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摘 要
隨著數控技術的發(fā)展和普及，加工中心的作用越發(fā)突顯它的重要性。為進一步提高數控機床的加工效率，數控機床正向著工件在一臺機床一次裝夾即可完成多道工序或全部工序加工的方向發(fā)展，因此出現了各種類型的加工中心機床，如車削中心、鏜銑加工中心、鉆削中心等等。這類多工序加工的數控機床在加工過程中要使用多種刀具，因此必須有自動換刀裝置，也就是所說的刀庫，以便選用不同刀具，完成不同工序的加工工藝。自動換刀裝置應當具備換刀時間短、刀具重復定位精度高、足夠的刀具儲備量、占地面積小、安全可靠等特性。
本論文是開發(fā)設計出一種體積小、結構緊湊、價格較低、生產周期短的小型立式加工中心無機械手換刀刀庫。首先介紹了國內外加工中心研究現狀及發(fā)展趨勢，闡明了本課題研究的目的、意義。然后進一步介紹本小型加工中心刀庫總體結構和各部件方案的選擇，并在此基礎上進行了小型加工中心刀庫的機械結構的設計計算，主要包括刀盤部件設計（含刀盤，夾塊，刀爪），刀庫轉動定位機構設計（含轉臂，槽輪，滾子，鎖止盤），刀庫總體機構設計（含軸承套，軸，箱蓋，箱體）刀庫移動部分設計。
關鍵詞：數控系統 加工中心 刀庫
Abstract
Along with the numerical control technology development and the popularization, the processing center function reveals its importance even more suddenly. For further enhances the numerical control engine laths the processing efficiency, the numerical control engine laths is clamping to the work piece in an engine laths attire then completes the multi-channel working procedure or the complete working procedure processing direction develops, therefore appeared each kind of type processing center engine laths, ike the turning center, the boring mill processing center, drills truncates center and so on. This kind of working procedure processing numerical control engine laths must use many kinds of cutting tools in the processing process, therefore must have trades the knife installment automatically, also is the knife storehouse which said, in order to select the different cutting tool, completes the different working procedure the processing craft. Trades the knife equipment to have automatically to have trades the knife time short, the cutting tool repetition pointing accuracy high, the enough cutting tool margin, the area small, safe reliable and so on the characteristics.
The present paper is the development designs one kind of volume slightly, the structure compact, the price is low, production cycle short small vertical processing center knife storehouse this article. Then further introduced this small processing center knife storehouse overall structure and various parts plan choice, and has carried on the small processing center knife storehouse mechanism design calculation in this foundation, mainly includes the knife storehouse overall organization design, the electrical machinery selection, the knife storehouse rotation detent mechanism design knife storehouse migration part design and so on.
Keywords: numerically controlled lathe machining centers cut database
目 錄
摘要……………………………………………………………………………i
Abstract………………………………………………………………………ii
1 緒論…………………………………………………………………………1
1.1 國內外的研究現狀和發(fā)展趨勢…………………………………………1
1.1.1 當前世界NC機床的研究現狀……………………………………1
1.1.2 我國數控機床產業(yè)的發(fā)展狀況……………………………………2
1.1.3 加工中心的發(fā)展動向………………………………………………3
1.1.4 我國數控機床研究存在的問題……………………………………3
1.2 加工中心概論……………………………………………………………4
1.2.1 自動換刀系統產品化的意義和前景………………………………6
1.3 本論文研究的目的和意義………………………………………………6
1.4 本論文完成的主要工作…………………………………………………6
2 總體方案的設計……………………………………………………………8
2.1 運動方案的設計…………………………………………………………8
2.1.1 運動數目的確定……………………………………………………8
2.1.2 運動方案的確定……………………………………………………8
2.2 功能部件的設計方案……………………………………………………9
2.2.1 主傳動系統…………………………………………………………9
2.2.2 進給伺服系統………………………………………………………10
2.2.3自動換刀系統………………………………………………………11
2.2.4 基礎部件……………………………………………………………13
2.2.5 數控系統……………………………………………………………14
2.2.6 輔助裝置……………………………………………………………14
2.3 總體布局…………………………………………………………………14
2.4 主要技術參數……………………………………………………………14
2.5 小結………………………………………………………………………16
3 刀庫的設計…………………………………………………………………17
3.1 刀庫的結構設計…………………………………………………………17
3.1.1 刀庫主要參數的確定………………………………………………17
3.1.2 刀盤部分的設計……………………………………………………17
3.1.3 刀庫轉動定位機構的設計…………………………………………18
3.1.4 軸的設計……………………………………………………………21
3.1.5 滾動軸承的選擇計算………………………………………………24
3.1.6 鍵的選用與計算……………………………………………………25
3.1.7 刀庫的支承部分的設計……………………………………………25
3.2 刀庫移動部分的設計……………………………………………………26
3.2.1 刀庫支承橫梁和導軌的設計………………………………………26
3.2.2 刀庫移動絲杠和電機的選擇………………………………………27
3.3 刀庫、橫梁的安裝………………………………………………………27
3.4 小結………………………………………………………………………38
結論………………………………………………………………………………29
致謝………………………………………………………………………………30
參考文獻…………………………………………………………………………31
iv
NUMERICAL CONTROL
Numerical control(N／C)is a form of programmable automation in which the processing equipment is controlled by means of numbers，letters，and other symbols．The numbers，letters，and symbols are coded in an appropriate format to define a program of instructions for a particular workpart or job．When the job changes，the program of instructions is changed．The capability to change the program is what makes N／C suitable for low-and medium-volume production．It is much easier to write programs than to make major alterations of the processing equipment．
There are two basic types of numerically controlled machine tools：point—to—point and continuous—path(also called contouring)．Point—to—point machines use unsynchronized motors，with the result that the position of the machining head Can be assured only upon completion of a movement，or while only one motor is running．Machines of this type are principally used for straight—line cuts or for drilling or boring．
The N／C system consists of the following components：data input，the tape reader with the control unit，feedback devices，and the metal—cutting machine tool or other type of N／C equipment．
