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Using digital computer to control overseas processing from the s began. In 1952, the Massachusetts institute of technology in a vertical milling machine mounted a set of experimental numerical control system, and successfully realizing and the control of three axis movement, it became the world's first numerical control machine. Since then, from 60 s, some other industrial countries, such as Germany and Japan were development production and use of numerical control machine. 1974 microprocessor directly for nc machine tools, and further promote the popularization and application of the numerical control machine and developing. Along with numerical control function of machine more and more perfect, reliability and performance more and more high, it gradually in manufacturing bear the more and more important role.
The development of numerical control machine in China began in 1958, after decades of development, until after the 80 s introduced Japan, the United States, Spain and other countries CNC servo and servo system technology, the numerical control technology in our country have qualitative leap; applications gradually spread out, numerical control technology industry to gradually form scale.
In recent years, our country business enterprise of numerical control machine tool share is rising year by year, in large and medium-sized enterprise has more
Use, in the small and medium-sized enterprises and even individual enterprises generally also in begin to use. 2001 domestic numerical control metal-cutting lathes production has up to 1. 80000 units, a year-on-year growth 28. 5%, numerical control machine tool industry output rate from 2000 in 17. 4% increase to 2001 years of 22. 7%. In 2001, China's industrial output has entered the world machine 5 th, machine tool in the world's consumption rose to third place to 47. $3.9 billion, after the United States 53. 6.7 billion dollars, spending up 25% on the previous year. But because the home-made numerical control machine tool can't meet the demand of the market, China's imports of goods machine show ascendant trend, the import of 2001 machine tools jumped to second place in the world, for 24. $0.6 billion, a 27% increase from the previous year. In recent years, our country export growth of large nc machine tools have CNC lathe, CNC grinding machine, CNC special processing machines, CNC cutting machine, CNC forming bending machine, CNC machines, ordinary machine tools have drilling machine, thread-rolling, slotting machines, broaching machine, combination machine tools, hydraulic press, woodworking machinery, etc. Export of the numerical control machine tool breed with cheap primarily.
Because of the rapid development of modern industry, the market demand change of more and more diverse, many varieties, medium and small batch and even single production occupies considerable proportion, has become more and more common machine tool can not meet the modern processing technology and improve labor productivity requirements. If the equipment all update replacement, not only little capital investment, cost is too high, and of the original equipment idle and would cause great waste. Now science and technology development soon, especially microelectronics technology and the development of computer technology faster, applied to numerical control system, it can improve the automation degree of machine tool, and can improve the machining precision, so the most economical way is the numerical control machine tool for ordinary transformation. This can improve the processing productivity, improve the processing technology, still can reduce funds, and to reduce the labor intensity, shorten the order a new numerical control machine delivery cycle time. Practice has shown the economical nc milling machine common transformation has the significant practical value, is this, in the old milling machine on the nc transformation has a good market prospect.
Our country at present the machine tool gross 380 more than ten thousand sets, of which only 113400 units total numerical control machine, numerical control machine tools in China that is less than 3%. In the past 10 years, our country numerical control machine tool annual output is about 0.6 ~ 08000 sets, and annual output value is about 1.8 billion yuan. The numerical control machine tool annual rate of 6%. YiLing machine tools in China for more than 10 years of above 60%; 10 years the following machine, automatic and semi-automatic machine is less than 20%, FMC/FMS automation production line more numbered (the United States and Japan to be automatic and semi-automatic machine tool is more than 60%). Most of our manufacturing industry is visible and enterprise production, processing equipment of the vast majority of the traditional machine tool, and more than half YiLing is over 10 years old machine tools. In this equipment processing out of the common product quality is poor, variety, top grade, and less, the high cost and low long delivery, and in the international and domestic market less competitive, directly affecting an enterprise products, market, benefits and affect the enterprise survival and development. So must raise the rate of numerical control machine tools. Since our country since the reform and opening up, a lot of enterprise introduced from abroad technology, equipment and production line technical reform. According to not complete count, from 1979 to 1988, 10 years, the introduction of technical renovation programs have 18446 items, about 16.58 billion dollars. These projects, most of the project for the economic construction of our country play a proper role. But some introduced project for a variety of reasons, equipment or production line can't run, even paralysis, make the efficiency of enterprises is affected, serious make enterprise in trouble. Some equipment, production line imported from abroad later, some bad digestion and absorption, spare parts is not complete, maintain undeserved, running the bad; Some introduction only pay attention to when importing the equipments, instruments, the production line, ignore software, technology, management, causing the project is not complete and equipment cannot exert potential; Some even cannot start the operation, doesn't play its role; Some in the production line of products sold very well, but because equipment failure can't DaChan standard; Some because of the products, high energy consumption is low and cause losses; Some has introduced a long time, need to update technology. A variety of reasons make some equipment not only create wealth, but consuming wealth. These can't use of equipment, production line is a burden, also is a group of large stock assets, fixed is wealth. As long as find the main technical difficulties, and solve the key technical issues, can activate the least investment the largest stock assets, to win the biggest economic benefits and social benefits. This is also a great transformation market.
