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附錄1
粘接減振片式多頭熱壓機(jī)是以系列化、標(biāo)準(zhǔn)化的通用部件為基礎(chǔ)，配以少量的專用部件組成的專用機(jī)床，因此，機(jī)床的制造和調(diào)整都很方便。近期，東營信義集團(tuán)又引進(jìn)了幾臺(tái)先進(jìn)的液壓機(jī)，這些液壓機(jī)都綜合應(yīng)用了信息技術(shù)、感應(yīng)傳感技術(shù)、計(jì)算機(jī)自動(dòng)控制技術(shù)、機(jī)械技術(shù)等先進(jìn)技術(shù)，其效率、功能、自動(dòng)化程度都相對現(xiàn)有機(jī)床有很大的提高。這讓我們看到了我國機(jī)床使用及制造的發(fā)展方向，也看到了機(jī)床未來的發(fā)展趨勢。本文設(shè)計(jì)的粘接減振片多頭式熱壓機(jī)的主結(jié)構(gòu)是兩壓頭式熱壓機(jī)，其設(shè)計(jì)的根據(jù)是信義集團(tuán)盤片車間福特生產(chǎn)線的粘接減振片單頭熱壓機(jī)。改進(jìn)的多頭式熱壓機(jī)的加工特點(diǎn)是：
1）采用兩個(gè)壓頭，在一次壓制過程中可以一次加工兩個(gè)剎車片，先在加工數(shù)量上提高一倍；
2）工作臺(tái)上安裝滑臺(tái)循環(huán)加工，滑臺(tái)上安裝工裝，可以根據(jù)剎車片的型號靈活更換，工作臺(tái)上放有 11 個(gè)滑臺(tái)，加工時(shí)滑臺(tái)在 PLC 程序控制下依次有順序的循環(huán)加工，所以在工作臺(tái)上可以同時(shí)放 11 對剎車片然后連續(xù)加工，而且只要一個(gè)操作員在出料口等待將工件拿出同時(shí)將未加工工件放入工裝上就可以完成此工序的加工，省去操作員的等待時(shí)間，此種工作臺(tái)可以提高生產(chǎn)效率數(shù)倍甚至數(shù)十倍，也可以大幅度的減少勞動(dòng)人員的勞動(dòng)強(qiáng)度。
多頭式熱壓機(jī)的結(jié)構(gòu)特點(diǎn)：
1）兩個(gè)壓頭采用立式液壓缸提供壓力，而且兩個(gè)液壓缸的型號是相同的，因此縮短了設(shè)計(jì)周期和設(shè)計(jì)過程；
2）兩個(gè)壓頭液壓缸的進(jìn)出液壓油采用同一個(gè)供油系統(tǒng)，而且兩液壓缸的進(jìn)出油口分別相連，即在進(jìn)油口有相同壓力，相同流量的壓力油，在出油口也一樣，實(shí)現(xiàn)了兩個(gè)壓頭的壓制壓力相等，解決了由于工裝形狀公差造成的剎車片在粘接減振片時(shí)表面壓力不等的問題，是減震片的拉拔力符合工藝要求；
3）滑臺(tái)的動(dòng)力源也采用液壓缸，在工作臺(tái)的四邊分別安裝有四個(gè)液壓缸，它們的供油系統(tǒng)只要加幾個(gè)控制閥也可以與壓頭液壓缸的供油系統(tǒng)相連，即整個(gè)粘接減振片熱壓機(jī)采用一個(gè)供油系統(tǒng)，節(jié)省了動(dòng)力能源，也簡化了機(jī)床的結(jié)構(gòu)；
4）粘接減振片的工作過程，無論是主運(yùn)動(dòng)，進(jìn)給運(yùn)動(dòng)還是輔助運(yùn)動(dòng)都采用一個(gè) PLC 程序控制，使控制準(zhǔn)確，有序；
5）根據(jù)兩壓頭原理，可以重新設(shè)計(jì)液壓缸支架，增加壓頭，由于大部分都是標(biāo)準(zhǔn)件，所以設(shè)計(jì)和制造比較簡單；
6）由于主結(jié)構(gòu)比較簡單，所以可以在機(jī)床上增加兩個(gè)機(jī)械手代替人工操作，一個(gè)負(fù)責(zé)將工件放入工裝，一個(gè)負(fù)責(zé)將工件取出，實(shí)現(xiàn)機(jī)床的自動(dòng)化和自動(dòng)生產(chǎn)線。
