CNC machine tools

Mainfeatures

TheoperationandmonitoringofCNCmachinetoolsareallcompletedinthisCNCunit,whichisthebrainofCNCmachinetools.Comparedwithordinarymachinetools,CNCmachinetoolshavethefollowingcharacteristics:

1.Strongadaptabilitytoprocessingobjects,adapttothecharacteristicsofsingle-pieceproductionofmoldsandotherproducts,andprovidesuitableprocessingmethodsformoldmanufacturing;

2.Highprocessingaccuracyandstableprocessingquality;

3.Multi-coordinatelinkagecanbecarriedout,andpartswithcomplexshapescanbeprocessed;

4,Whenmachiningpartschange,generallyonlyneedtochangethenumericalcontrolprogram,whichcansaveproductionpreparationtime;

5.3~5timesofthemachinetool);

6.Themachinetoolhasahighdegreeofautomation,whichcanreducelaborintensity;

7.Itisconducivetothemodernizationofproductionmanagement.Numericalcontrolmachinetoolsusedigitalinformationandstandardcodestoprocessandtransmitinformation,andusecomputercontrolmethods,whichlaysthefoundationfortheintegrationofcomputer-aideddesign,manufacturingandmanagement;

8.Higherrequirementsforthequalityofoperators,Thetechnicalrequirementsformaintenancepersonnelarehigher;

9,highreliability.

Comparedwithtraditionalmachinetools,CNCmachinetoolshavethefollowingcharacteristics.

1.Highlyflexible

MachiningpartsonCNCmachinetoolsmainlydependsontheprocessingprocedure.Itisdifferentfromordinarymachinetools.Itdoesnotneedtobemanufactured,andmanymoldsandfixturesneednotbereplacedfrequently.Readjustthemachinetool.Therefore,theCNCmachinetoolissuitablefortheoccasionswheretheprocessedpartsarefrequentlyreplaced,thatis,itissuitablefortheproductionofsingle-piece,small-batchproductsandthedevelopmentofnewproducts,therebyshorteningtheproductionpreparationcycleandsavingalotofprocessequipmentcosts.

2.Highmachiningaccuracy

ThemachiningaccuracyofCNCmachinetoolsisgenerallyupto0.05-0.1mm.CNCmachinetoolsarecontrolledintheformofdigitalsignals.EachtimetheCNCdeviceoutputsapulsesignal,Themovingpartsofthemachinetoolmoveapulseequivalent(usually0.001mm),andtheaverageerrorofthebacklashofthemachinetool'sfeedtransmissionchainandthescrewpitchcanbecompensatedbythenumericalcontroldevice.Therefore,thepositioningaccuracyofthenumericalcontrolmachinetoolisrelativelyhigh.

3,theprocessingqualityisstableandreliable

Processingthesamebatchofparts,onthesamemachinetool,underthesameprocessingconditions,usingthesametoolandprocessingprogram,thecuttingpathofthetoolisexactlythesame,Thepartshavegoodconsistencyandstablequality.

4.Highproductivity

TheCNCmachinetoolcaneffectivelyreducetheprocessingtimeandauxiliarytimeoftheparts.TheCNCmachinetoolhasalargerangeofspindlesoundspeedandfeed,allowingthemachinetooltoperformlargecuttingTheamountofpowerfulcutting.CNCmachinetoolsareenteringtheeraofhigh-speedmachining.TherapidmovementandpositioningofmovingpartsofCNCmachinetoolsandhigh-speedcuttinghavegreatlyimprovedproductivity.Inaddition,itcanbeusedinconjunctionwiththetoolmagazineofthemachiningcentertorealizethecontinuousprocessingofmultipleproceduresononemachinetool,reducingtheturnaroundtimeofsemi-finishedproductsandimprovingproductivity.

5.Improvelaborconditions

AftertheCNCmachinetoolisadjustedbeforeprocessing,entertheprogramandstartit,andthemachinetoolcanautomaticallyandcontinuouslyprocessuntiltheendoftheprocessing.Whattheoperatorhastodoisprograminput,editing,partsloadingandunloading,toolpreparation,processingstateobservation,andpartsinspection.Thelaborintensityisgreatlyreduced,andthelaborofmachinetooloperatorstendstobeintellectualwork.Inaddition,machinetoolsaregenerallycombined,whichisbothcleanandsafe.

6.Utilizethemodernizationofproductionmanagement

TheprocessingtimeofCNCmachinetoolscanbeaccuratelyestimatedinadvance,andthetoolsandfixturesusedcanbestandardized,modernizedmanagement,andeasytorealizeprocessinginformationThestandardizationhasbeenorganicallycombinedwithcomputer-aideddesignandmanufacturing(CAD/CAM),whichisthebasisofmodernintegratedmanufacturingtechnology.

Basiccomposition

ThebasiccompositionofaCNCmachinetoolincludesaprocessingprogramcarrier,anumericalcontroldevice,aservodrive,themainbodyofthemachinetoolandotherauxiliarydevices.Thebasicworkingprinciplesofeachcomponentaresummarizedbelow.

Processingprogramcarrier

WhentheCNCmachinetoolisworking,workersdonotneedtooperatethemachinedirectly.TocontroltheCNCmachinetool,theprocessingprogrammustbecompiled.Thepartprocessingprogramincludestherelativemotiontrajectoryofthetoolandtheworkpieceonthemachinetool,theprocessparameters(feedamount,spindlespeed,etc.),andauxiliarymotion.Thepartprocessingprogramisstoredinaprogramcarrierwithacertainformatandcode,suchaspunchedtape,cassettetape,floppydisk,etc.,andtheprograminformationisinputtotheCNCunitthroughtheinputdeviceoftheCNCmachinetool.

Numericalcontroldevice

NumericalcontroldeviceisthecoreofCNCmachinetool.ModernnumericalcontroldevicesalladopttheformofCNC(ComputerNumericalControl).ThiskindofCNCdevicegenerallyusesmultiplemicroprocessorstorealizenumericalcontrolfunctionsintheformofprogrammedsoftware,soitisalsocalledSoftwareNC(SoftwareNC).CNCsystemisakindofpositioncontrolsystem,itisbasedontheinputdatatointerpolatetheidealmotiontrajectory,andthenoutputtotheexecutioncomponenttoprocesstherequiredparts.Therefore,thenumericalcontroldeviceismainlycomposedofthreebasicparts:input,processingandoutput.Andallthesetasksarerationallyorganizedbythecomputersystemprogram,sothattheentiresystemcanworkinacoordinatedmanner.

1)Inputdevice:Inputthenumericalcontrolinstructiontothenumericalcontroldevice.Accordingtothedifferentprogramcarrier,therearedifferentinputdevices.Therearemainlykeyboardinput,diskinput,CAD/CAMsystemdirectcommunicationinputandDNC(directnumericalcontrol)inputconnectedtoahigher-levelcomputer.Therearestillmanysystemsthatstillretainthepapertapeinputformofphotoelectricreaders.

(1)Papertapeinputmethod.Thepartprogramcanbereadinwithapapertapephotoelectricreadertodirectlycontrolthemovementofthemachinetool,orthecontentofthepapertapecanbereadintothememory,andthepartprogramstoredinthememorycanbeusedtocontrolthemotionofthemachinetool.

(2)MDImanualdatainputmethod.Theoperatorcanusethekeyboardontheoperationpaneltoinputtheinstructionsoftheprocessingprogram,whichissuitableforrelativelyshortprograms.

Intheeditstateofthecontroldevice(EDIT),usethesoftwaretoinputtheprocessingprogramandstoreitinthememoryofthecontroldevice.Thisinputmethodcanreusetheprogram.Thismethodisgenerallyadoptedformanualprogramming.

Onthenumericalcontroldevicewithconversationalprogrammingfunction,youcanselectdifferentmenusaccordingtothequestionspromptedonthedisplay,andusethemethodofman-machinedialoguetoinputtherelevantsizenumbers,andthentheprocessingprogramcanbeautomaticallygenerated.

(3)DNCdirectnumericalcontrolinputmethodisadopted.Savethepartprogramintheupper-levelcomputer,andtheCNCsystemreceivessubsequentprogramsegmentsfromthecomputerwhileprocessing.TheDNCmethodismostlyusedwhenusingCAD/CAMsoftwaretodesigncomplexworkpiecesanddirectlygeneratepartprograms.

