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中 國 地 質 大 學 長 城 學 院 本 科 畢 業(yè) 設 計 外 文 翻 譯 系 別 工程技術系 專 業(yè) 機械設計制造及其自動化 姓 名 丁磊 學 號 05208416 2012 年 3 月 22 日 On the development of machining production line ABSTRACT The machining production line at the rhythm of time flexibility and progress machining accuracy integrated automation reliability and utilization areas of progress and development are described And its future development trends are analyzed and looking forward to Keywords Flexible automation machining accuracy 20 years beginning from the twentieth century with the automobile bearings small motors and sewing machines and other industrial development machinery manufacturing automatic production line began to appear first appeared that the combination of machine automatic production line Mechanical processing and manufacturing there casting forging stamping heat treatment welding machining and mechanical assembly automated line also including the different types of processes such as the blank manufacturing processing assembling testing and packaging an integrated automatic lines Automatic production line of products should be large enough to yield product design and process should be advanced stable reliable and the long period of time remains basically unchanged In a large a large number of automatic production line can improve labor productivity stability and improve product quality improve working conditions reducing the production area lower production costs shorten production cycle to ensure the production of balanced there has been a significant economic benefits 1 machining production line development of In automobiles tractors internal combustion engines and compressors and many other areas of industrial production combination machine tool production line is still the high volume machinery to achieve efficient high quality and economical production and processing of key equipment but also an irreplaceable key processing equipment Is for the combination of machine tool production line to illustrate the processing of domestic machinery production line development Modern portfolio of machine tool production line as the mechanical and electrical integration of product which is the control drive measure monitor tools and mechanical components of a comprehensive reflection of technologies such as China s traditional combination of machine tools automatic production line mainly uses the mechanical electrical gas hydraulic control in recent years with the numerical control technology electronics technology computer technology the development of combined machine tool mechanical structure and control systems have also undergone enormous changes 1 Beat the time be further reduced The early production line to achieve a short beat often to be used or set side by side duplex two way Now mainly by shortening the basic time and auxiliary time to achieve The main way to shorten the basic time is the introduction of new materials and novel tool knives in order by improving the cutting speed and feed rate to shorten the basic time Shorten the lead time is shorter including auxiliary parts delivery processing and rapid introduction of the module and processing module is converted to work by the fast forward to the knife cut into the workpiece after entering the time spent At present the accompanying high speed conveyor clamps are commonly used in electro hydraulic proportional valve control or cycloid driven conveyor device 2 Flexible rapid progress The emergence of numerical control machine tool portfolio not only completely