因此，改進(jìn)后的粘接減振片多頭式熱壓機(jī)不僅提高工作效率，而且可以大幅度的降低工人的勞動(dòng)強(qiáng)度，可以實(shí)現(xiàn)產(chǎn)品的自動(dòng)生產(chǎn)線和提高機(jī)床的自動(dòng)化程度。這種機(jī)床適合大批量產(chǎn)品的生產(chǎn)，而且造價(jià)比較低，改造比較靈活，適合現(xiàn)代工業(yè)發(fā)展的要求。
液壓系統(tǒng)的正確維護(hù)
1）選擇適合的液壓油
液壓油在液壓油系統(tǒng)中起著傳遞壓力、潤滑、冷卻、密封的作用，液壓油選擇不恰當(dāng)是液壓系統(tǒng)早期故障和耐久性下降的主要原因。應(yīng)按隨機(jī)使用說明書中規(guī)定的牌號選擇液壓油，特殊情況需要使用代用油時(shí)，應(yīng)力求其性能與原牌號性能相同。不同牌號的液壓油不能混合使用，以防液壓油產(chǎn)生化學(xué)反應(yīng) 、性能發(fā)生變化。深褐色、乳白色、有異味的液壓油是變質(zhì)油，不能使用。
2） 防止固體雜質(zhì)混入液壓系統(tǒng)
清潔的液壓油是液壓系統(tǒng)的生命。液壓系統(tǒng)中有許多精密零件，有的設(shè)阻尼小孔或縫隙等。若固體雜質(zhì)入侵將造成精密零件拉傷，發(fā)卡、油道堵塞等,危害液壓系統(tǒng)的安全運(yùn)行。一般固體物質(zhì)入侵途徑有:液壓油不清潔；加油工具不清潔；加油和維修、保養(yǎng)不慎；液壓元件脫屑等。可以從以下幾個(gè)方面防止固體雜質(zhì)入侵系統(tǒng)：加油時(shí)液壓油必須過濾，加油工具應(yīng)可靠清潔。不能為了提高加油速度而去掉液壓油箱加油口處的過濾器。加油人員應(yīng)使用干凈的手套和工作服。
保養(yǎng)時(shí)拆卸液壓油箱加油蓋、濾清器蓋、檢測孔、液壓油管等部位，液壓系統(tǒng)油道暴露時(shí)要避開揚(yáng)塵 ，拆卸部位要先徹底清潔后才能打開。如拆卸液壓油箱加油蓋時(shí)，先除去油箱蓋四周的灰塵，擰松油箱蓋后清除殘留在接合部位的雜物 (不能用水沖洗以免水滲入油箱)，確認(rèn)清潔后才能打開油箱蓋。如需使用擦試材料和鐵錘時(shí)，應(yīng)選擇不掉纖維雜質(zhì)的擦拭材料和擊打面附著橡膠的專用鐵錘。液壓元件、液壓膠管要認(rèn)真清洗，用高壓風(fēng)吹干后組裝。選用包裝完好的正品濾芯 (若包裝損壞，雖然濾芯完好，也可能不潔)。換油同時(shí)清洗濾清器，安裝濾芯前應(yīng)用擦試材料認(rèn)真清除濾清器殼內(nèi)部污物。
液壓系統(tǒng)的清洗油必須使用與系統(tǒng)所用牌號相同的液壓油，油溫在 45—80℃之間，用大流量盡可能將系統(tǒng)中雜質(zhì)帶走。液壓系統(tǒng)要反復(fù)清洗 3次以上，每次清冼完后趁油熱時(shí)將其全部放出系統(tǒng)。清冼完畢再清洗濾清器，更換新濾芯后加注新油。
3）防止空氣和水入侵液壓系統(tǒng)
防止空氣入侵液壓系統(tǒng)在常壓常溫下液壓油中含有容積比為6％～8％的空氣，壓力降低時(shí)空氣會(huì)從油中游離出來，氣泡破裂使液壓元件“氣蝕”，產(chǎn)生噪聲。大量的空氣進(jìn)入油液中將使 “氣蝕”現(xiàn)象加劇，液壓油壓縮性增大，工作不穩(wěn)定，降低工作效率，執(zhí)行元件出現(xiàn)“爬行”等不良后果。另外，空氣還會(huì)使液壓油氧化，加速其變質(zhì)。防止空氣入侵應(yīng)注意以下幾點(diǎn)：維修和換油后要按隨機(jī)使用說明書規(guī)定排除系統(tǒng)中的空氣；液壓油泵的吸油管口不得露出油面，吸油管路必須密封良好；油泵驅(qū)動(dòng)軸的密封應(yīng)良好，更換該處油封時(shí)應(yīng)使用“雙唇”正品油封，不能用“單唇”油封代替，因?yàn)椤皢未健庇头庵荒軉蜗蚍庥?，不具備封氣的功能?