DifferenttypesofCNCmachinetools(13photos)

2)Informationprocessing:TheinputdevicetransmitstheprocessinginformationtotheCNCunitandcompilesitintoinformationthatcanberecognizedbythecomputer.Aftertheinformationprocessingpartstoresandprocessesstepbystepinaccordancewiththeregulationsofthecontrolprogram,thepositionandspeedcommandsaresenttotheservosystemandthemainmotioncontrolpartthroughtheoutputunit.TheinputdataoftheCNCsystemincludes:thecontourinformationofthepart(startpoint,endpoint,straightline,arc,etc.),processingspeedandotherauxiliaryprocessinginformation(suchastoolchange,speedchange,coolantswitch,etc.).ThepurposeofdataprocessingistocompletetheinsertionPreparationsbeforethecomplementoperation.Thedataprocessingprogramalsoincludestoolradiuscompensation,speedcalculationandauxiliaryfunctionprocessing.

3)Outputdevice:Theoutputdeviceisconnectedwiththeservomechanism.Theoutputdevicereceivestheoutputpulseofthearithmeticunitaccordingtothecommandofthecontroller,andsendsittotheservocontrolsystemofeachcoordinate.Afterpoweramplification,theservosystemisdriventocontrolthemachinetooltomoveaccordingtothespecifiedrequirements.

Servoandmeasurementfeedbacksystem

ServosystemisanimportantpartofCNCmachinetools,usedtorealizethefeedservocontrolandspindleservocontrolofCNCmachinetools.Thefunctionoftheservosystemistoconvertthecommandinformationreceivedfromthenumericalcontroldeviceintolineardisplacementorangulardisplacementmotionofthemachinetool'sexecutionpartsafterpoweramplificationandshaping.SincetheservosystemisthelastlinkoftheCNCmachinetool,itsperformancewilldirectlyaffecttheaccuracyandspeedoftheCNCmachinetoolandothertechnicalindicators.Therefore,theservodrivedeviceoftheCNCmachinetoolrequiresgoodfastresponseperformanceandaccurateandsensitivetrackingoftheCNCdevice.Thedigitalcommandsignalsentoutcanfaithfullyexecutethecommandfromthenumericalcontroldevicetoimprovethesystem'sdynamicfollowingcharacteristicsandstatictrackingaccuracy.

Theservosystemincludestwoparts,thedrivedeviceandtheactuator.Thedrivedeviceiscomposedofaspindledriveunit,afeeddriveunit,aspindleservomotor,andafeedservomotor.Steppingmotors,DCservomotorsandACservomotorsarecommonlyuseddrivingdevices.

ThemeasuringelementdetectstheactualdisplacementvalueofeachcoordinateaxisoftheCNCmachinetoolandinputsitintotheCNCdeviceofthemachinetoolthroughthefeedbacksystem.TheCNCdevicecomparesthefeedbackactualdisplacementvaluewiththecommandvalueandsendsittotheTheservosystemoutputsthedisplacementcommandrequiredtoreachthesetvalue.

Themainbodyofthemachinetool

ThemainbodyofthemachinetoolisthemainbodyoftheCNCmachinetool.Itincludesmachinepartssuchasbed,base,column,beam,slidingseat,worktable,headstock,feedmechanism,toolpostandautomatictoolchanger.ItisamechanicalpartthatautomaticallycompletesvariouscuttingprocessesonaCNCmachinetool.Comparedwithtraditionalmachinetools,themainbodyofCNCmachinetoolshasthefollowingstructuralcharacteristics:

1)Anewmachinetoolstructurewithhighrigidity,highshockresistanceandlessthermaldeformationisadopted.Generally,methodssuchasimprovingthestaticstiffnessofthestructuralsystem,increasingthedamping,adjustingthequalityofthestructuralpartsandthenaturalfrequencyareusedtoimprovethestiffnessandseismicresistanceofthemachinetoolhost,sothatthemainbodyofthemachinetoolcanadapttotheneedsofCNCmachinetoolsforcontinuousandautomaticcutting.Takingmeasuressuchasimprovingthelayoutofthemachinetool,reducingheatgeneration,controllingtemperaturerise,andadoptingthermaldisplacementcompensation,canreducetheimpactofthermaldeformationonthehostmachineofthemachinetool.

2)Thehigh-performancespindleservodriveandfeedservodrivearewidelyusedtoshortenthetransmissionchainofCNCmachinetoolsandsimplifythestructureofthemachinetoolmechanicaltransmissionsystem.

3)Usehightransmissionefficiency,highprecision,nogaptransmissiondevicesandmovingparts,suchasballscrewnutpairs,plasticslidingguides,linearrollingguides,hydrostaticguides,etc.

AuxiliarydevicesforCNCmachinetools

AuxiliarydevicesarenecessarysupportingdevicestoensurefulluseofthefunctionsofCNCmachinetools.Commonlyusedauxiliarydevicesinclude:pneumaticandhydraulicdevices,Chipremovaldevice,coolingandlubricationdevice,rotarytableandnumericalcontrolindexinghead,protection,lightingandotherauxiliarydevices.

Technicalapplication

Numericalcontrolmachinetoolisanautomaticmachinetoolequippedwithaprogramcontrolsystem,whichcanmakethemachinetoolmoveandprocesspartsaccordingtotheprogrammedprogram.Itintegratesthelatesttechnologiesofmachinery,automation,computer,measurement,microelectronics,etc.,andusesavarietyofsensors.ThesensorsusedonCNCmachinetoolsmainlyincludephotoelectricencoders,lineargratings,proximityswitches,temperaturesensors,Hallsensors,andcurrentSensors,voltagesensors,pressuresensors,liquidlevelsensors,resolvers,inductionsynchronizers,speedsensors,etc.,aremainlyusedtodetectposition,linearandangulardisplacement,speed,pressure,temperature,etc.

1.RequirementsforsensorsofCNCmachinetools

1)Highreliabilityandstronganti-interference;

2)Meettherequirementsofaccuracyandspeed;

3)Easytouseandmaintain,suitableformachinetooloperatingenvironment;

4)Lowcost.

DifferenttypesofCNCmachinetoolshavedifferentrequirementsforsensors.Generallyspeaking,large-scalemachinetoolsrequirehighspeedresponse,andmedium-sizedandhigh-precisionCNCmachinetoolsrequireprecision.

2.Applicationofinductosyn

Inductosynismadeusingtheprinciplethatthemutualinductanceoftwoplanarwindingsvarieswithdifferentpositions.Itsfunctionistoconverttheangularorlineardisplacementintothephaseoramplitudeoftheinducedelectromotiveforce,whichcanbeusedtomeasurethelinearorangulardisplacement.Accordingtoitsstructure,itcanbedividedintolineartypeandrotarytype.Thelinearinductionsynchronizeriscomposedoftwoparts:afixedlengthandaslidingrule.Thefixedlengthisinstalledonthemachinebed,andtheslidingruleisinstalledonthemovingpartsandmoveswiththeworktable.Thestatoroftherotaryinductionsynchronizerisafixeddisc,andtherotorForrotatingdiscs.Inductionsynchronizerhastheadvantagesofhighaccuracyandresolution,stronganti-interferenceability,longservicelife,simplemaintenance,long-distancedisplacementmeasurement,goodmanufacturability,andlowcost.Rotaryinductionsynchronizersarewidelyusedinturntablesofmachinetoolsandinstruments,andvariousrotaryservocontrolsystems.

MachiningCenter

ThefirstmachiningcenterwasfirstdevelopedbyCarney-Treckin1958.ItaddsanautomatictoolchangeronthebasisoftheCNChorizontalboringandmillingmachine,whichrealizesthecentralizedprocessingofmultipleprocessessuchasmilling,drilling,boring,reaming,andtappingaftertheworkpieceisclampedonce.ThemachiningcenterisahighlyautomatedmultifunctionalCNCmachinetoolwithatoolmagazineandanautomatictoolchanger.Aftertheworkpieceisclampedonthemachiningcenteronce,multipleprocessescanbecompletedformorethantwosurfaces,andtherearemultipletoolchangeortoolselectionfunctions,whichgreatlyimprovestheproductionefficiency.

Machiningcentersaredividedintoboringandmillingandturningaccordingtotheirprocessingprocedures,andcanbedividedintothree-axis,four-axisandfive-axismachiningcentersaccordingtothenumberofcontrolaxes.

Maintenanceandoverhaul

Extendthelifeofcomponentsandthewearcycleofparts,preventvariousfailures,andincreasetheaveragetrouble-freeworkingtimeandservicelifeofCNCmachinetools.

Cautionsforuse

1.TheuseenvironmentofCNCmachinetools:ForCNCmachinetools,itisbesttoplacetheminaconstanttemperatureenvironmentandawayfromequipmentwithlargevibrations(suchaspunchingmachines)andElectromagneticinterferenceequipment;

2,powerrequirements;

3,CNCmachinetoolsshouldhaveoperatingprocedures:regularmaintenance,maintenance,failuretonoterecordstoprotectthesite,etc.;

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4.CNCmachinetoolsarenotsuitableforlong-termstorage,aslong-termstoragesystemfailureanddatalosswillresult;

5.Payattentiontotrainingandequippingoperators,maintenancepersonnelandprogrammingpersonnel.