changed the relay circuit from the past that a combination of machine tool control systems but also so that the mechanical structure of modular machine tool components as well as common standards has occurred or is undergoing tremendous change The traditional sense of the combination of machine tool rigidity automatic line and production line also has a certain amount of flexibility CNC machining modules from the combination of flexible machine tools and flexible automatic lines and change through the application of numerical procedures for automatic tool changing auto replacement of multi axle box and change the processing of travel work cycle cutting parameters and processing locations in order to meet the changing varieties processing Coordinate processing module consists of a single station CNC sliding and spindle components or multi axle including for multi axle component Pairs of coordinate processing module consists of CNC Cross Slide and composition of spindle components such as CNC milling module pairs of coordinates Multi axis machining module is another important module mainly for processing box and chuck workpieces flexible combination of machine tools and flexible automatic lines Type of module has a variety of different structural forms but basically can be divided into automatic processing module for box type multi axis multi axis turret processing module and multi axis machining modules Rotary Table Wrap Box modules can be specifically set up because of the multi axle box to store large libraries of multi axle it can be used to process more different kinds of artifacts The Rotary Table turret and multi axis machining modules due to the turret head and turning the table to allow a limited number of installed multi axle so this process can only achieve a limited variety of module processing In addition to the variety of CNC machining modules the robot and servo driven machine tools and jigs is also a flexible combination of flexible automatic lines are important components Particularly in the flexible automatic line is now more widespread use of an empty shelf gantry robot automatic loading and unloading of workpieces for workpiece transfer bits or flip For the handling of different workpieces can be automatic line side gripper library in order to achieve the automatic gripper change Fixture is equipped with servo drives to adapt to different workpiece ethnic automatic workpiece clamping 3 Increasing machining accuracy In order to meet users workpiece machining accuracy of the high demand in addition to further enhance the spindle parts boring bar fixtures including the boring mode the accuracy of a new special tool to optimize machining processes using tool size measurement and control system and control of machine tool and The thermal deformation of the workpiece and a series of measures the present the hollow taper shank tools HSK and the process of statistical quality control SPC application has become the automatic line to enhance and monitor the machining accuracy of a new and important technical means Tool is a hollow taper shank radial cone and axial face Positioning of the innovative two way tool its advantages are high bending stiffness torsional stiffness and high repeatability SPC is based on process capability for monitoring the quality of workpiece machining methods At present the automatic line of such quality assurance systems being used more and more of the entire production process for continuous monitoring of processing quality 4 Reliability and efficiency continue to improve and improve To