This topic is X53K vertical milling machine around will transform into economical CNC milling machine on the design, economical nc milling machine is to point to the price cheap, convenient in operation, and suitable for China's national conditions of a simple numerical control system of high efficiency automation machine tools. Small and medium enterprise in order to develop production, often hope on the original old machine tool transformation, achieve numerical control, automation. Economical nc milling machine system is combined with the actual production of reality, and combined with actual situation in China, and to meet the basic function system, under the precondition of prices as low as possible. Cheap price, performance to price moderate is the most main characteristic, especially suitable for occupies the larger proportion in the equipment of ordinary milling machine transformation, suitable for the first line in the production of large area promotion. Enterprise application type economical nc system to equipment after the transformation, the product will improve the machining accuracy and batch production ability and keep the "universal processing" and "special high efficiency" the two properties, improve equipment to upgrade their products of strain capacity, enhance the enterprise the competitive ability.
Using the microcomputer transform the existing common milling machine, the main problems which should be solved is how to mechanical drive into manual control tool to and the inversion, and into to transform into controlled by computer automatic transfer tool and automatically feed processing a milling machine, namely economical nc milling machine.
For the renovation of the numerical control machine is very necessary. Numerical control machine tool can well solve the complex shape, precision and small batch and changeable parts processing problem. Can stable quality and improve production efficiency processing, but the use of numerical control machine have also been other limitations. Such as: the numerical control machine tool is expensive, one-time investment huge etc, therefore, the CNC milling machine common transformation, bright prospects. It is suitable for China's economic level, the education level and production level, has become China's equipment technical reform one of main direction. And is currently in the machinery industry, with the development of market economy, the product update cycle more and more short, medium and small batch production possession of proportion is more and more big, the precision of mechanical products and