MaintenanceRegulations

MaintenanceofCNCSystem

1.Strictlyabidebytheoperatingproceduresanddailymaintenancesystem.

2.Preventdustfromenteringthenumericalcontroldevice:Floatingdustandmetalpowdercaneasilycausetheinsulationresistancebetweencomponentstodecrease,resultinginfailureorevendamagetothecomponents.

3.CleantheheatdissipationandventilationsystemoftheCNCcabinetregularly.

4.Frequentlymonitorthegridvoltageofthenumericalcontrolsystem:thegridvoltagerangeis85%to110%oftheratedvalue.

5.Regularlyreplacethestoragebattery.

6.Maintenanceofthenumericalcontrolsystemwhenitisnotinuseforalongtime:oftenpoweronthenumericalcontrolsystemorallowthenumericalcontrolmachinetooltorunawarm-upprogram.

7.Maintenanceofsparecircuitboards.Maintenanceofmechanicalparts.

Maintenanceofmechanicalparts

1.Maintenanceoftoolmagazineandtoolchangemanipulator

1)ManuallymovetothetoolmagazineWheninstallingthetool,ensurethatitisinplaceandcheckwhetherthelockingonthetoolholderisreliable;

2)Itisstrictlyforbiddentoloadoverweightandoverlongtoolsintothetoolmagazinetopreventtherobotfromdroppingorcuttingtoolswhenchangingthetools.Collisionwithworkpieces,fixtures,etc.;

3)Whenusingsequentialtoolselection,payattentiontowhethertheorderinwhichthetoolsareplacedonthetoolmagazineiscorrect.Othertoolselectionmethodsshouldalsopayattentiontowhetherthenumberofthechangedtoolisconsistentwiththerequiredtool,topreventaccidentscausedbychangingthewrongtool;

4)Payattentiontokeepingthetoolholderandsleeveclean;

5)Frequentlycheckwhetherthezeroreturnpositionofthetoolmagazineiscorrect,checkwhetherthemachinespindlereturntothetoolchangepointpositionisinplace,andadjustitintime,otherwisethetoolchangeactioncannotbecompleted;

6)Whenthemachineisturnedon,Thetoolmagazineandmanipulatorshouldberundryfirsttocheckwhethereachpartworksnormally,especiallywhethereachtravelswitchandsolenoidvalvecanoperatenormally.

2.Maintenanceoftheballscrewpair

1)Regularlycheckandadjusttheaxialclearanceofthescrewnutpairtoensurethereversetransmissionaccuracyandaxialrigidity;

2)Regularlycheckwhethertheconnectionbetweenthescrewsupportandthebedislooseandwhetherthesupportbearingisdamaged.Ifyouhaveanyoftheaboveproblems,youmusttightentheloosepartsintimeandreplacethesupportbearings;

3)Forballscrewswithgrease,cleantheoldgreaseonthescreweverysixmonthsandreplacewithnewgrease.Theballscrewlubricatedwithlubricatingoil,addoilonceadaybeforethemachinetoolworks;

4)Takecaretopreventharddustorchipsfromenteringthescrewguardandhittingtheguardduringwork.TheprotectivedevicehasoneDamagedshouldbereplacedintime.

3.Maintenanceofthemaindrivechain

1)Regularlyadjustthetightnessofthespindledrivebelt;

2)Preventvariousimpuritiesfromenteringthefueltank.Changethelubricatingoilonceayear;

3)Keeptheconnectingpartofthespindleandthetoolholderclean.Itisnecessarytoadjustthedisplacementofthehydrauliccylinderandpistonintime;

4)Adjustthecounterweightintime.

4.Hydraulicsystemmaintenance

1)Regularlyfilterorreplacetheoil;

2)Controlthetemperatureoftheoilinthehydraulicsystem;

3)Preventthehydraulicsystemfromleaking;

4)Regularlyinspectandcleanthefueltankandpipeline;

5)Implementadailypointinspectionsystem.

5.Maintenanceofpneumaticsystem

1)Removeimpuritiesandmoisturefromthecompressedair;

2)Checktheoilsupplyofthelubricatorinthesystem;

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3)Maintainthetightnessofthesystem;

4)Payattentiontoadjustingtheworkingpressure;

5)Cleanorreplacepneumaticcomponentsandfilterelements.

Troubleshooting

InCNCmachinetools,mostofthefaultshavedatatocheck,buttherearealsosomefaults.Thealarminformationprovidedisvagueorevennoalarmatall,orthereisLongcycle,irregularandirregular,whichbringsalotofdifficultiestosearchandanalysis.Forsuchmachinetoolfailures,itisnecessarytoanalyzethespecificconditionsandconductpatientsearch.Inaddition,comprehensiveknowledgeofmechanics,electricity,hydraulics,etc.isespeciallyrequiredduringtheinspection,otherwiseitisdifficulttoquicklyandcorrectlyfindtherealcauseofthefailure.

Abnormalmachiningaccuracyfailure:systemparameterchangesorchanges,mechanicalfailure,machinetoolelectricalparametersarenotoptimized,abnormalmotoroperation,abnormalmachinetoolpositionlooporincorrectcontrollogic,whichisanabnormalfailureofCNCmachinetoolmachiningaccuracyduringproductionThecommoncauseofthemachinetoolcanberestoredtonormalbyfindingouttherelevantfaultpointsanddealingwiththem.Inproduction,weoftenencounterfaultswithabnormalmachiningaccuracyofCNCmachinetools.Suchfaultsarehighlyconcealedanddifficulttodiagnose.

Therearefivemainreasonsforthistypeoffailure:

1.Thefeedunitofthemachinetoolischangedorchanged;

2.Thezerooffset(NULLOFFSET)isabnormal;

3,theaxialbacklash(BACKLASH)isabnormal;

4,themotoroperatingstateisabnormal,thatis,theelectricalandcontrolpartsarefaulty;

5.Mechanicalfailures,suchasscrewrods,bearings,shaftcouplingsandothercomponents.

Inaddition,thepreparationoftheprocessingprogram,theselectionoftoolsandhumanfactorsmayalsocauseabnormalprocessingaccuracy.

Machiningaccuracyabnormalitiescausedbymechanicalfailuresshouldbecheckedonebyoneinthefollowingaspects.

1.Checkthemachiningprogramsegmentthatisrunningwhenthemachinetoolaccuracyisabnormal,especiallythetoollengthcompensation,theproofreadingandcalculationofthemachiningcoordinatesystem(G54～G59).

2.Inthejogmode,movetheZaxisrepeatedly,anddiagnosethemotionstatebysight,touch,andlisten.ItisfoundthatthesoundoftheZ-directionmotionisabnormal,especiallywhenthejogisfast,thenoiseismoreobvious.Judgingfromthis,theremaybehiddendangersinmachinery.

Troubleshooting

1.Initializationresetmethod:Undernormalcircumstances,thesystemalarmscausedbytransientfaultscanbeclearedbyhardwareresetorswitchsystempowerinturn.IfthesystemisworkingIfthestorageareaischaoticduetopowerfailure,unpluggingofcircuitboardsorbatteryundervoltage,thesystemmustbeinitializedandcleared.Beforeclearing,youshouldmakeadatacopyrecord.Ifthefaultcannotbeeliminatedafterinitialization,performhardwarediagnosis.

2.Parameterchanges,programcorrectionmethod:Systemparametersarethebasisfordeterminingsystemfunctions,andparametersettingerrorsmaycausesystemfailuresorinvalidfunctions.Sometimesduetouserprogramerrorscanalsocausefailurestostop,thiscanbecheckedbythesystem'sblocksearchfunctiontocorrectallerrorstoensureitsnormaloperation.

3,adjustment,optimizationadjustmentmethod:adjustmentisthemostsimpleandeasyway.Correctthesystemfailurebyadjustingthepotentiometer.Forexample,duringmaintenanceinafactory,thesystemdisplayscreenischaotic,anditisnormalafteradjustment.Forexample,inafactory,beltslippageoccurswhenthemainshaftstartsandbrakes.Thereasonisthatthemainshaftloadtorqueislarge,andtheramp-uptimeofthedrivedeviceissettoosmall,whichisnormalafteradjustment.