Data input，also called“man—to—control link”，may be provided to the machine tool manually，or entirely by automatic means．Manual methods when used as the sole source of input data are restricted to a relatively small number of inputs．Examples of manually operated devices are keyboard dials，pushbuttons，switches，or thumbwheel selectors．These are located on a console near the machine．Dials ale analog devices usually connected to a syn-chro-type resolver or potentiometer．In most cases，pushbuttons，switches，and other similar types of selectors aye digital input devices．Manual input requires that the operator set the controls for each operation．It is a slow and tedious process and is seldom justified except in elementary machining applications or in special cases．In practically all cases，information is automatically supplied to the control unit and the machine tool by cards，punched tapes，or by magnetic tape．Eight—channel punched paper tape is the most commonly used form of data input for conventional N／C systems．The coded instructions on the tape consist of sections of punched holes called blocks．Each block represents a machine function，a machining operation，or a combination of the two．The entire N／C program on a tape is made up of an accumulation of these successive data blocks．Programs resulting in long tapes all wound on reels like motion-picture film．Programs on relatively short tapes may be continuously repeated by joining the two ends of the tape to form a loop．Once installed，the tape is used again and again without further handling．In this case，the operator simply loads and unloads the parts．Punched tapes ale prepared on type writers with special tape—punching attachments or in tape punching units connected directly to a computer system．Tape production is rarely error-free．Errors may be initially caused by the part programmer，in card punching or compilation，or as a result of physical damage to the tape during handling，etc．Several trial runs are often necessary to remove all errors and produce an acceptable working tape．
While the data on the tape is fed automatically，the actual programming steps ale done manually．Before the coded tape may be prepared，the programmer，often working with a planner or a process engineer, must select the appropriate N／C machine tool，determine the kind of material to be machined，calculate the speeds and feeds，and decide upon the type of tooling needed. The dimensions on the part print are closely examined to determine a suitable zero reference point from which to start the program．A program manuscript is then written which gives coded numerical instructions describing the sequence of operations that the machine tool is required to follow to cut the part to the drawing specifications．
The control unit receives and stores all coded data until a complete block of information has been accumulated．It then interprets the coded instruction and directs the machine tool through the required motions．
The function of the control unit may be better understood by comparing it to the action of a dial telephone，where，as each digit is dialed，it is stored．When the entire number has been dialed，the equipment becomes activated and the call is completed．
Silicon photo diodes，located in the tape reader head on the control unit，detect light as it passes through the holes in the moving tape．The light beams are converted to electrical energy，which is amplified to further strengthen the signal．The signals are then sent to registers in the control unit, where actuation signals are relayed to the machine tool drives．
Some photoelectric devices are capable of reading at rates up to 1000 characters per second．High reading rates are necessary to maintain continuous machine—tool motion；otherwise dwell marks may be generated by the cutter on the part during contouring operations．The reading device must be capable of reading data blocks at a rate faster than the control system can process the data．
A feedback device is a safeguard used on some N／C installations to constantly compensate for errors between the commanded position and the actual location of the moving slides of the machine tool．An N／C machine equipped with this kind of a direct feedback checking device has what is known as a closed-loop system．Positioning control is accomplished by a sensor which，during the actual operation，records the position of the slides and relays this information back to the control unit．Signals thus received ale compared to input signals on the tape，and any discrepancy between them is automatically rectified．In an alternative system，called an open—loop system，the machine is positioned solely by stepping motor drives in response to commands by a controllers．There are three basic types of NC motions, as follows:
Point-to-point or Positional Control In point-to-point control the machine tool elements (tools, table, etc.) are moved to programmed locations and the machining operations performed after the motions are completed. The path or speed of movement between locations is unimportant; only the coordinates of the end points of the motions are accurately controlled. This type of control is suitable for drill presses and some boring machines, where drilling, tapping, or boring operations must be performed at various locations on the work piece. Straight-Line or Linear Control Straight-Line control systems are able to move the cutting tool parallel to one of the major axes of the machine tool at a controlled rate suitable for machining. It is normally only possible to move in one direction at a time, so angular cuts on the work piece are not possible, consequently, for milling machines, only rectangular configurations can be machined or for lathes only surfaces parallel or perpendicular to the spindle axis can be machined. This type of controlled motion is often referred to as linear control or a half-axis of control. Machines with this form of control are also capable of point-to-point control.