quality requirements are constantly to improve and push forward. So the common machine getting more and more difficult to meet the requirement of treatment, and because of the technical level of the increase, the price of numerical control machine in declining, therefore, nc machine tools in the use of mechanical industry will become more and more common, and the original of the machine tool to ordinary numerical control reform should also be more and more widely, in accordance with the design of the task design X53K vertical milling machine numerical control the transformation.
國外利用數(shù)字計(jì)算機(jī)進(jìn)行控制加工是從40年代開始的。1952年美國麻省理工學(xué)院在一臺(tái)立式銑床上裝了一套試驗(yàn)性的數(shù)控系統(tǒng)，成功地實(shí)現(xiàn)同時(shí)控制三軸的運(yùn)動(dòng)，它成了世界上第一臺(tái)數(shù)控機(jī)床。此后，從60年代開始，其他一些工業(yè)國家如德國、日本等陸續(xù)地開發(fā)生產(chǎn)及使用數(shù)控機(jī)床。1974年微處理機(jī)直接用于數(shù)控機(jī)床，進(jìn)一步促進(jìn)了數(shù)控機(jī)床的普及應(yīng)用和大力發(fā)展。隨著數(shù)控機(jī)床的功能越來越完善，可靠性和性能越來越高，它在制造業(yè)中逐漸擔(dān)當(dāng)了越來越重要的角色。
我國數(shù)控機(jī)床的研制是從1958年開始的，經(jīng)歷了幾十年的發(fā)展，直至80年代后引進(jìn)了日本、美國、西班牙等國數(shù)控伺服及伺服系統(tǒng)技術(shù)后，我國的數(shù)控技術(shù)才有質(zhì)的飛躍，應(yīng)用面逐漸鋪開，數(shù)控技術(shù)產(chǎn)業(yè)才逐步形成規(guī)模。
近年來我國企業(yè)的數(shù)控機(jī)床占有率逐年上升，在大中企業(yè)已有較多
的使用，在中小企業(yè)甚至個(gè)體企業(yè)中也普遍開始使用。2001年國內(nèi)數(shù)控金切機(jī)床產(chǎn)量已達(dá)1. 8萬臺(tái)，比上年增長28. 5%，機(jī)床行業(yè)產(chǎn)值數(shù)控化率從2000年的17. 4%提高到2001年的22. 7%。2001年，我國機(jī)床工業(yè)產(chǎn)值己進(jìn)入世界第5名，機(jī)床消費(fèi)額在世界排名上升到第3位，達(dá)47. 39億美元，僅次于美國的53. 67億美元，消費(fèi)額比上一年增長25%。但由于國產(chǎn)數(shù)控機(jī)床不能滿足市場的需求，使我國機(jī)床的進(jìn)口額呈逐年上升態(tài)勢，2001年進(jìn)口機(jī)床躍升至世界第2位，達(dá)24. 06億美元，比上年增長27％。近年來我國出口額增幅較大的數(shù)控機(jī)床有數(shù)控車床、數(shù)控磨床、數(shù)控特種加工機(jī)床、數(shù)控剪板機(jī)、數(shù)控成形折彎機(jī)、數(shù)控壓鑄機(jī)等，普通機(jī)床有鉆床、鋸床、插床、拉床、組合機(jī)床、液壓壓力機(jī)、木工機(jī)床等。出口的數(shù)控機(jī)床品種以中低檔為主。
由于現(xiàn)代工業(yè)的飛速發(fā)展，市場需求變的越來越多樣化，多品種、中小批量甚至單件生產(chǎn)占有相當(dāng)大的比重，普通機(jī)床已越來越不能滿足現(xiàn)代加工工藝及提高勞動(dòng)生產(chǎn)率的要求。如果設(shè)備全部更新替換，不僅資金投入太大，成本太高，而且原有設(shè)備的閑置又將造成極大的浪費(fèi)。如今科學(xué)技術(shù)發(fā)展很快，特別是微電子技術(shù)和計(jì)算機(jī)技術(shù)的發(fā)展更快，應(yīng)用到數(shù)控系統(tǒng)上，它既能提高機(jī)床的自動(dòng)化程度，又能提高加工精度，所以最經(jīng)濟(jì)的辦法就是進(jìn)行普通機(jī)床的數(shù)控改造。這樣既可以提高加工生產(chǎn)率，改善加工工藝，還可以減少資金投入，減輕工人的勞動(dòng)強(qiáng)度，縮短訂購新的數(shù)控機(jī)床的交貨周期時(shí)間。實(shí)踐已經(jīng)證明普通銑床的經(jīng)濟(jì)型數(shù)控改造具有重大的實(shí)際價(jià)值，為此，在舊有銑床上進(jìn)行數(shù)控改造有著較好的市場前景。