Optimizationadjustmentisacomprehensiveadjustmentmethodthatsystematicallyachievesthebestmatchbetweentheservodrivesystemandthedraggedmechanicalsystem.Themethodisverysimple.Useamulti-linerecorderorastorageAfunctionaldual-trackoscilloscopetoobservetheresponserelationshipbetweencommandsandspeedfeedbackorcurrentfeedbackrespectively.Byadjustingtheproportionalcoefficientandintegraltimeofthespeedregulator,theservosystemcanachievethebestworkingconditionwithhighdynamicresponsecharacteristicswithoutoscillation.Intheabsenceofanoscilloscopeorrecorderonsite,basedonexperience,adjusttomakethemotorvibrate,andthenslowlyadjustinthereversedirectionuntilthevibrationiseliminated.

4.Sparepartsreplacementmethod:replacethefaultycircuitboardwithagoodsparepart,anddothecorrespondinginitialstartup,sothatthemachinetoolcanbequicklyputintonormaloperation,andthenthebrokenboardisrepairedorrepaired.ThisisthemostCommontroubleshootingmethods.

5.Methodofimprovingpowerquality:Regulatedpowersupplyisgenerallyusedtoimprovepowersupplyfluctuations.Capacitorfilteringmethodcanbeusedforhighfrequencyinterference,throughthesepreventivemeasurestoreducethefailureofthepowerboard.

6.Maintenanceinformationtrackingmethod:Somelargemanufacturingcompaniesconstantlymodifyandimprovesystemsoftwareorhardwarebasedonaccidentalfailurescausedbydesigndefectsinactualwork.Thesemodificationsarecontinuouslyprovidedtomaintenancepersonnelintheformofmaintenanceinformation.Usingthisasabasisfortroubleshooting,thefaultcanbeeliminatedcorrectlyandthoroughly.

Diagnosismethod

TheelectricalfaultdiagnosisofCNCmachinetoolshasthreestages:faultdetection,faultjudgment,isolationandfaultlocation.ThefirststageoffaultdetectionistotesttheCNCmachinetooltodeterminewhetherthereisafault;thesecondstageistodeterminethenatureofthefaultandisolatethefaultycomponentormodule;thethirdstageistolocatethefaulttoareplaceablemoduleorprintCircuitboardtoshortenrepairtime.Inordertofindthefaultinthesystemintime,quicklydeterminethelocationofthefaultandeliminateitintime,itisrequiredthatfaultdiagnosisshouldbeasfewandsimpleaspossible,andthetimerequiredforfaultdiagnosisshouldbeasshortaspossible.Tothisend,thefollowingdiagnosticmethodscanbeused:

1.Intuitivemethod

Usingthesensoryorgans,payattentiontovariousphenomenawhenthefaultoccurs,suchaswhetherthereissparkorbrightlightduringthefault,Whetherthereisabnormalnoise,whereisabnormalheat,andwhetherthereisburningsmell,etc.Carefullyobservethesurfaceconditionofeachprintedcircuitboardthatmaybemalfunctioning,whetherthereisburntordamagetraces,tofurthernarrowtheinspectionscope,thisisoneofthemostbasicandmostcommonlyusedmethods.

2.Theself-diagnosisfunctionoftheCNCsystem

RelyingontheabilityoftheCNCsystemtoquicklyprocessdata,itcanperformmulti-channelandrapidsignalacquisitionandprocessingoftheerrorlocation,andthenthediagnosticprogramwillperformLogicanalysisandjudgmenttodeterminewhetherthereisafaultinthesystem,andtolocatethefaultintime.Theself-diagnosisfunctionofmodernCNCsystemcanbedividedintothefollowingtwocategories:

1)Power-onself-diagnosisPower-onself-diagnosismeansthatfromthestartofeachpower-ontothenormaloperationpreparationstate,theinternaldiagnosticprogramofthesystemautomaticallyPerformfunctionaltestsbeforetheoperationoftheCPU,memory,bus,I/Ounitandothermodules,printedcircuitboards,CRTunits,photoelectricreadersandfloppydiskdrivestoconfirmwhetherthemainhardwareofthesystemcanworknormally.

2)FailureinformationpromptsWhenafailureoccursduringtheoperationofthemachinetool,thenumberandcontentwillbedisplayedontheCRTdisplay.Accordingtotheprompts,consulttherelevantmaintenancemanualtoconfirmthecauseofthefailureandthetroubleshootingmethod.Generallyspeaking,thericherthefaultinformationpromptedbytheCNCmachinetooldiagnosticfunction,themoreconvenientitwillbeforfaultdiagnosis.However,itshouldbenotedthatsomefaultscandirectlyconfirmthecauseofthefaultaccordingtothefaultcontentpromptandrefertothemanual;whiletherealcauseofsomefaultsdoesnotmatchthefaultcontentprompt,orafaultshowsmultiplefaultcauses,whichrequiresmaintenancepersonneltoFindouttheinternalconnectionbetweenthemandindirectlyconfirmthecauseofthefailure.

3.Dataandstatuscheck

Theself-diagnosisoftheCNCsystemcannotonlydisplayfaultalarminformationontheCRTdisplay,butalsodisplaymultiplepagesof"diagnosticaddress"and"diagnosticdata""formprovidesmachineparametersandstatusinformation.Commondataandstatuschecksincludeparametercheckandinterfacecheck.

1)ParametercheckThemachinetooldataofCNCmachinetoolsisanimportantparameterobtainedafteraseriesoftestsandadjustments,andisaguaranteeforthenormaloperationofthemachinetool.Thesedataincludegain,acceleration,contourmonitoringtolerance,backlashcompensationvalueandscrewpitchcompensationvalue.Whensubjectedtoexternalinterference,datawillbelostordisordered,andthemachinetoolwillnotworknormally.

2)InterfacecheckTheinput/outputinterfacesignalsbetweentheCNCsystemandthemachinetoolincludetheinterfaceinput/outputsignalsbetweentheCNCsystemandthePLC,andbetweenthePLCandthemachinetool.Theinput/outputinterfacediagnosisoftheCNCsystemcandisplaythestatusofalldigitalsignalsontheCRTdisplay.Use"1"or"0"toindicatewhetherthesignalispresentornot.UsethestatusdisplaytocheckwhethertheCNCsystemhasoutputthesignaltothemachinetool.Onthemachineside,whethersignalssuchastheswitchvalueonthemachinetoolsidehavebeeninputtotheCNCsystem,sothatthefaultcanbelocatedonthemachinetoolsideorintheCNCsystem.

4.Alarmindicatorshowsfailure

Inadditiontotheabove-mentionedself-diagnosisfunctionandstatusdisplayandother"software"alarms,therearemany"hardware"alarmsinsidetheCNCsystemofmodernCNCmachinetools."Alarmindicatorlights,theyaredistributedonthepowersupply,servodriveandinput/outputdevices,andthecauseofthefailurecanbejudgedaccordingtotheinstructionsofthesealarmlights.

5.Spareboardreplacementmethod

Usingasparecircuitboardtoreplaceatemplatewithafaultypointisaquickandsimplemethodtodeterminethecauseofthefault,oftenusedinCNCsystemsThefunctionalmodules,suchasCRTmodules,memorymodules,etc.Itshouldbenotedthatbeforereplacementofthespareboard,therelevantcircuitshouldbecheckedtoavoiddamagetothegoodboardduetoashortcircuit.Atthesametime,itshouldbecheckedwhethertheselectorswitchandjumperonthetestboardareconsistentwiththeoriginaltemplate.Sometemplatesshouldalsopayattentiontothetemplate.Adjustmentoftheupperpotentiometer.Afterreplacingthememoryboard,thememoryshouldbeinitializedaccordingtotherequirementsofthesystem,otherwisethesystemstillcannotworknormally.

6.Exchangemethod

InCNCmachinetools,thereareoftenmodulesorunitswiththesamefunction.ExchangethesamemodulesorunitswitheachotherandobservethefailuretransfersituationtoquicklydetermineThelocationofthefault.Thismethodisoftenusedforfaultcheckingofservofeeddrives,anditcanalsobeusedfortheinterchangeofthesamemodulesintheCNCsystem.

7.Percussionmethod

TheCNCsystemiscomposedofvariouscircuitboards,andeachcircuitboardhasmanysolderjoints.Anyfalsesolderingorpoorcontactmaycausemalfunctions.Whenusinganinsulatortogentlytapthecircuitboard,connectororelectricalcomponentwiththesuspectedfault,ifafaultoccurs,thefaultislikelytobeattheknockedpart.