Continuous Path or Contouring Control In continuous path control the motions of two or more of the machine axes are controlled simultaneously, so that the position and velocity of the can be tool are changed continuously. In this way curves and surfaces can be machined at a controlled feed rate. It is the function of the interpolator in the controller to determine the increments of the individual controlled axes of the machines necessary to produce the desired motion. This type of control is referred to as continuous control or a full axis of control.Some terminology concerning controlled motions for NC machines has been introduced. For example, some machines are referred to as four-or five-or even six-axis machines. For a vertical milling machine three axes of control are fairly obvious, these being the usual X, Y, Z coordinate directions. A fourth or fifth axis of control would imply some form of rotary table to index the work piece or possibly to provide angular motion of the work head. Thus, in NC terminology an axis of control is any controlled motion of the machine elements (spindles, tables, etc). A further complication is use of the term half-axis of control; for example, many milling machines are referred to as 2.5-axis machine. This means that continuous control is possible for two motions (axes) and only linear control is possible for the third axis. Applied to vertical milling machines, 2.5axis control means contouring in the X, Y plane and linear motion only in the Z direction. With these machines three-dimensional objects have to be machined with water lines around the surface at different heights. With an alternative terminology the same machine could be called a 2CL machine (C for continuous, L for linear control). Thus, a milling machine with continuous control in the X, Y, Z directions could be termed be a three-axis machine or a 3c machine, Similarly, lathes are usually two axis or 2C machines. The degree of work precision depends almost entirely upon the accuracy of the lead screw and the rigidity of the machine structure．With this system．there is no self-correcting action or feedback of information to the control unit．In the event of an unexpected malfunction，the control unit continues to put out pulses of electrical current．If，for example，the table on a N／C milling machine were suddenly to become overloaded，no response would be sent back to the controller．Because stepping motors are not sensitive to load variations，many N／C systems are designed to permit the motors to stall when the resisting torque exceeds the motor torque．Other systems are in use，however，which in spite of the possibility of damage to the machine structure or to the mechanical system，ale designed with special high—torque stepping motors．In this case，the motors have sufficient capacity to“overpower’’the system in the event of almost any contingency．