4）定期保養(yǎng)注意事項(xiàng)
防止水入侵液壓系統(tǒng) ，液壓油中含有過量水分會(huì)使液壓元件銹蝕，油液乳化變質(zhì)，潤滑油膜強(qiáng)度降低，加速機(jī)械磨損。除了維修保養(yǎng)時(shí)要防止水分入侵外，還要注意儲(chǔ)油桶不用時(shí)要擰緊蓋子，最好倒置放置；含水量大的液壓油要經(jīng)多次過濾，每過濾一次要更換一次烘干的濾紙。在沒有專用儀器檢測時(shí)，可將液壓油滴到燒熱的鐵板上，沒有蒸汽冒出并立即燃燒方能加注。
目前有的機(jī)床液壓系統(tǒng)設(shè)置了智能裝置，該裝置對液壓系統(tǒng)某些隱患有警示功能，但其監(jiān)測范圍和準(zhǔn)確程度有一定的局限性，所以液壓系統(tǒng)的檢查保養(yǎng)應(yīng)將智能裝置監(jiān)測結(jié)果與定期檢查保養(yǎng)相結(jié)合。
液壓系統(tǒng)的保養(yǎng)
1） 250h檢查保養(yǎng)
檢查濾清器濾網(wǎng)上的附著物，如金屬粉末過多，往往標(biāo)志著油泵磨損或油缸拉缸。對此，必須確診并采取相應(yīng)措施后才能開機(jī)。如發(fā)現(xiàn)濾網(wǎng)損壞、污垢積聚，要及時(shí)更換，必要時(shí)同時(shí)更換液壓油。
2） 500h檢查保養(yǎng)
機(jī)床機(jī)械運(yùn)行 500h后，不管濾芯狀況如何均應(yīng)更換 ，因?yàn)閼{肉眼難以察覺濾芯的細(xì)小損壞情況，如果長時(shí)間高溫作業(yè)還應(yīng)適當(dāng)提前更換濾芯。
3） 1000h檢查保養(yǎng)
此時(shí)應(yīng)清洗濾清器、清洗液壓系統(tǒng)要換濾芯和液壓油 ，長期高溫作業(yè)換油時(shí)間要適當(dāng)提前。如能通過油質(zhì)檢測分析來指導(dǎo)換油是最經(jīng)濟(jì)的，但要注意延長使用的液壓油，每隔 100h應(yīng)檢測一次，以便及時(shí)發(fā)現(xiàn)并更換變質(zhì)的液壓油。
4） 7000h和10000h檢查維護(hù)
根據(jù)實(shí)踐，進(jìn)口液壓泵、液壓馬達(dá)工作10000h必須大修，否則液壓泵、液壓馬達(dá) 因失修可能損壞，對液壓系統(tǒng)是致命性的破壞。隨著液壓系統(tǒng)在工業(yè)生產(chǎn)中的廣泛使用，液壓系統(tǒng)的正確使用、維護(hù)和保養(yǎng)成為機(jī)床使用、維護(hù)和保養(yǎng)不可缺少的一部分。在機(jī)床的使用過程中，只有正確使用與維護(hù)每一個(gè)系統(tǒng)，才能降低機(jī)床故障率，延長使用壽命，提高工作效率。
附錄2
The long hot press bonding damping type is generic components to serialization, standardization as the foundation, special machine tools, components with a small number of dedicated components. Therefore, manufacture and adjustment of machine tool is very convenient. Recently, Dongying Xinyi Group and the introduction of several sets of advanced hydraulic machine, the hydraulic machine is the comprehensive application of the information technology, the induction sensor technology, computer automatic control technology, mechanical technology and other advanced technology, its efficiency, function, the degree of automation compared with the existing machine tools have greatly improved. This allows us to see the development direction of China's machine tool use and manufacturing, also see the future development trend of machine tool. The main structural bonding damping piece the long hot press is two head hot press, its design is based on the Ford disc workshop production line Xinyi Group bonding damping sheet single head hot press. The processing characteristics of improved bull type hot press is:
1) The two head, can be a processing two brake pads in a pressing process, first in the processing quantity is doubled;
2) Table recycling processing is arranged on the working table, the slipway mounting fixture, can replace flexibly according to the brake model, bench with 11 slide, processing slide under the control of a PLC program are circulating processing sequence, so also placed 11 on the brakes and continuous processing can be on the bench., and as long as an operator in the outlet for the workpiece processing at the same time will not take the workpiece into the fixture can complete this process, waiting time save operator, the work table can improve production efficiency several times even dozens of times, but also can greatly reduce the labor intensity of workers.