improve process reliability availability and quality of workpieces using the process of monitoring equipment to its constituent functions processes and workpiece quality control in order to quickly identify faults and rapid fault diagnosis and early warning process deviation so that operators and maintenance personnel to intervene in a timely manner in order to shorten the debug cycle facilities reduce equipment downtime and avoid the processing quality of bias Fault Diagnosis Technology for knowledge based fault diagnosis techniques can produce automatic line running all the fault diagnosis but not limited to diagnosis of the most frequently occurring failure to determine the position and the reasons for failure which won for the rapid troubleshooting time thus significantly reducing debugging time and the automatic line downtime At present the automatic line of control technology has been focused on control mode shift toward decentralized control mode Based on this new control model studies have shown that a decentralized control system than a centralized control systems can be cost savings This is mainly due to distributed control systems can reduce cabling costs using the bus system to reduce the electrical maintenance and repair costs due to increased transparency eliminating the need for control of the counter frame distributed control system control cabinet directly to set up the automatic line processing station on and no need to set focus on the cooling devices In addition the overall configuration of distributed control system as simple and beneficial to speed up the automatic line put into operation and because at a glance the structure of configuration fault in the production is very easy to determine the site of failure Finally the distributed control system is also modular and standardized help to reduce costs and increase transparency 2 machining production line trends As market competition intensifies and the increase in demand for products high precision high productivity flexible multi variety short cycle numerical control machine tools and automatic lines were combined impact of the traditional combination of machine tool production line therefore the development of modular machine tool production line idea must be to improve the combination of machining precision modular machine tool flexibility reliability and combined portfolio of machine tool technology complete sets of machines as the main direction Machine tool equipment high speed and ultra high speed machining technology the key is to improve the machine tool spindle speed and feed rate Complex multi functional multi axis was also optimistic about the prospect of Control In the increasingly integrated components at the same time reduce the number of processing the shape is increasingly complex Control multi axis machine tools and equipment for processing of complex shape of the workpiece In addition the shortening of product life cycle also requires machine tools can readily adjust and adapt to new changes to meet the processing needs of a wide variety of products even more crucial however is that modern communications technology in machine tools and equipment in the application of information and communication technology enables the introduction of modern to further enhance the degree of automation of machine tools the operator via the Web or mobile phones to remotely program the machine changes to the status of the operation to monitor and accumulate the relevant data through the network to the remote equipment maintenance and inspection to provide