8.Measurementcomparisonmethod

Fortheconvenienceofdetection,themoduleorunitisequippedwithdetectionterminals,andthelevelorwaveformdetectedthroughtheseterminalsisusedbyinstrumentssuchasmultimetersandoscilloscopes,Comparingthenormalvaluewiththevalueatthetimeofthefailure,thecauseofthefailureandthelocationofthefailurecanbeanalyzed.DuetothecomprehensivenessandcomplexityofCNCmachinetools,therearemanyfactorsthatcausefailures.Theabove-mentionedfaultdiagnosismethodssometimesrequireseveralsimultaneousapplicationstoconductacomprehensiveanalysisofthefault,andquicklydiagnosethefaultypart,soastoeliminatethefault.Atthesametime,somefailurephenomenaareelectrical,butthecauseismechanical;conversely,itisalsopossiblethatthefailurephenomenonismechanicalbutthecauseiselectrical;orboth.Therefore,itsfaultdiagnosiscannotbeattributedsolelytoelectricalormechanicalaspects,butmustbeintegratedandconsideredinanall-roundway.

Machinetoolacceptance

Generally,acceptanceiscarriedoutintwostages.

1.Pre-acceptance

Thepurposeistocheckandverifywhetherthemachinetoolcanmeettheuser'sprocessingqualityandproductivity,andtochecktheinformationandsparepartsprovidedbythesupplier.Thesuppliercancarryoutpre-acceptanceonlyafterthemachinetoolpassesthenormalrunningtestcuttingandtheproductionofqualifiedmachiningpartsisinspected.

2.Finalacceptance

Accordingtotheacceptancecriteria,thetechnicalindicatorsprovidedonthecertificatearemeasured.Theacceptanceworkisdividedintothefollowingsteps:

(1)Unpackinginspection;

(2)Visualinspection;

(3)AcceptanceofmachinetoolperformanceandCNCfunction;

(4)AcceptanceofaccuracyofCNCmachinetool(Includingpositionaccuracyandworkaccuracy).

Whenacceptingthegeometricaccuracyofthemachinetool,itiscompletedonceafterthemachinefineadjustment,anditisnotallowedtoadjustoneinspectionitem.Thepositionaccuracyinspectionshallbecarriedoutinaccordancewiththecorrespondingaccuracyacceptancestandards.Theworkingaccuracyofamachinetoolisacomprehensiveaccuracy,whichnotonlyreflectsthegeometricaccuracyandpositionaccuracyofthemachinetool,butalsoincludeserrorscausedbyvariousfactorssuchasthematerialofthetestpiece,theambienttemperature,thetoolperformance,andthecuttingconditions.

IntheacceptanceofCNCmachinetools,strengtheningtheinspectionoftheaboveaspectsisverybeneficialtotheequipmentmanagementworkandcanreduceunnecessarylosses.

Developmenthistory

TheCNCmachinetoolwasinventedbytheAmericaninventorJohnParsonsinthe20thcentury.Withthedevelopmentofelectronicinformationtechnology,theworld'smachinetoolindustryhasenteredtheeraofmechatronicswithdigitalmanufacturingtechnologyasthecore,ofwhichCNCmachinetoolsareoneoftherepresentativeproducts.CNCmachinetoolsaretheprocessingmothermachineofthemanufacturingindustryandtheimportantfoundationofthenationaleconomy.Itprovidesequipmentandmeansforallsectorsofthenationaleconomy,andhasunlimitedeconomicandsocialeffects.IndustrializedcountriessuchasEurope,theUnitedStates,andJapanhavesuccessivelycompletedtheindustrializationprocessofCNCmachinetools,whileChinastartedinthe1980sandisstillinthedevelopmentstage.

U.S.Development

TheU.S.governmentattachesgreatimportancetothemachinetoolindustry.TheU.S.DepartmentofDefenseandotherdepartmentscontinuetoproposethedevelopmentdirectionandscientificresearchtasksofmachinetoolsduetotheirmilitaryneeds,andprovidesufficientfunds.Italsorecruitstalentsfromallovertheworld,payingparticularattentionto"efficiency"and"innovation"andfocusingonbasicscientificresearch.Therefore,continuousinnovationinmachinetooltechnology,suchasthedevelopmentoftheworld'sfirstCNCmachinetoolin1952,thecreationofamachiningcenterin1958,thedevelopmentofFMSintheearly1970s,andthefirstopenCNCsystemin1987.SincetheUnitedStatesfirstcombinedtheneedsofautomobileandbearingproduction,fullydevelopedalargenumberofautomaticlinesrequiredformassproductionautomation,andtheelectronicandcomputertechnologyistheworld'sleading,soitsCNCmachinetoolhostdesign,manufacturingandCNCsystemhaveasolidfoundationandhavealwaysattachedimportancetoit.Scientificresearchandinnovation,soitshigh-performanceCNCmachinetooltechnologyhasbeenleadingtheworld.Today’sAmericanproductionofhigh-performanceCNCmachinetoolsusedinaerospaceandotherindustrieshasalessonthatitemphasizesbasicscientificresearchandneglectsappliedtechnology.Inthe1980s,thegovernmentoncerelaxeditsguidance,resultinginaslowincreaseintheoutputofCNCmachinetools.ThelessadvancedJapansurpassedandimportedalot.Sincethe1990s,thepastdeviationshavebeencorrected,thetechnologyofCNCmachinetoolshasbecomepractical,andtheoutputhasgraduallyincreased.

GermanyDevelopment

TheGermangovernmenthasalwaysattachedimportancetotheimportantstrategicpositionofthemachinetoolindustryandvigorouslysupporteditinmanyaspects.AfterthefirstCNCmachinetoolwasdevelopedin1956,Germanypaidspecialattentiontoscientificexperiments,combiningtheorywithpractice,andpayingequalattentiontobasicscientificresearchandappliedtechnologyscientificresearch.Thecompanyandtheuniversity'sscientificresearchdepartmentworkcloselytoconductin-depthresearchonthecommonalityandcharacteristicsofCNCmachinetools,andstriveforexcellenceinquality.GermanCNCmachinetoolsareofgoodqualityandperformance,advanced,practical,andgenuine,andareexportedallovertheworld.Especiallylarge,heavy,precisionCNCmachinetools.GermanyattachesgreatimportancetotheadvancedpracticalityofCNCmachinetoolsandaccessories.Itsmechanical,electrical,hydraulic,pneumatic,optical,cuttingtools,measurement,CNCsystems,andvariousfunctionalcomponentsareamongthebestintheworldintermsofqualityandperformance.

DevelopmentofJapan

TheJapanesegovernmentattachesgreatimportancetothedevelopmentofthemachinetoolindustry,andhaspassedplanningandregulations(suchas"MachineVibrationLaw","MechanicalandElectricalLaw","MechanicalInformationLaw",etc.)Guidedevelopment.LearnfromGermanyinfocusingontalentsandmachinetoolcomponents,andlearnfromtheUnitedStatesinqualitymanagementandCNCmachinetooltechnology,andevenoutofblueisbetterthanblue.SincethefirstCNCmachinetoolwasdevelopedin1958,itsoutputsurpassedthatoftheUnitedStatesin1978,anditsoutputandexportvolumehaveconsistentlyrankedfirstintheworld.Strategicallyimitatefirstandthencreate,Mr.'smid-rangeCNCmachinetoolswithlargeandwideoutputareexportedinlargequantities,occupyingtheworld'svastmarket.Inthe1980s,itbegantofurtherstrengthenscientificresearchanddeveloptowardshigh-performanceCNCmachinetools.

China'sdevelopment

Asthecornerstoneofmodernindustry,themachinetoolindustryisakeyissuethatcannotbebypassedintheprocessofindustrialeconomicdevelopment.China'smachinetoolindustryhasalwaysbeenThedevelopmentofhigh-endmachinetoolprojectshasfallentothemainstreamlevelofforeigncountriesandisintheprocessofcatchingup.

China'sCNCmachinetoolsarestillrelativelybackward.China'sCNCmachinetoolmarketishuge.Comparedwithforeignproducts,China'sgapismainlyinthehigh-speed,high-efficiencyandprecisionofmachinetools.Chinaisinthemiddleofindustrialization,thatis,itisgraduallytransformingfromsolvingshortagestoopeninguptobuildinganeconomicpower,frompovertyalleviationTobecomerich,anumberofhigh-growthindustriesbasedonheavyindustries,suchascoal,automobiles,steel,realestate,buildingmaterials,machinery,electronics,andchemicals,havedevelopedstrongly,formingahugedemandforthemachinetoolmarket,especiallyCNCmachinetools.

TheacceleratedtransformationofChina'smachinetoolindustryfacesfourmajorconstraints.China'sCNCmachinetooltechnologycanonlyachievefive-axislinkageatmost,andaccordingtorelevantsources,thisfive-axisisstillmostlyforshow.Almostallofthefive-axisandaboveareimported,andthetechnologyofmulti-pointlinkageisverysimilartoforeigntechnology.Biggap.