Structural characteristics of multi type hot press:
1) Two head adopts a vertical hydraulic cylinder with pressure, and the two cylinder model is the same, thus shorten the design cycle and design process;
2) Two head hydraulic cylinder and hydraulic oil with a fuel supply system, and the two hydraulic cylinders are respectively connected with the oil inlet and outlet, which has the same pressure at the inlet, the oil pressure of the same flow, as well as in the oil outlet, the two pressure head pressure is equal, solution will the tooling shape tolerance caused by brake pads in the bonding damping sheet surface pressure range problem, is the damping sheet drawing force comply with process requirements;
3) Table power source is also adopts hydraulic cylinder, in the work of the four sides are provided with four hydraulic cylinders, fuel supply system they just add a few control valve can also be connected with the oil supply system head of hydraulic cylinder, the adhesive damping plate hot press with a fuel supply system, saving energy, but also simplify the structure of machine tool;
4) The working process of bonding damping sheet, regardless of is the main movement, movement or auxiliary motion using a PLC program control, the control is accurate, orderly;
5) According to the principle of two head, can be re design of hydraulic cylinder support, increasing the pressure head, because most of them are standard parts, so the design and manufacture of relatively simple;
6) The main structure is relatively simple, so can increase instead of manual operation two manipulators in machine tools, a charge will be put into the fixture workpiece, a workpiece will be responsible for take out, realize automation of machine tools and automatic production line.
Therefore, the bonding damping sheet is improved after the long hot press not only improve work efficiency, and can greatly reduce the labor intensity of the workers, the automatic production line can realize products and improve the degree of automation of machine tool. This machine is suitable for mass production, and relatively low cost, improvement is more flexible, suitable for the requirements of the development of modern industry.
Proper maintenance of the hydraulic system
1) select a suitable hydraulic oil
Hydraulic oil pressure plays a pass, lubrication, cooling, sealing the role of hydraulic system in oil, hydraulic oil is not appropriate to select the hydraulic system failure and the durability of the early decline. According to the provisions of the random instructions of the brand choice of hydraulic oil, special circumstances to use for fuel, should strive for the same performance with the original brand performance. Different grade mix of hydraulic oil, hydraulic oil to prevent chemical reaction, change in performance. Dark brown, white, and the hydraulic oil is the smell of oil deterioration, can not be used.
2) to prevent the solid impurities mixed with the hydraulic system
Cleanliness of hydraulic oil in hydraulic system of life. There are a lot of precision parts in the hydraulic system, some with damping holes or gaps. If the solid impurity invasion will cause a hairpin, precision parts, oil passage blockage, threat to the safe operation of hydraulic system. General solid substance invasion pathways: hydraulic oil is not clean; gas tool is not clean; refueling and repair, maintenance accidentally; scaling and other hydraulic components. Can from the following several aspects to prevent the solid impurity invasion system: on the hydraulic oil must be filtered, gas tools should be reliable clean. Cannot remove the hydraulic gas tank outlet filter in order to improve the gas speed and. Service personnel should use clean gloves and work clothes.