我國目前機(jī)床總量380余萬臺(tái)，而其中數(shù)控機(jī)床總數(shù)只有11.34萬臺(tái)，即我國機(jī)床數(shù)控化率不到3％。近10年來，我國數(shù)控機(jī)床年產(chǎn)量約為0.6～0.8萬臺(tái)，年產(chǎn)值約為18億元。機(jī)床的年產(chǎn)量數(shù)控化率為6％。我國機(jī)床役齡10年以上的占60％以上；10年以下的機(jī)床中，自動(dòng)/半自動(dòng)機(jī)床不到20％，F(xiàn)MC/FMS等自動(dòng)化生產(chǎn)線更屈指可數(shù)（美國和日本自動(dòng)和半自動(dòng)機(jī)床占60％以上）?？梢娢覀兊拇蠖鄶?shù)制造行業(yè)和企業(yè)的生產(chǎn)、加工裝備絕大數(shù)是傳統(tǒng)的機(jī)床，而且半數(shù)以上是役齡在10年以上的舊機(jī)床。用這種裝備加工出來的產(chǎn)品普遍存在質(zhì)量差、品種少、檔次低、成本高、供貨期長，從而在國際、國內(nèi)市場上缺乏競爭力，直接影響一個(gè)企業(yè)的產(chǎn)品、市場、效益，影響企業(yè)的生存和發(fā)展。所以必須大力提高機(jī)床的數(shù)控化率。我國自改革開放以來，很多企業(yè)從國外引進(jìn)技術(shù)、設(shè)備和生產(chǎn)線進(jìn)行技術(shù)改造。據(jù)不完全統(tǒng)計(jì)，從1979～1988年10年間，全國引進(jìn)技術(shù)改造項(xiàng)目就有18446項(xiàng)，大約165.8億美元。這些項(xiàng)目中，大部分項(xiàng)目為我國的經(jīng)濟(jì)建設(shè)發(fā)揮了應(yīng)有的作用。但是有的引進(jìn)項(xiàng)目由于種種原因，設(shè)備或生產(chǎn)線不能正常運(yùn)轉(zhuǎn)，甚至癱瘓，使企業(yè)的效益受到影響，嚴(yán)重的使企業(yè)陷入困境。一些設(shè)備、生產(chǎn)線從國外引進(jìn)以后，有的消化吸收不好，備件不全，維護(hù)不當(dāng)，結(jié)果運(yùn)轉(zhuǎn)不良；有的引進(jìn)時(shí)只注意引進(jìn)設(shè)備、儀器、生產(chǎn)線，忽視軟件、工藝、管理等，造成項(xiàng)目不完整，設(shè)備潛力不能發(fā)揮；有的甚至不能啟動(dòng)運(yùn)行，沒有發(fā)揮應(yīng)有的作用；有的生產(chǎn)線的產(chǎn)品銷路很好，但是因?yàn)樵O(shè)備故障不能達(dá)產(chǎn)達(dá)標(biāo)；有的因?yàn)槟芎母摺a(chǎn)品合格率低而造成虧損；有的已引進(jìn)較長時(shí)間，需要進(jìn)行技術(shù)更新。種種原因使有的設(shè)備不僅沒有創(chuàng)造財(cái)富，反而消耗著財(cái)富。這些不能使用的設(shè)備、生產(chǎn)線是個(gè)包袱，也是一批很大的存量資產(chǎn)，修好了就是財(cái)富。只要找出主要的技術(shù)難點(diǎn)，解決關(guān)鍵技術(shù)問題，就可以最小的投資盤活最大的存量資產(chǎn)，爭取到最大的經(jīng)濟(jì)效益和社會(huì)效益。這也是一個(gè)極大的改造市場。
本課題是圍繞將X53K立式銑床改造成經(jīng)濟(jì)型數(shù)控銑床展開設(shè)計(jì)的，經(jīng)濟(jì)型數(shù)控銑床是指價(jià)格低廉、操作使用方便，適合我國國情的裝有簡易數(shù)控系統(tǒng)的高效自動(dòng)化機(jī)床。中小型企業(yè)為了發(fā)展生產(chǎn)，常希望對原有舊機(jī)床進(jìn)行改造，實(shí)現(xiàn)數(shù)控化、自動(dòng)化。經(jīng)濟(jì)型數(shù)控銑床系統(tǒng)就是結(jié)合現(xiàn)實(shí)的的生產(chǎn)實(shí)際，結(jié)合我國國情，在滿足系統(tǒng)基本功能的前提下，盡可能降低價(jià)格。價(jià)格便宜、性能價(jià)格比適中是其最主要的特點(diǎn)，特別適合在設(shè)備中占有較大比重的普通銑床改造，適合在生產(chǎn)第一線大面積推廣。企業(yè)應(yīng)用經(jīng)濟(jì)型數(shù)控型系統(tǒng)對設(shè)備進(jìn)行改造后，將提高產(chǎn)品加工精度和批量生產(chǎn)的能力，同時(shí)又能保持“萬能加工”和“專用高效”這兩種屬性，提高設(shè)備自身對產(chǎn)品更新?lián)Q代的應(yīng)變能力，增強(qiáng)企業(yè)的競爭能力。
利用微機(jī)改造現(xiàn)有的普遍銑床，主要應(yīng)該解決的問題是如何將機(jī)械傳動(dòng)的進(jìn)給和手工控制的刀架轉(zhuǎn)位，進(jìn)給改造成由計(jì)算機(jī)控制的刀架自動(dòng)轉(zhuǎn)位以及自動(dòng)進(jìn)給加工銑床，即經(jīng)濟(jì)型數(shù)控銑床。
進(jìn)行數(shù)控機(jī)床的改造是非常有必要的。數(shù)控機(jī)床可以很好地解決形狀復(fù)雜、精密、小批量及多變零件的加工問題。能夠穩(wěn)定加工質(zhì)量和提高生產(chǎn)效率，但是數(shù)控機(jī)床的運(yùn)用也受到其他條件的限制。如：數(shù)控機(jī)床價(jià)格昂貴，一次性投資巨大等，因此，普通銑床的數(shù)控改造，大有可為。它適合我國的經(jīng)濟(jì)水平、教育水平和生產(chǎn)水平，已成為我國設(shè)備技術(shù)改造主要方向之一。并且目前在機(jī)械行業(yè)中，隨著市場經(jīng)濟(jì)的發(fā)展，產(chǎn)品更新周期越來越短，中小批量的生產(chǎn)所占有的比例越來越大，對機(jī)械產(chǎn)品的精度和質(zhì)量要求也在不斷地提高與推進(jìn)。所以普通機(jī)床越來越難以滿足加工的要求，同時(shí)由于技術(shù)水平的提高，數(shù)控機(jī)床的價(jià)格在不斷下降，因此，數(shù)控機(jī)床在機(jī)械行業(yè)中的使用將越來越普遍，而對原有普通機(jī)床的數(shù)控化改造也應(yīng)是越來越廣泛，依照設(shè)計(jì)任務(wù)本設(shè)計(jì)對X53K立式銑床進(jìn)行了數(shù)控化改造。