Intensifiedinternationalcompetitioninthedomesticmarket:Duetotheshrinkageofthemid-to-low-endCNCmachinetoolmarketandexcessproductioncapacity,coupledwiththeinfluxofforeignproductsatlowprices,marketcompetitionwillfurtherintensify.Ashigh-endproductshavebeendependentonimportsforalongtime,domesticproductsarefacingseverechallengesfrominternationalcompetition.

Thetechnology-leadingstrategyisshiftingtoacustomer-centricstrategy:economiccrisesoftenleadtolarge-scaleindustrialupgradingandenterprisetransformation.Themachinetoolindustryrealizestheservice-orientedmanufacturingindustry,andthecoreliesincustomer-orientedCenter,andactivelyprovidepersonalizedservicesthatcustomersneed.Therefore,ithasbecomethecurrenttrendtoshiftfromsimplysellingproductstoprovidingoverallsolutions,andfrombeingtechnology-centrictocustomer-centric.

ThereisabigcontrastbetweenChineseproductsandChinesemarketdemand,andtheproductstructureisinurgentneedofrapidadjustment:AlthoughChina’smachinetoolindustryhasmaintainedsustainedandrapiddevelopmentformanyyears,thephenomenonofunreasonableindustrialandproductstructurestillexists.Notstrong,high-endproductsstillrelyheavilyonimports.Althoughthedomesticmarketshareofdomesticmachinetoolshasincreasedtoacertainextent,thedomesticmarketshareofhigh-endCNCmachinetoolsandcorefunctionalcomponentsisstillverylow,andtheentireindustryhasahugepotentialtoreplaceimports.

Thetechnologicalinnovationmodelofenterprisesneedstobeimproved:Asthestatus,industrializationlevelandbrandinfluenceofChinesemachinetoolenterprisesaregraduallyincreasing,tobecomeanindustrialpower,theacquisitionofitstechnologycannolongerrelyonothers.Inthepast,Chinahastakenapathfromimitationtointroduction.Fromnowon,itmusttakethepathofindependentinnovation.Enterprisetechnologyencountersanewblockade,andtheestablishmentofanindependent,newandstrategicinnovationmodelofproduction,educationandresearchistheonlywaytosupportthesourceoftechnologyforproductstructureadjustment.

China'sCNCmachinetoolindustrywillcontinuethemomentumofstructuraladjustmentandcontinuetooccupyalargermarketwithnewproductsandnewhighlights.Accordingtothecuttingmethod,CNCcuttingmachinetoolscanbedividedintotwocategories:flamecuttingandplasmacutting.Withthecontinuousincreaseindemandindownstreamindustries,greaterdemandandhigherrequirementshavebeenputforwardforCNCmachinetoolaccessories.

ThedevelopmentofNortheastChinaisnotfast,andthedevelopmentofotherplacesisalsorelativelyslow.Thethirdistoadjustthestructureandpromotethetransformationtoachieveresults.Expertsbelievethatinthefaceofthefinancialcrisis,themajorityofenterprisesshouldcontinuetoadjusttheirstructure,improvequality,increasevarietiesandpromoteindustrialupgrading.Coupledwiththestrengtheningofmanagementandreductionofcosts,corporateefficiencyhasimprovedsignificantly.ThedecorativedevelopmenttrendofCNCcuttingmachinetoolscanbeseen.CNCcuttingmachinetoolsaremoreemphasizedintermsofmechanicalperformance,easyoperation,economicalprice,andstableprocessingaccuracy.Metalmaterialprocessingisincreasinglyrequiringpopularizationandmassproduction.Inadditiontosatisfyingtheabove-mentionedfunctions,CNCcuttingmachinetoolsmusthavetheapplicabilityofmultiplecuttingmethods.

Inordertoimprovetheirownstrengthandexpandtheinternationalmarketfaster,domesticCNCmachinetoolcompanieswilladoptavarietyofmethodstospeeduptheintegrationwithforeigncompaniestoimproveproductqualityandenhancecompetitiveness.WhilecontinuingtoexplorethemarketsoftheUnitedStates,Japanandothercountries,ithasalsoblossomedinSoutheastAsia,theMiddleEast,Russia,Europe,andAfrica.ItisunderstoodthatthecurrentoperationofthemetalcuttingCNCmachinetoolindustryhasthefollowingcharacteristics:First,itismoredifficultforexportenterprises.Fromthepointofviewofenterprisesabovedesignatedsize,brand-nameenterprisesthatmainlyselldomesticallyhavearelativelygoodmomentumofdevelopment.Thedevelopmentofsmallandmedium-sizedenterpriseswithoutabrandismoredifficult.Second,thedevelopmentofvariousregionsisnotbalanced.Zhejiang,Shandong,Hebei,BeijingandSichuanhavedevelopedrelativelyfast,andprivateenterprisesinGuangdonghavealsodevelopedrapidly.

MostcompaniesintheCNCcuttingmachinetoolindustryrelyonloweringproductpricestogainaccesstothemarket.Theconsequencesarelowproductprices,lowaddedvalue,lowprofits,andcompaniesdonothaveenoughfundsforsustainabledevelopment.Withthedevelopmentoftheindustryandtheupgradingofcompetition,improvingthetechnicalcontentofproducts,owningindependentpatentsanddesigns,focusingonbrandbuildingandmarketingisthebestchoiceforlong-termdevelopmentofanenterprise.

Inthepastfewyears,China’smachinetoolindustryhasachievedsustainedultra-high-speeddevelopment.Untilthefirsthalfof2011,demandwasstillstrong.However,startingfromthesecondhalfoftheyear,demandgrowthhassloweddownsignificantlyandnewordershavebeenadded.Withasharpdecline,theeconomicperformancesituationhasgraduallybecomesevere,andtheprofitratehascontinuedtodecline.

Duringthe"TwelfthFive-YearPlan"period,thecountryimplementedaproactivefiscalpolicyandaprudentmonetarypolicy.Withtechnologicalprogress,productupgrades,andthecontinuousadvancementofnationalkeyprojectsandlocalinvestmentprojects,varioussectorsofthenationaleconomyThelevelofdemandformachinetoolproductswillfurtherincrease,thedemandforhigh-levelmachinetoolsfornationaldefensemodernizationwillbemoreurgent,themarketdemandwilldeveloptoahigherlevel,andthenewroundofmarketcompetitionwillbecomemoreintense.

Duetothedownturnintheindustryandthedecliningdemandformachinetoolsbydownstreammanufacturingenterprises,mycountry'smachinetoolindustryhasbeeninadownturn.Upgradeandtransformationhavebecomethekeywordoftheindustry.EconomicalCNCmachinetoolshavebecomethekeytorevitalizingtheequipmentmanufacturingindustry.Oneofthekeypoints.

mycountry'sfoundrymachinetoolindustryhasmadecertainachievements,butitsdevelopmentstillfacesmanyrestrictiveproblems.Technologicalinnovationhasalwaysbeenaflawinthedomesticfoundrymachinetoolindustry.Comparedwithforeignfoundrymachinetoolindustry,mycountry'sfoundrymachinetoolindustryisobviouslylaggingbehindinthelevelofmanufacturingtechnology,whichmakesithaveobviousdeficienciesinthetechnicallevelandoperatingspeedofcoreoperatingcomponents,productaccuracyretention,andmachinetoolreliability..

mycountry'sfoundrymachinetoolenterpriseslacktheawarenessandabilityofindependentinnovationandbasictheoreticalresearch,whichrestrictsthedevelopmentofmycountry'sfoundrymachinetooltechnology.Tochangethissituation,itisnecessarytodeeplystudythecharacteristicsoftheuserindustry'sproducttechnologyTomeettherequirements,develophigh-levelprocessingequipmentincombinationwithprocesscharacteristics,andatthesametime,payattentiontotheresearchofbasictheoreticalwork,sothatmycountry'sfoundrymachinetoolindustrycanhaveabetterdevelopmentinthenearfuture.Thestatehasissuedaseriesofpoliciestovigorouslybuildemergingenterprisesandhigh-techenterprises.Seizingthisopportunity,theenterprisehasintroducedaseriesofpoliciessuchas"adjustmentandrevitalization"and"independentinnovation"toupgradethemachinetooltechnologyoftheenterpriseandstrictlyguaranteetheproducts.Qualityprovidesagoodenvironmentandmarketforacceleratingthedevelopmentofthefoundrymachinetoolindustry.

Asanationalbasicandstrategicindustry,themachinetoolindustryhasclearlymadeindependentinnovationTosupportandleadthedevelopmentoftheindustry.Thedevelopmentofmycountry'smachinetoolindustrymustbebasedonindependentinnovation,andachievekeytechnologicalbreakthroughsandindustrialupgradesthroughindependentresearchanddevelopmentoforiginalinnovation,introductionoftechnologydigestion,absorptionandre-innovation,andintegrationofexistingtechnologyinnovations.Constructandperfectatechnologicalinnovationsystemthatisenterprise-oriented,market-oriented,andacombinationofindustry,academia,researchandapplication;insistonincreasingtheinvestmentinresearchanddevelopment;strengthenresearchonkeytechnologiesandcommontechnologies,andstrivetomakebreakthroughsinbasicandcommontechnologyresearch,Improvethetechnicallevelofproductdevelopment.

