数控淬火机床恒线速度控制系统设计
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摘要
随着感应加热技术的应用,数控感应淬火机床已经系列化。传统的数控感应淬火机床是一种零件配一种感应器,生产效率低下。近些年,随着通用数控感应淬火机床的发展,虽然可以在一台机床上对性能要求不同的零件进行感应加热淬火,降低了成本,提高了效率,但是通用淬火机床在加工零件时存在问题是:它对零件每个部分加热时间不等,因此造成各部分温度不同,使淬火效果不理想。本文在使用通用感应器的前提下,提出了一种恒线速度控制的方法,很好地解决了由于工件各处加热时间不等而造成的缺陷,提高了淬火质量。
本文的研究内容可分为三部分:平面盘型凸轮轮廓曲线的研究与仿真;硬件系统的搭建与调试;控制程序的编写与调试。在对盘型凸轮轮廓曲线的研究中,首先以直动滚子从动件盘型凸轮为研究对象,对典型的盘型凸轮轮廓曲线的数学模型进行了研究和编程仿真;然后建立了任意盘型凸轮轮廓曲线的数学模型,提出了一种新的解决任意盘型凸轮轮廓曲线的方法,充分分析了其中的误差影响,获得了描述任意盘型凸轮轮廓曲线的方法,实现了在任意形状曲线上的恒线速度控制。在硬件系统的搭建与调试中,简单说明了运动控制芯片MCX314在数控系统应用中的优势,介绍了运动控制卡MC6212P的功能和技术指标,设计了电气控制系统,依据运动控制卡的要求设计了板卡接口,并给出了相应的原理图。控制程序的编写主要是对运动控制卡MC6212P进行基于典型的盘型凸轮轮廓曲线恒线速度任务的软件二次开发;设计了数控系统的人机交互界面;描述了Matlab与VB的无缝链接方法,进行了软件代码设计及软硬件的调试;最后对系统的恒线速度控制进行了实验验证,分析了其中产生误差的主要原因,保证了系统的可靠性。
本课题通过理论分析和实验验证,使用通用感应器解决了数控感应淬火恒线速度控制难题,同时提出并解决了任意盘型凸轮轮廓曲线的程式化,为获得复杂的凸轮轮廓曲线打下了坚实的理论基础。
Along with the application of the induction heating technology, CNC Induction Hardening Machine has been serialized. The traditional induction hardening CNC machine is a kind of parts with a sensor and the efficiency is lower. In recent years, with the development of numerical control machine induction hardening, different required performance of spare parts can be heated in a same machine and reduce the cost and improve the efficiency. However, using generic quenching machine tool have a problem is: for every part of its components, the heating time is different and so the spare parts temperature is different and quenching effect is not ideal. Based on using the general sensors, this paper puts forward a constant speed control method to solve the defects which caused by the heating time is unequaled and improve the quality of quenching.
This research contents can be divided into three parts: researching and simulating of the plane disc cam outline curve. Building and debugging of the hardware system. The compilation and debugging of the control process. First of all, take the straight moving roller follower disc cam as the research object. Having a study and simulation of the mathematical model which of typical disc cam contour curve. Second, setting up mathematical model of any disk cam of the contour curve. Bring a new kind of solving random disc cam contour curve method forward. Analyzes the effect of error and get a method to describe the cam contour curve arbitrarily plate type, and realized the controlling of the curving shape at any constant speed. In the hardware system construction and commissioning, briefly describe the advantages of CNC applications of the motion control chip MCX314 and introduces the function and technical indexes of movement control cards MC6212P. Based on motion control card board, we Design the electrical control system and the request interface and the corresponding schematic. Control program is mainly based on MC6212P movement control cards of the disc cam contour curve constant speed of software development. Designed the interactive interface of CNC system, describing the seamless way of Matlab and VB, and Writing the software code and debugging the hardware system. Finally, analyzed the main reasons of the errors to ensure the reliability of the system and the constant linear speed control system was experimentally verified.
Through theoretical analysis and experimental verification, this subject solved the constant linear induction hardening control technology which using the general sensors. At the same time, putting forward and solving any disk-type cam profile curve programmed in order to obtain a complex cam profile curve and laid a solid the theoretical basis.