Maintenance to remove the hydraulic tank filler cap, filter cover, a detection hole, hydraulic parts, hydraulic system to avoid oil exposure dust, removing parts must first thoroughly cleaned before opening. Such as removing hydraulic gas tank cover, remove the dust around fuel tank cover, unscrew the oil tank cover to remove residual in the engagement portion of the debris (not wash with water to prevent water infiltration tank), confirmed after cleaning to open the fuel tank cap. If you want to use as material and the hammer, hammer should choose not to drop for wiping material and the impact surface fiber impurity attached rubber. Hydraulic components, hydraulic hose to wash, with high pressure air drying after assembly. Selection of good authentic filter packing (if damaged packaging, although the filter intact, may also not clean). Change oil and filter cleaning, filter application installed before wiping material carefully remove the dirt inside the filter shell.
Clean the oil hydraulic system must use the same brand of hydraulic oil and the system, the oil temperature is between 45 ℃ - 80 ℃, with large flow as far as possible away impurities in. Hydraulic system to be cleaned repeatedly 3 times, each time the Qing Xian wanhou while the oil heat when it all off system. Qing Xian after filter cleaning, replacement after adding new oil filter.
3) to prevent the air and water intrusion in hydraulic system
To prevent the air intrusion hydraulic system contains a volume ratio of 6% to 8% of the air in the hydraulic oil pressure at room temperature, pressure drop of air will free from oil, bubble rupture of the hydraulic components "cavitation", produce noise. Large quantities of air into the oil will make "cavitation" phenomenon aggravate, compressibility of hydraulic oil increases, unstable work, reduce the efficiency of work, executing element "crawl" and other adverse consequences. In addition, the air will make the hydraulic oil oxidation, accelerate the deterioration. To prevent the air intrusion should note the following points: repair and change according to the provisions of the use of random instructions to exclude air in the system; the suction nozzle hydraulic pump shall not be exposed out of the oil, oil pipeline must be sealed well; pump drive shaft seal should be good, the replacement of the seal should be the use of "lips" authentic seal, do not use the "single lip seal" instead of "single lip seal, because" only one-way sealing oil, does not have the function of sealing gas.
4) regular maintenance attention
To prevent water intrusion in hydraulic system, the hydraulic oil which contains excess water will cause corrosion of hydraulic element, oil emulsion modification, reduces the lubricating oil film strength, accelerate the mechanical wear. In addition to repair and maintenance to prevent moisture intrusion, but also pay attention to the oil tank is not to tighten the lid, the best place to inverted; after filtration with hydraulic oil content of each filter, a minor change a drying filter paper. In the absence of special equipment inspection, the hydraulic oil to the hot iron, no steam and immediately combustion can filler.
At present, some machine tool hydraulic system set up a smart device, the device has functions of some hidden trouble of hydraulic system, but its monitoring range and accuracy have certain limitations, so hydraulic system inspection and maintenance should be monitoring results and regular maintenance of intelligent device combination.
Hydraulic system maintenance
1) 250h inspection and maintenance
Check the filter screen on the attachments, such as metal powder too much, often marks the pump wear or cylinder scoring. In this regard, must be diagnosed and take corresponding measures in order to boot. Such as the discovery of screen damage, dirt accumulation, must be promptly replaced, if necessary, replace the hydraulic oil.
2) 500h inspection and maintenance
Machine running 500h, no matter how the filter should be replaced, because by tiny invisible element damage, if the long time high temperature operation should be appropriately ahead of time to replace the filter.
3) 1000h inspection and maintenance
This should filter cleaning, cleaning of hydraulic system to filter and hydraulic oil, long time to replace the oil temperature homework in advance. Such as oil quality through analysis to guide the oil is the most economic, but attention should be paid to extend the use of hydraulic oil, should be inspected once every 100h, in order to detect and replacement of hydraulic oil metamorphism.
4) 7000h 10000h inspection and maintenance
According to the practice, imported hydraulic pump, hydraulic motor 10000h must overhaul, or hydraulic motor hydraulic pump, due to disrepair may be damaged, the hydraulic system is a deadly destruction. With the wide use of the hydraulic system in industrial production, proper use of hydraulic system, and maintenance of machine tool use, maintenance and maintenance has become an indispensable part of. In the use process of machine tools, only the correct use and maintenance of each system, can reduce the machine failure rate, prolong the service life, improve work efficiency.