Technologydevelopment

Highspeed,precision,compound,intelligenceandgreenarethegeneraltrendsinthedevelopmentofCNCmachinetools,whichhavebeenachievedinpracticalityandindustrialization.Gratifyingresults.Themainmanifestationsare:

1.Furtherexpansionofmachinetoolcompoundtechnology.WiththeadvancementofCNCmachinetooltechnology,compoundprocessingtechnologyisbecomingmoreandmoremature,includingmilling-turningcompounding,turning-millingcompounding,turning-boring-drilling-gearprocessing,etc.Theprecisionandefficiencyofcompoundprocessingaregreatlyimprovedbycompounding,turningandgrindingcompounding,formingcompoundprocessing,specialcompoundprocessing,etc.Theconceptsof"amachinetoolisaprocessingplant"and"one-timeinstallation,completeprocessing"arebeingacceptedbymorepeople,andthedevelopmentofcompoundprocessingmachinetoolsisshowingadiversifiedtrend.

2.TherearenewbreakthroughsintheintelligenttechnologyofCNCmachinetools,whichhavebeenmorereflectedintheperformanceoftheCNCsystem.Suchas:automaticadjustmentofinterferenceandanti-collisionfunction,theworkpieceautomaticallyexitsthesafeareaafterpowerfailure,power-offprotectionfunction,processingpartsdetectionandautomaticcompensationlearningfunction,high-precisionprocessingpartsintelligentparameterselectionfunction,automaticeliminationofmachinevibrationduringprocessing,etc.Inthepracticalstage,intelligencehasimprovedthefunctionandqualityofthemachinetool.

3.Therobotmakestheflexiblecombinationmoreefficient.Theflexiblecombinationoftherobotandthehostiswidelyused,whichmakestheflexiblelinemoreflexible,thefunctionisfurtherexpanded,theflexiblelineisfurthershortened,andtheefficiencyishigher.Robotsandmachiningcenters,turning-millingcompoundmachinetools,grinders,gearprocessingmachinetools,toolgrinders,electricalprocessingmachinetools,sawingmachines,stampingmachinetools,laserprocessingmachinetools,watercuttingmachinetoolsandotherformsofflexibleunitsandflexibleproductionlineshavebeguntobeapplied.

4.Theprecisionmachiningtechnologyhasmadenewprogress.ThemachiningaccuracyofCNCmetalcuttingmachinetoolshasbeenimprovedfromtheoriginalsilklevel(0.01mm)tothemicronlevel(0.001mm),andsomevarietieshavereachedabout0.05μm.Theprecisionofmicrocuttingandgrindingofultra-precisionCNCmachinetoolscanbestablyuptoabout0.05μm,andtheshapeaccuracycanreachabout0.01μm.Theprecisionofspecialprocessingusingoptical,electrical,chemicalandotherenergysourcescanreachnanometerlevel(0.001μm).Throughtheoptimizationofmachinetoolstructuredesign,ultra-finishingandpreciseassemblyofmachinetoolparts,theuseofhigh-precisionfullclosed-loopcontrolanddynamicerrorcompensationtechnologiessuchastemperatureandvibrationtoimprovethegeometricaccuracyofmachinetoolprocessing,reduceformandpositionerrors,surfaceroughness,etc.,Thusenteringtheeraofsub-micronandnano-levelsuperfinishing.

5.Theperformanceoffunctionalcomponentscontinuestoimprove.Functionalcomponentscontinuetodevelopinthedirectionofhighspeed,highprecision,highpowerandintelligence,andhaveachievedmatureapplications.FullydigitalACservomotorsanddrivingdevices,high-techelectricspindles,torquemotors,linearmotors,high-performancelinearrollingcomponents,high-precisionspindleunitsandotherfunctionalcomponentsarepopularizedandapplied,whichgreatlyimprovesthetechnicallevelofCNCmachinetools.

Developmentissues

ThedomesticdemandforCNCmachinetoolsisincreasing,andthedevelopmentofCNCmachinetoolshaspromotedtheinnovationandupgradingofCNCmachinetoolfunctionalcomponents.Thekeyfunctionalcomponentindustryofmycountry'shigh-endCNCmachinetoolscannotmeetdomesticneeds.ThedomesticCNCfunctionalcomponentindustrymainlyhasthefollowingproblems.

1.Theadaptabilityandsatisfactionarefarbelowthemarketdemand

FromthecurrentdevelopmenttrendofCNCmachinetoolsinmycountry,theadaptabilityandsatisfactionofdomesticfunctionalcomponentsfarreachLessthanthemarketdemand.Mainlymanifestedin:

1)Thereisacertaingapbetweentheproductleveloffunctionalcomponentsinmycountryandforeigncountries.Mostofthefunctionalcomponentsproducedinmycountryaremainlylabor-intensiveandhavelowtechnicalcontent,whichmakesitdifficulttoadapttothedevelopmentspeedandtechnicalrequirementsofdomesticCNCmachinetools,especiallyhigh-endCNCmachinetools.

2)mycountry'sfunctionalcomponentdevelopmentcapabilitiesarerelativelyweak,andthespeedofnewproductdevelopmentisslow.Mostfunctionalcomponentsneedtobedeveloped,co-produced,jointventures,orevenassembledwithforeigncountries.Althoughthesituationhaschangedsignificantlyinthepasttwoyears,mycountryisstillintheprocessofdevelopinghigh-techandlatestfunctionalcomponents,andthemarketshareprospectsarestillnotoptimistic.

2.Thescaleofmycountry'snumericalcontrolfunctionalcomponentmanufacturersissmall

Accordingtostatistics,therearemorethan70functionalcomponentmanufacturerswithfixedassetsofmorethan10millionyuaninmycountry,accountingformorethan7010%orless.Therearefourkindsof"origins"inmycountry'sfunctionalcomponentmanufacturers:oneistheenterprisedevelopedfromresearchinstitutes,collegesanduniversitieswithtechnicalsupport,whichcanbecalled"institutetype".Thecharacteristicsofthesecompaniesare:theyhaveacertaintechnologicalfoundationandtalentfoundation,andhaveanumberoftechnologicaldevelopmentpotentials,buttheproductionmethodsareweak,itisdifficulttoformanindustrialscaleinashorttime,andtherearealsosomegapsincost,marketing,andservices;Thesecondisanenterprisethatisgradually"independent"and"separated"fromthemainenginefactoryanddevelopedmainlytoproducecertainfunctionalcomponents,whichcanbecalledthe"mainfactorytype".Theseenterprisescanadapttomarketdemandintermsofproductioncapacity,technologicallevelanduseexperience,andcanformascaletoacertainextent.However,duetotheirinextricablylinkedconnectionswiththeoriginalOEMs,theyoftenmakeusersdoubtfulincompetition.Affectsitsmarketdevelopment,andatthesametime,itsdevelopmentcapabilitieshavecertainlimitations,soitisdifficulttoformafamousbrand;third,alargenumberofprivateenterpriseshaveemergedinJiangsuandZhejiang,whichcanbecalled"privateenterprisetype."Thesecompaniesaremainlylabor-intensiveandsingle-variety,suchaschainguards,carriages,fuelinjectionpipes,chipconveyors,andlightingequipment.Duetothefiercecompetition,itsqualityandpricecanmeetthemarketneedsofmediumandlow-endCNCmachinetools.Althoughthesekindsofhigh-endproductscannotbemanufacturedyet,andtheystillneedtobeimported,theyaretoalargeextentadaptedtotheoverallneedsofthedevelopmentofCNCmachinetoolsinmycountry;therearealsosomeforeignjointventuresorwholly-ownedenterprisesthatproducehigh-levelfunctionalcomponents.However,thebatchsizeissmall,andthereisnoindependenttechnologicaldevelopmentcapability,anditisdifficulttobecomethemainbodyandmainstreamoffunctionalcomponents.

3.Alargenumberofcorecomponentsrelyonimports

ThedevelopmentofChina'sCNCmachinetoolindustryiseye-catching.In2008,China'sCNCmachinetoolindustrycompletedatotalindustrialoutputvalueof3472.3billionyuanandproductsalesoutputvalue.334.83billionyuan,ayear-on-yearincreaseof27.5%and26.0%respectively.From2002to2008,Chinawastheworld'slargestconsumerandimporterofmachinetools.However,behindtherapiddevelopmentoftheindustry,afactthatcannotbeignoredisthattheproductionofkeypartsandcomponentsinmycountryisstillcontrolledbyothers,resultinginlowprofitsandlackofcorecompetitivenessinproducts.