本文的研究内容可分为三部分:平面盘型凸轮轮廓曲线的研究与仿真;硬件系统的搭建与调试;控制程序的编写与调试。在对盘型凸轮轮廓曲线的研究中,首先以直动滚子从动件盘型凸轮为研究对象,对典型的盘型凸轮轮廓曲线的数学模型进行了研究和编程仿真;然后建立了任意盘型凸轮轮廓曲线的数学模型,提出了一种新的解决任意盘型凸轮轮廓曲线的方法,充分分析了其中的误差影响,获得了描述任意盘型凸轮轮廓曲线的方法,实现了在任意形状曲线上的恒线速度控制。在硬件系统的搭建与调试中,简单说明了运动控制芯片MCX314在数控系统应用中的优势,介绍了运动控制卡MC6212P的功能和技术指标,设计了电气控制系统,依据运动控制卡的要求设计了板卡接口,并给出了相应的原理图。控制程序的编写主要是对运动控制卡MC6212P进行基于典型的盘型凸轮轮廓曲线恒线速度任务的软件二次开发;设计了数控系统的人机交互界面;描述了Matlab与VB的无缝链接方法,进行了软件代码设计及软硬件的调试;最后对系统的恒线速度控制进行了实验验证,分析了其中产生误差的主要原因,保证了系统的可靠性。
本课题通过理论分析和实验验证,使用通用感应器解决了数控感应淬火恒线速度控制难题,同时提出并解决了任意盘型凸轮轮廓曲线的程式化,为获得复杂的凸轮轮廓曲线打下了坚实的理论基础。
Along with the application of the induction heating technology, CNC Induction Hardening Machine has been serialized. The traditional induction hardening CNC machine is a kind of parts with a sensor and the efficiency is lower. In recent years, with the development of numerical control machine induction hardening, different required performance of spare parts can be heated in a same machine and reduce the cost and improve the efficiency. However, using generic quenching machine tool have a problem is: for every part of its components, the heating time is different and so the spare parts temperature is different and quenching effect is not ideal. Based on using the general sensors, this paper puts forward a constant speed control method to solve the defects which caused by the heating time is unequaled and improve the quality of quenching.
This research contents can be divided into three parts: researching and simulating of the plane disc cam outline curve. Building and debugging of the hardware system. The compilation and debugging of the control process. First of all, take the straight moving roller follower disc cam as the research object. Having a study and simulation of the mathematical model which of typical disc cam contour curve. Second, setting up mathematical model of any disk cam of the contour curve. Bring a new kind of solving random disc cam contour curve method forward. Analyzes the effect of error and get a method to describe the cam contour curve arbitrarily plate type, and realized the controlling of the curving shape at any constant speed. In the hardware system construction and commissioning, briefly describe the advantages of CNC applications of the motion control chip MCX314 and introduces the function and technical indexes of movement control cards MC6212P. Based on motion control card board, we Design the electrical control system and the request interface and the corresponding schematic. Control program is mainly based on MC6212P movement control cards of the disc cam contour curve constant speed of software development. Designed the interactive interface of CNC system, describing the seamless way of Matlab and VB, and Writing the software code and debugging the hardware system. Finally, analyzed the main reasons of the errors to ensure the reliability of the system and the constant linear speed control system was experimentally verified.
Through theoretical analysis and experimental verification, this subject solved the constant linear induction hardening control technology which using the general sensors. At the same time, putting forward and solving any disk-type cam profile curve programmed in order to obtain a complex cam profile curve and laid a solid the theoretical basis.
引文
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[2]周海,曾少鹏,袁石根.感应加热淬火技术的发展及应用.2008 .29(3) .9-15.
[3]杨坤怡.制造技术.国防工业出版社, 2005.08.
[4]杜君文.机械制造技术装备与设计.天津大学出版社, 2007.10.
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[6]周凯.数控原理系统及应用.机械工业出版社,2006.03.
[7]李诚人.数控化改造.清华大学出版社, 2006.07.
[8]李勇,李伟光.机械设备数控技术.国防工业出版社, 2007.9.
[9] Chen,Jin-Rong.Jinshu High frequency induction hardening for pinion. Rechuli/Heat Treatment of Metals,2006.02.
[10] Marquis, Fabien. Induction hardening of gears offers various approaches. Heat Treating Progress,2007.07.
[11] Esteve,V. Induction heating inverter with simultaneous dual-frequency output.Conference Proceedings - IEEE Applied Power Electronics Conference and Exposition– APECs, 2006.06.
[12]杨连弟.感应淬火设备的引进与吸收.汽车工艺与材料,2006.08.
[13]董广强.非圆曲线轮廓零件数控加工的研究.煤矿机械, 2007.12.
[14] Li, Yue-Ying. Surface hardening and tribological properties of a cam materials. Jilin DaxueXuebao,2007.09.
[15]孙恒,陈作模,葛文杰.《机械原理》[M].7版北京:高等教育出版社, 2006.5.
[16]薛年喜. Matlab在数字信号处理中的应用.[M] 2版北京:清华大学出版社,2008.1.
[17]郑阿奇,曹弋.Matlab实用教程. [M].2版北京:电子工业出版社,2007.8.
[18]陆垚光.精通MATLAB GUI设计.电子工业出版社,2008.2.
[19]谭晓东.用于齿轮淬火的圆柱坐标机器人单元.组合机床与自动化加工技术, 2005.11.