The original N／C used the closed—loop system．Of the two systems，closed and open loop，closed loop is more accurate and，as a consequence，is generally more expensive．Initially，open—loop systems were used almost entirely for light-duty applications because of inherent power limitations previously associated with conventional electric stepping motors．Recent advances in the development of electro hydraulic stepping motors have led to increasingly heavier machine load applications.
數控技術
數控是可編程自動化技術的一種形式，通過數字、字母和其他符號來控制加工設備。數字、字母和符號用適當的格式編碼為一個特定工件定義指令程序。當工件改變時，指令程序就改變。這種改變程序的能力使數控適合于中、小批量生產，寫一段新程序遠比對加工設備做大的改動容易得多。
數控機床有兩種基本形式：點位控制和連續(xù)控制(也稱為輪廓控制)。點位控制機床采用異步電動機，因此，主軸的定位只能通過完成一個運動或一個電動機的轉動來實現。這種機床主要用于直線切削或鉆孔、鏜孔等場合。
數控系統由下列組件組成：數據輸入裝置，帶控制單元的磁帶閱讀機，反饋裝置和切削機床或其他形式的數控設備。
數據輸人裝置，也稱“人機聯系裝置”，可用人工或全自動方法向機床提供數據。人工方法作為輸人數據唯一方法時，只限于少量輸入。人工輸入裝置有鍵盤，撥號盤，按鈕，開關或撥輪選擇開關，這些都位于機床附近的一個控制臺上。撥號盤通常連到一個同步解析器或電位計的模擬裝置上。在大多數情況下，按鈕、開關和其他類似的旋鈕是數據輸入元件。人工輸入需要操作者控制每個操作，這是一個既慢又單調的過程，除了簡單加工場合或特殊情況，已很少使用。幾乎所有情況下，信息都是通過卡片、穿孔紙帶或磁帶自動提供給控制單元。在傳統的數控系統中，八信道穿孔紙帶是最常用的數據輸入形式，紙帶上的編碼指令由一系列稱為程序塊的穿孔組成。每一個程序塊代表一種加工功能、一種操作或兩者的組合。紙帶上的整個數控程序由這些連續(xù)數據單元連接而成。帶有程序的長帶子像電影膠片一樣繞在盤子上，相對較短的帶子上的程序可通過將紙帶兩端連接形成一個循環(huán)而連續(xù)不斷地重復使用。帶子一旦安裝好，就可反復使用而無需進一步處理。此時，操作者只是簡單地上、下工件。穿孔紙帶是在帶有特制穿孔附件的打字機或直接連到計算機上的紙帶穿孔裝置上做成的。紙帶制造很少不出錯，錯誤可能由編程、卡片穿孔或編碼、紙帶穿孔時的物理損害等形成。通常，必須要試走幾次來排除錯誤，才能得到一個可用的工作紙帶。
雖然紙帶上的數據是自動進給的，但實際編程卻是手工完成的，在編碼紙帶做好前，編程者經常要和一個計劃人員或工藝工程師一起工作，選擇合適的數控機床，決定加工材料，計算切削速度和進給速度，決定所需刀具類型，仔細閱讀零件圖上尺寸，定下合適的程序開始的零參考點，然后寫出程序清單，其上記載有描述加工順序的編碼數控指令，機床按順序加工工件到圖樣要求。
控制單元接受和儲存編碼數據，直至形成一個完整的信息程序塊，然后解釋數控指令，并引導機床得到所需運動。
為更好理解控制單元的作用，可將它與撥號電話進行比較，即每撥一個數字，就儲存一個，當整個數字撥好后，電話就被激活，也就完成了呼叫。
裝在控制單元里的紙帶閱讀機，通過其內的硅光二極管，檢測到穿過移動紙帶上的孔漏過的光線，將光束轉變成電能，并通過放大來進一步加強信號，然后將信號送到控制單元里的寄存器，由它將動作信號傳到機床驅動裝置。
有些光電裝置能以高達每秒1000個字節(jié)的速度閱讀，這對保持機床連續(xù)動作是必須的，否則，在輪廓加工時，刀具可能在工件上產生劃痕。閱讀裝置必須要能以比控制系統處理數據更快的速度來閱讀數據程序塊。
反饋裝置是用在一些數控設備上的安全裝置，它可連續(xù)補償控制位置與機床運動滑臺的實際位置之間的誤差。裝有這種直接反饋檢查裝置的數控機床有一個閉環(huán)系統裝置。位置控制通過傳感器實現，在實際工作時，記錄下滑臺的位置，并將這些信息送回控制單元。接受到的信號與紙帶輸入的信號相比較，它們之間的任何偏差都可得到糾正。
在另一個稱為開環(huán)的系統中，機床僅由響應控制器命令的步進電動機驅動定位，工件的精度幾乎完全取決于絲杠的精度和機床結構的剛度。有幾個理由可以說明步進電機是一個自動化申請的非常有用的驅動裝置。對于一件事物，它被不連續(xù)直流電壓脈沖驅使,是來自數傳計算機和其他的自動化的非常方便的輸出控制系統。當多數是索引或其他的自動化申請所必備者的時候，步進電機對運行一個精確的有角進步也是理想的。因為控制系統不需要監(jiān)聽就提供特定的輸出指令而且期待系統適當地反應的公開- 環(huán)操作造成一個回應環(huán)，步進電機是理想的。 一些工業(yè)的機械手使用高抬腿運步的馬乘汽車駕駛員，而且步進電機是有用的在數字受約束的工作母機中。 這些申請的大部分是公開- 環(huán) ,但是雇用回應環(huán)檢測受到驅策的成份位置是可能的。 環(huán)的一個分析者把真實的位置與需要的位置作比較，而且不同是考慮過的錯誤。 那然后駕駛員能發(fā)行對步進電機的電脈沖，直到錯誤被減少對準零位。在這個系統中，沒有信息反饋到控制單元的自矯正過程。出現誤動作時，控制單元繼續(xù)發(fā)出電脈沖。比如，一臺數控銑床的工作臺突然過載，阻力矩超過電機轉矩時，將沒有響應信號送回到控制器。因為，步進電機對載荷變化不敏感，所以許多數控系統設計允許電機停轉。然而，盡管有可能損壞機床結構或機械傳動系統，也有使用帶有特高轉矩步進電機的其他系統，此時，電動機有足夠能力來應付系統中任何偶然事故。
最初的數控系統采用開環(huán)系統。在開、閉環(huán)兩種系統中，閉環(huán)更精確，一般說來更昂貴。起初，因為原先傳統的步進電動機的功率限制，開環(huán)系統幾乎全部用于輕加工場合，最近出現的電液步進電動機已越來越多地用于較重的加工領域。