4.Lackofhigh-techcontentthreatensindustrialsafety

mycountry'smachinetoolexportshavemaintainedagratifyingtrendforyears,buttheembarrassmentof"increasingvolumeanddecreasingprices"directlyreflectsourtechnologicallevel.Thelackofalargenumberofcoretechnologiesandthedependenceonkeycomponentsdirectlyaffectthesafetyofmycountry'smachinetoolindustry.Therefore,weneedtostrengthentheawarenessofearlywarningwork,gatherthewisdomandstrengthoftheindustry,andmaintainindustrialsafety.

Choiceofmillingcutters

TheindexablefacemillingcuttersforCNCmachinetoolsaremainlyusedformillingplanes.Whenroughmilling,chooseasmallerdiameterofthemillingcutter,becausethecuttingforceislargeduringroughmilling,andchoosingasmalldiametermillingcuttercanreducethecuttingtorque.WhentheCNCmachinetoolisusedforfinishingmilling,thediameterofthemillingcuttershouldbelarger,anditisbesttocovertheentirewidthofthesurfacetobemachinedtoimprovetheprecisionandefficiencyofaddingT.Whenthemachiningallowanceofthemachinetoolislargeanduneven,thetooldiametershouldbesmaller,otherwise,thecuttingqualityoftheworkpiecewillbeaffectedduetothedeepknifemarkofthehangingtool.

High-speedsteelendmillsaremostlyusedforprocessingbossesandgrooves,andaregenerallynotusedforprocessingthesurfaceoftheblank,becausethehardenedlayerandsandinclusiononthesurfaceoftheblankwillacceleratetoolwear.

Whenmachiningthesurfaceoftheblankorroughingthehole,youcanchooseanendmillorcornmillingcutterwithcementedcarbideforpowerfulcutting.

Whenmachiningtheperipheralcontourofaplaneworkpiece,theendmillCisoftenused.

Inordertoincreasetheaccuracyofthegroovewidthandreducethenumberoftoolchanges,amillingcutterwithadiameterof7thanthegroovewidthcanbeusedduringprocessing.Themiddlepartofthegrooveismilledfirst,andthenbothsidesofthegroovearemilledbythetoolradiuscompensationfunction..

Whenprocessingthree-dimensionalcurvedsurfacesorcontourswithvariablebevelangles,ball-endmillingcutters,ringmillingcutters,drummillingcutters,taperedmillingcutters,discmillingcutters,etc.areoftenused.

Whenthemachiningallowanceissmallandthesurfaceroughnessrequirementsarehigh,youcanchooseafacemillingcutterwithcubicboronnitrideinsertsorceramicinsertstoenablehigh-speedcuttingonmachinetools.

Powerrequirements

Asweallknow,high-speedmachiningtechnologyisdevelopingrapidly,anditisCNCmachinetoolsthatpromotesthisdevelopmenttrend.HowtomakereasonableuseoftheperformanceofCNCmachinetoolsandmaintainthemachinetoolsTheaccuracyofitisveryimportant.

Thepowersupplyistheenergysupportpartthatmaintainsthenormaloperationofthesystem.Thedirectresultofitsfailureorfailureistheshutdownofthesystemorthedestructionoftheentiresystem.Inaddition,someoperatingdata,settingdataandprocessingprogramsoftheCNCsystemaregenerallystoredinRAMmemory.Afterthesystemispoweredoff,itismaintainedbythebackupbatteryorlithiumbatteryofthepowersupply.Therefore,thedowntimeisrelativelylong,andpluggingorunpluggingthepowersupplyormemorymaycausedatalossandmakethesysteminoperable.

Atthesametime,becausethenumericalcontrolequipmentusesathree-phaseAC380Vpowersupply,safetyisalsoanimportantpartofthepreliminaryworkofthenumericalcontrolequipmentinstallation.Basedontheabovereasons,thepowersupplyforthenumericalcontrolequipmenthasthefollowingRequirements:

1.Gridvoltagefluctuationsshouldbecontrolledwithin+10%～-15%.However,China’spowersupplyfluctuatesgreatly,thequalityispoor,andtherearehiddeninterferencessuchashigh-frequencypulses.Humanfactors(suchassuddenpowerfailure,etc.).Duringpeakelectricityperiods,suchasaboutanhourbeforegoingtoworkorleavinggetoffworkduringtheday,andatnight,thereareoftenmoredeviations,evenupto±20%.Makethemachinetoolalarmandfailtoworknormally,andcausedamagetothemachinetoolpowersystem.Itevenleadstothelossofrelatedparameterdata.ThisphenomenonhasoccurredinCNCmachiningcentersorturningcentersandothermachinetoolsandequipment,andthefrequencyisrelativelyhigh,whichshouldbepaidattentionto.

ItisrecommendedtoconfigureanACvoltagestabilizedpowersupplysystemwithautomaticcompensationadjustmentfunctionintheworkshopwhereCNCmachinetoolsaremoreconcentrated;asingleCNCmachinetoolcanbeconfiguredwithanACvoltagestabilizerseparately.

2.Itisrecommendedtoconnectmechanicalandelectricalequipmenttoasinglepowersource.Ifitisnecessarytouseotherpowersourcestosupplypowertocertainpartsofelectricalequipment(suchaselectroniccircuits,electromagneticclutches),thesepowersourcesshouldbetakenasmuchaspossiblefromdevicesthatformpartofthemechanicalelectricalequipment(suchastransformers,transducers,etc.).Forlargeandcomplexmachinery,includingmanymachinerythatworktogetherinacoordinatedmannerandoccupyalargespace,morethanonepowersupplymayberequired,whichdependsontheconfigurationofthesitepowersupply.

Unlessthemechanicalandelectricalequipmentisdirectlyconnectedtothepowersourcewithaplug/socket,itisrecommendedthatthepowercordbedirectlyconnectedtothepowerterminalofthepowercut-offswitch.Ifthisisnotpossible,aseparateterminalblockshouldbeprovidedforthepowercord.

Thehandleofthepowercut-offswitchshouldbeeasilyaccessible,andshouldbeinstalledbetween0.6and1.9mabovetheeasy-to-operateposition.Theupperlimitisrecommendedtobe1.7m.Inthisway,thepowercanbecutoffquicklyintheeventofanemergency,reducinglossesandcasualties.

3,CNCequipmentrequirementsforcompressedairsupplysystemCNCmachinetoolsgenerallyusealotofpneumaticcomponents,sotheplantshouldbeconnectedtoacleananddrycompressedairsupplysystemnetwork.Itsflowandpressureshouldmeettherequirements.ThecompressedairmachineshouldbeinstalledfarawayfromtheCNCmachinetool.Accordingtothelayoutoftheplantandtheamountofairconsumption,considerationshouldbegiventoinstallingrefrigeratedaircompressors,airfilters,airstoragetanks,safetyvalvesandotherequipmenttothecompressedairsupplysystemnetwork.

4.Numericalcontrolequipmentrequirementsforworkingenvironment.Precisionnumericalcontrolequipmentgenerallyhasrequirementsforaconstanttemperatureenvironment.Onlyunderconstanttemperatureconditionscanthemachinetoolaccuracyandprocessingdegreebeensured.Generally,ordinaryCNCmachinetoolshavenospecificrequirementsforroomtemperature,butalotofpracticeshowsthatthefailurerateoftheCNCsystemgreatlyincreaseswhentheroomtemperatureistoohigh.

AhumidenvironmentwillreducethereliabilityofCNCmachinetools.Especiallyinahumidenvironmentwithhighacidgas,theprintedcircuitboardsandconnectorswillrust,andtheelectricalfailureofthemachinewillincrease.Therefore,someusersinsouthernChinashouldtakemeasurestodehumidifytheenvironmentofCNCmachinetoolsinsummerandrainyseason.

1)Theworkingenvironmenttemperatureshouldbebetween0～35℃,avoiddirectsunlighttotheCNCmachinetool,andtheroomshouldbeequippedwithgoodlightingequipment.

2)Inordertoimprovetheaccuracyoftheprocessedpartsandreducethethermaldeformationofthemachinetool,ifpossible,theCNCmachinetoolcanbeinstalledinarelativelyclosedworkshopwithair-conditioningequipment.

3)Therelativehumidityoftheworkingenvironmentshouldbelessthan75%.TheCNCmachinetoolshouldbeinstalledinaplaceawayfromliquidsplashes,andpreventtheworkshopfromdrippingandleaking.

4)Stayawayfromenvironmentswithexcessivedustandcorrosivegases.