[20] M. Mehl, C.L. Kahles.Metcut. Machining Data for Numerical Control Field.Research Associates ,2006.03.
[21] Kurek. Numerical simulation of superficial induction hardening process, Krzyszt of International Journal of Materials and Product Technology,2007.04.
[22] Wang,Ai-Qin. Effect of induction hardening on rolling wear properties of 45 steel. Cailiao Rechuli Xuebao/Transactions of Materials and Heat Treatment,2007.02.
[23] Ge,Yunwang.Optimization control of induction hardening process. 2006 IEEE International Conference on Mechatronics and Automation ,2006.12.
[24] Nacke, Bernard.Design of complex induction hardening problems by means of numerical simulation,Archives of Electrical Engineering, 2005.11.
[25] Behulova, Maria.Static and dynamic induction heating-Experiment and numerical simulation, Material pruefung/Materials Testing ,2006.5.
[26]葛运旺.双工位立式通用淬火机床设计.热处理技术与装备,2007.01.
[27]葛运旺.由PLC和HMI构成的感应淬火机床数控系统.热加工工艺,2005.09.
[28]葛运旺.基于现场总线的感应淬火机床控制系统设计.工业仪表与自动化装置,2005.05.
[29]刘旭波.模具型面高频淬火数控机床的设计.组合机床与自动化加工技术,2005.09.
[30] Erkorkmaz, K.CIRP, Virtual computer numerical control system Annals - Manufacturing Technology ,2006.01.
[31]张皞.MCX314As型四轴运动控制器的原理及应用.杭州电子科技大学自动化学院, 2006.05.
[32]曹世奇,李占贤.基于MCX314As的喷釉机手控制系统设计.河北理工大学机械工程学院,2007.11.
[33]周刚,王秀霞.基于MCX314的运动控制器设计.河南工业大学电气工程学院,2006.12.
[34]朱斯国,姜长泓.基于运动控制芯片MCX314As的多轴运动控制器的设计.长春工业大学电气工程学院,2007.03.
[35]蔡晓雯.基于运动控制芯片MCX314的运动控制器设计.电子应用,2007.10.
[36]张建民.基于MCX314控制器的机床数控系统设计.数控加工技术,2005.03.
[37] Wang, Tai-Yong. Design of CNC system based on embedded technology.Tianjin Daxue Xuebao ,2006.12.
[38]徐彬.变频调速系统恒线速控制器的设计.控制工程,2005.10.
[39]鲁远栋.机床电气控制技术.电子工业出版社,2007.07.
[40]葛运旺.利用配方功能实现通用淬火机床数控系统工件管理和编程.制造技术与机床, 2006.06.
[41] Klasztorny, M. Numerical simulation of rheological processes in plastic hardening s under stress control. Mechanics of Composite Materials ,2007.03.
[42] Yu, Tao.Research on system theory of integrated numerical control.Proceedings of the Annual Southeastern Symposium on System Theory,2006.06.
[43]南京顺康数码科技有限公司MC6212P运动控制卡使用手册.2006.1.
[44]曹恒.软件设计模式在数控系统人机界面开发中的应用.华东理工大学学报(自然科学版), 2007.06.
[45]温丽.浅谈数控机床人机界面设计.四川职业技术学院学报,2007.04.
[46] Dolezel,Ivo.Continual induction hardening of axi-symmetric bodies.Journal of Materials Processing Technology,2005.4.
[47] Glenn Doug.Continuous improvement ideas forinduction hardening IndustrialHeating, 2006.05.
[48]龚沛曾,杨志强,陆慰民.Visual Basic程序设计教程.高等教育出版社,2006.12.
[49]申晓东,白一凡.数控机床调试维修与实践.中国社会劳动保障出版社,2007.7.
[50]马永光.数控机床FANUC系统安装调试维修.中国社会劳动保障出版社,2008.7.
[2]周海,曾少鹏,袁石根.感应加热淬火技术的发展及应用.2008 .29(3) .9-15.
[3]杨坤怡.制造技术.国防工业出版社, 2005.08.
[4]杜君文.机械制造技术装备与设计.天津大学出版社, 2007.10.
[5]周旭.数控机床实用技术.国防大学出版社,2006.06.
[6]周凯.数控原理系统及应用.机械工业出版社,2006.03.
[7]李诚人.数控化改造.清华大学出版社, 2006.07.
[8]李勇,李伟光.机械设备数控技术.国防工业出版社, 2007.9.
[9] Chen,Jin-Rong.Jinshu High frequency induction hardening for pinion. Rechuli/Heat Treatment of Metals,2006.02.
[10] Marquis, Fabien. Induction hardening of gears offers various approaches. Heat Treating Progress,2007.07.
[11] Esteve,V. Induction heating inverter with simultaneous dual-frequency output.Conference Proceedings - IEEE Applied Power Electronics Conference and Exposition– APECs, 2006.06.
