslyfeedstothese,andcancausethecorrectmainaxlespeed,thecorrectfeedrateandsoonallparameterstorealizethesynchronization.OkumaCorporation'scollisionavoidancesystemdesignbasedonactualprocessingoperatingmodeanti-collisionsimulation,therefore,iftheoperatorhasinstalledthewrongcuttingtoolorhasestablishedthewrongparameter,thecontrolsystemwillexamineandpreventstheenginebedtoentertheprocessingcondition.ThroughcooperateswiththeSiemens,INDEXCorporationmayprovidethe3Dpatternnow“thehypothesizedenginebed”,hascustom-madeaccordingtosomespecificmodel'senginebed.Theresultindicatedthatthesimulationprocessesnotonlythefabricatedpartsandtheactualendproductissimilar,istheone-to-onecopysimply.Theintuitiontypecontrolinterface,thesimulationaswellasothersoftwaretechniqueareprogressive,themoreProductionworkshopshaveopenedwidethefrontdoortothemulti-purposeaggregatemachine-tools,butifdoesnothavethecorrespondingknowledgetotrainandtosolvethequestioncreativity,themanufacturerisalsoverydifficulttorealizeandthefulluseadvancedenginebedflexibilityaspectsuperiority.Theworkwhichdoestothemachinearemore,themachinewillbemorecomplex,alsoneedstohavethestrongerskillpersoncorrespondinglytobeabletooperateit.Ifmachinistpastonedayoperated3enginebeds,thenhehasthiskindofmulti-purposeenginebednow,mightproducemorecomponents.Moreimportantly,hemaydrawsupportfromsoftware'shelptocausetheproductionefficiencytobehigher,regardingtransformationprocessingcomponentspreparation,mayalsoestablishtheprocessingcraftplan.Becausethereplacementcomponentsneedtolower3mainaxles,thereforebeforereplacingthecomponents,theworkshopshouldprocessasfaraspossiblemanycomponents.Regardingthemulti-purposeenginebeds,thetransformationcomponentsspeedisquick,theproductionbatchoftimeintervalisshorter,thestockislower,theproductionefficiencyishigher.Canusemulti-purposeenginebed'ssomeworkshopsfully,veryquickwilldiscoverthepostfunctiontheunification.Now,aworkshopmayonlyuseanoperator,anadjusterandaprogrammingteacher,inthefuturethese3workdefinitelymaydobyaperson.Inthetraditionalpostdescriptionthemachinistwilltransitbecomesonetoadjustengineer,ifthisengineerthefamiliarcomponentsprocessingprogramming,thatwerealsomoreideal.Regardingsuchtransformation,traininghasbeensimple,solongastrains1individualline,butisnot3individuals.Lookingfromthelongviews,thiswillprovidetothepeoplethehigherpostdegreeofsatisfaction.Whenadjustsengineertoberesponsibletoprocesstheprogramming,andpaysattentiontothecomponentsprocessingpersonallytimetheentireprocess,hecompletelyhasbecomethiscomponentscontrol.Inaddition,butshouldalsomakesmoreeffortinthecuttingtoolchoiceandtheprogrammingaspect,mustmakeanymodelthemulti-purposeaggregatemachine-tooltosucceed,theworkshopneedstoprovidetheskilledmachinist,hasabilityandcompletesmanykindsofoperationsnimbly.Therefore,crosswisetrainingwasatanytimeinthepastmoreimportant.Regardedasthemillingandthelatheworkthedifferentdisciplinetheviewpointnevertoreturn.Regardingtheprogrammers,thisbelongstotheirtime.Regardingpersonnelwhowillprogram,willunderstandtheenginebedandcontrolsit,thiswillbetheirabilitymanifestation.Thecuttingtoolwillchoosemostpeoplenottoinstallthepassengervehicletiretotheracecaron,butprocessedthecuttingtooltohavesuchsituation.Thecuttingtoolshouldmatchwiththenewenginebed,isconceivablyredundantonthenewenginebedusestheoldcuttingtooltotheproductionefficiencyinfluence.Inordertomatchthemulti-purposeaggregatemachine-tools,thenewcuttingtoolandthecuttingtooladaptertechnologywasalreadydeveloped.Atpresenttheindustrialfieldisdevelopingthedevelopmenttheprocessingcuttingtool,maycompletetheturningontheidenticaltoolrest,boringanddrillstruncatestheprocessing,isonlyprocessesthephasetodifferfromregardingtheworkpieceangle.Theprocessingoperatesthedifferenceevenconfusesisunclear.Thenewprocessingcuttingtoolmaycompletethemillingandtheturning.Sincehasmovedthetechnology(enginebed)isthiscenturydevelopsisextremelyrapidandoneofinfluenceenormousscienceandtechnology.Themodernautomationtechnologyisonekindofcompletelynewproductiveforces,isoneofdirectcreationpublicwealthprincipalmeansthatisplayingtheenormouspromotioneffecttohumanity'sproductionactivityandthematerialcivilization.Therefore,theautomatedtechnologyreceivesvariouscountrieswidelytotakeseriouslywithmoreandmoreapplications.Themachineryautomation(enginebed),mainlyreferstothemachine-buildingindustryappliestheautomatedtechnology,realizestheprocessingobjectcontinuouslytheautomaticproduction,realizestheoptimizedeffectiveautomaticproductionprocess,theincreaseproductioninvestmentprocessingtransformationandtheflowrate.Themachineryautomationtechnology'sapplicationandthedevelopment,arethemachine-buildingindustrytechnologicaltransformations,thetechnologyadvancementprincipalmeansandthetechnologicaldevelopmentmaindirection.Machineryautomationtechnicalstandards,notonlyaffectstheentiremachine-buildingindustrythedevelopment,andhastheverytremendousimmediateinfluencetothenationaleconomyvariousdepartments'technologyadvancement.Therefore,developsourcountry'smachine-buildingindustryautomationtechnology,conformstoourcountrysocialismbasicprinciple,conformstoourcountrymodernproductionlawofdevelopment.Howtodevelopourcountry'smachineryautomationtechnology(enginebed),herehasthetechnicalpolicyquestion,shouldberealistic,allembarkfromourcountry'sconcretenationalcondition,doeachfoundationwork,takestheChina'sroadofmachineryautomationtechnologicaldevelopment.Thedomesticandforeignindustryhistorytellsus,realizesthemachineryautomationisfromtohigh-level,fromsimplytocomplex,fromispreliminarilyimperfecttheconsummationthedevelopingprocess.Aftermachine'soperationusestheautomaticregulator,theproductionmethodonlythengraduallytransitsfromthemechanizationtothemechanismcontrol(tradition)automated,thenumericalcontrolautomation,thecomputercontrolautomation.OnlythenafterhavingestablishedtheAutomatedfactory,theproductionprocesscanoverallautomate,canmaketheproductivitytoenhancecomprehensively,achievesautomatedthehigh-levelidealstage.Themachineryautomationtechnologyfirststartsfromthe1920sinthemachinemanufacturecoldfinishingproductioninenormousquantitiesprocesstodeveloptheapplication,afterinthe60s,toadaptthemarketdemandandthechange,fortheenhancementmachine-buildingindustrytothemarketnimblerapidreaction'sability,startstoestablishthevariableautomationproductionsystem,namelyrevolvesthecomputertechnologytheflexibleautomation.Itisinthemanufacturesysteminvariableorinthechangesmallsituation,themachineryequipmenteitherproductionmanagementprocessthroughtheautomaticdetection,theinformationprocessing,theanalysisjudgmentrealizestheanticipatedoperationorsomekindofprocessautomatically,andcanfrommakeonekindofcomponentstotransformautomaticallytomakesanotherkindofdifferentcomponents.Thesocialpracticeprovedthatunderthiskindofdefinition'smanufacturesystemautomationandthecontemporarymajorityenterprisesarenotactuallyaccommodating.Thecontemporarysocietyalsonotinthescienceandtechnology,thematerial

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