[12]杨连弟.感应淬火设备的引进与吸收.汽车工艺与材料,2006.08.
[13]董广强.非圆曲线轮廓零件数控加工的研究.煤矿机械, 2007.12.
[14] Li, Yue-Ying. Surface hardening and tribological properties of a cam materials. Jilin DaxueXuebao,2007.09.
[15]孙恒,陈作模,葛文杰.《机械原理》[M].7版北京:高等教育出版社, 2006.5.
[16]薛年喜. Matlab在数字信号处理中的应用.[M] 2版北京:清华大学出版社,2008.1.
[17]郑阿奇,曹弋.Matlab实用教程. [M].2版北京:电子工业出版社,2007.8.
[18]陆垚光.精通MATLAB GUI设计.电子工业出版社,2008.2.
[19]谭晓东.用于齿轮淬火的圆柱坐标机器人单元.组合机床与自动化加工技术, 2005.11.
[20] M. Mehl, C.L. Kahles.Metcut. Machining Data for Numerical Control Field.Research Associates ,2006.03.
[21] Kurek. Numerical simulation of superficial induction hardening process, Krzyszt of International Journal of Materials and Product Technology,2007.04.
[22] Wang,Ai-Qin. Effect of induction hardening on rolling wear properties of 45 steel. Cailiao Rechuli Xuebao/Transactions of Materials and Heat Treatment,2007.02.
[23] Ge,Yunwang.Optimization control of induction hardening process. 2006 IEEE International Conference on Mechatronics and Automation ,2006.12.
[24] Nacke, Bernard.Design of complex induction hardening problems by means of numerical simulation,Archives of Electrical Engineering, 2005.11.
[25] Behulova, Maria.Static and dynamic induction heating-Experiment and numerical simulation, Material pruefung/Materials Testing ,2006.5.
[26]葛运旺.双工位立式通用淬火机床设计.热处理技术与装备,2007.01.
[27]葛运旺.由PLC和HMI构成的感应淬火机床数控系统.热加工工艺,2005.09.
[28]葛运旺.基于现场总线的感应淬火机床控制系统设计.工业仪表与自动化装置,2005.05.
[29]刘旭波.模具型面高频淬火数控机床的设计.组合机床与自动化加工技术,2005.09.
[30] Erkorkmaz, K.CIRP, Virtual computer numerical control system Annals - Manufacturing Technology ,2006.01.
[31]张皞.MCX314As型四轴运动控制器的原理及应用.杭州电子科技大学自动化学院, 2006.05.
[32]曹世奇,李占贤.基于MCX314As的喷釉机手控制系统设计.河北理工大学机械工程学院,2007.11.
[33]周刚,王秀霞.基于MCX314的运动控制器设计.河南工业大学电气工程学院,2006.12.
[34]朱斯国,姜长泓.基于运动控制芯片MCX314As的多轴运动控制器的设计.长春工业大学电气工程学院,2007.03.
[35]蔡晓雯.基于运动控制芯片MCX314的运动控制器设计.电子应用,2007.10.
[36]张建民.基于MCX314控制器的机床数控系统设计.数控加工技术,2005.03.
[37] Wang, Tai-Yong. Design of CNC system based on embedded technology.Tianjin Daxue Xuebao ,2006.12.
[38]徐彬.变频调速系统恒线速控制器的设计.控制工程,2005.10.
[39]鲁远栋.机床电气控制技术.电子工业出版社,2007.07.
[40]葛运旺.利用配方功能实现通用淬火机床数控系统工件管理和编程.制造技术与机床, 2006.06.
[41] Klasztorny, M. Numerical simulation of rheological processes in plastic hardening s under stress control. Mechanics of Composite Materials ,2007.03.
[42] Yu, Tao.Research on system theory of integrated numerical control.Proceedings of the Annual Southeastern Symposium on System Theory,2006.06.
[43]南京顺康数码科技有限公司MC6212P运动控制卡使用手册.2006.1.
[44]曹恒.软件设计模式在数控系统人机界面开发中的应用.华东理工大学学报(自然科学版), 2007.06.
[45]温丽.浅谈数控机床人机界面设计.四川职业技术学院学报,2007.04.
[46] Dolezel,Ivo.Continual induction hardening of axi-symmetric bodies.Journal of Materials Processing Technology,2005.4.
[47] Glenn Doug.Continuous improvement ideas forinduction hardening IndustrialHeating, 2006.05.
[48]龚沛曾,杨志强,陆慰民.Visual Basic程序设计教程.高等教育出版社,2006.12.
[49]申晓东,白一凡.数控机床调试维修与实践.中国社会劳动保障出版社,2007.7.
[50]马永光.数控机床FANUC系统安装调试维修.中国社会劳动保障出版社,2008.7.