after sales service In advanced countries our country in these areas there is a considerable gap between so China s machine tool production line combined high speed high precision flexible modular adjustable variable arbitrary and processing of the application of communications technology will be the future direction of development From the above discussion we can see that China s current production lines machining time in the rhythm flexibility and progress machining accuracy integrated automation reliability and utilization and other aspects of the great progress and development Control technology is also from the centralized control mode shift toward decentralized control mode The future will be high speed high precision flexibility and digital direction 淺談機械加工生產線發(fā)展狀況 摘 要 對機械加工生產線在節(jié)拍時間 柔性化進展 加工精度 綜合自動化程度 可靠性和利 用率等方面的進步和發(fā)展進行了闡述 并對其未來發(fā)展趨勢進行了分析 展望 關鍵詞 柔性化 自動化 加工精度 從二十世紀 20 年代開始 隨著汽車 滾動軸承 小型電動機和縫紉機等工業(yè)發(fā)展 機械加工制造中開始出現自動線 最早出現的是組合機床自動線 機械加工制造業(yè)中有 鑄造 鍛造 沖壓 熱處理 焊接 切削加工和機械裝配等自動線 也有包括不同性質 的工序 如毛坯制造 加工 裝配 檢驗和包裝等的綜合自動線 采用自動線進行生產 的產品應有足夠大的產量 產品設計和工藝應先進 穩(wěn)定 可靠 并在較長時間內保持 基本不變 在大批 大量生產中采用自動線能提高勞動生產率 穩(wěn)定和提高產品質量 改善勞動條件 縮減生產占地面積 降低生產成本 縮短生產周期 保證生產均衡性 有顯著的經濟效益 1 機械加工生產線的發(fā)展狀況 在汽車 拖拉機 內燃機和壓縮機等許多工業(yè)生產領域 組合機床生產線仍是大批 量機械產品實現高效 高質量和經濟性生產加工的關鍵裝備 也是不可替代的主要加工 設備 現針對組合機床生產線來說明一下國內機械加工生產線的發(fā)展情況 現代組合機床生產線作為機電一體化產品 它是控制 驅動 測量 監(jiān)控 刀具和 機械組件等技術的綜合反映 我國傳統(tǒng)的組合機床自動線主要采用機 電 氣 液壓控 制 近年來隨著數控技術 電子技術 計算機技術等的發(fā)展 組合機床的機械結構和控 制系統(tǒng)也發(fā)生了翻天覆地的變化 1 1 節(jié)拍時間進一步縮短 早期的生產線要實現短的節(jié)拍 往往要采用并列的雙 工位或設置雙線的辦法 現在主要是通過縮短基本時間和輔助時間來實現的 縮短基本 時間的主要途徑是采用新的刀具材料和新穎刀具 以通過提高切削速度和進給速度來縮 短基本時間 縮短輔助時間主要是縮短包括工件輸送 加工模塊快速引進以及加工模塊 由快進轉換為工進后至刀具切入工件所花的時間 目前 隨行夾具高速輸送裝置常用的 有電液比例閥控制的或擺線驅動的輸送裝置 1 2 柔性化進展迅速 數控組合機床的出現 不僅完全改變了過去那種由繼電器 電路組成的組合機床的控制系統(tǒng) 而且也使組合機床機械結構乃至通用部件標準發(fā)生了 或正在發(fā)生著巨大的變化 傳統(tǒng)意義上的組合機床剛性自動線和生產線 也具有了一定 的柔性 由數控加工模塊組成的柔性組合機床和柔性自動線 可通過應用和改變數控程 序來實現自動換刀 自動更換多軸箱和改變加工行程 工作循環(huán) 切削參數以及加工位 置等 以適應變型品種的加工 單坐標加工模塊由數控滑臺和主軸部件 或多軸箱 包括可換多軸箱 組成 雙坐 標加工模塊由數控十字滑臺和主軸部件組成 例如數控雙坐標銑削模塊 多軸加工模塊是又一種重要模塊 主要用于加工箱體和盤類工件的柔性組合機床和 柔性自動線 這類模塊有多種不同的結構形式 但基本上可分為自動換箱式多軸加工模 塊 轉塔式多軸加工模塊和回轉工作臺式多軸加工模塊 自動換箱式模塊由于可在專門 設置的多軸箱庫中儲存較多的多軸箱 故可用來加工較多不同品種的工件 而轉塔式和 回轉工作臺式多軸加工模塊 由于在轉塔頭和回轉工作臺上允許裝的多軸箱數量有限 所以這種加工模塊只能實現有限品種的加工 除上述各種 CNC 加工模塊外 機器人和伺服驅動的夾具也是柔性組合機床和柔性自 動線的重要部件 特別在柔性自動線上 目前已較普遍地采用龍門式空架機器人進行工 件的自動上下料 用于工件的轉位或翻轉 為搬運不同的工件 可在自動線旁設置手爪 庫 以實現手爪的自動更換 夾具配備伺服驅動裝置 以適應工件族內不同工件的自動 夾緊 1 3 加工精度日益提高 為了滿足用戶對工件加工精度的高要求 除了進一步提 高主軸部件 鏜桿 夾具 包括鏜模 的精度 采用新的專用刀具 優(yōu)化切削工藝過程 采用刀具尺寸測量控制系統(tǒng)和控制機床及工件的熱變形等一系列措施外 目前 空心工 具錐柄 HSK 和過程統(tǒng)計質量控制 SPC 的應用已成為自動線提高和監(jiān)控加工精度的 新的重要技術手段 空心工具錐柄是一種采用徑向 錐面 和軸向 端面 雙向定位的 新穎工具 其優(yōu)點是具有較高的抗彎剛度 扭轉剛度和很高的重復精度 SPC 是基于工 序能力的用于監(jiān)控工件加工質量的一種方法 目前 在自動線上這種質量保證系統(tǒng)愈來 愈多地被用來對整個生產過程中的加工質量進行連續(xù)監(jiān)控 1 4 可靠性和利用率不斷改善和提高 為提高加工過程的可靠性 利用率和工 件的加工質量 采用過程監(jiān)控 對其各組成設備的功能 加工過程和工件加工質量進行 監(jiān)控 以便快速識別故障 快速進行故障診斷和早期預報加工偏差 使操作人員和維修 人員能及時地進行干預 以縮短設備調試周期 減少設備停機時間和避免加工質量偏差 故障診斷技術中的基于知識的故障診斷技術 可對自動線運行中產生的所有故障進 行診斷 而不是局限于診斷最常出現的故障 確定故障部位及其原因 這為迅速排除故 障贏得了時間 從而顯著地縮短自動線的調試時間和停機時間 當前 自動線的控制技術已由集中控制方式轉向分散控制方式 根據對這種新的控 制模式的研究表明 采用分散控制系統(tǒng)要比采用集中控制系統(tǒng)可節(jié)省費用 這主要是由 于分散控制系統(tǒng)可減少電纜敷設費用 采用總線系統(tǒng) 減少電氣保養(yǎng)維修費 由于提高 了透明度 省去控制柜臺架 分散控制系統(tǒng)的控制柜直接設置在自動線的加工工位上 和無需設置集中冷卻裝置等 此外 這種分散控制系統(tǒng)由于總體配置簡單 有利于加快 自動線的投入運行 并由于一目了然的結構配置 在產生故障時很容易確定故障的部位 最后 分散控制系統(tǒng)的模塊化和標準化也有利于降低成本和提高透明度 2 機械加工生產線的發(fā)展趨勢 隨著市場競爭的加劇和對產品需求的提高 高精度 高生產率 柔性化 多品種 短周期 數控組合機床及其自動線正在沖擊著傳統(tǒng)的組合機床生產線 因此 組合機床 生產線的發(fā)展思路必須是以提高組合機床加工精度 組合機床柔性 組合機床工作可靠 性和組合機床技術的成套性為主攻方向 機床裝備的高速和超高速加工技術的關鍵是提高機床的主軸轉速和進給速度 復合 多功能 多軸化控制的前景亦被看好 在零部件一體化程度不斷提高 數量減少的同時 加工的形狀卻日益復雜 多軸化控制的機床裝備適合加工形狀復雜的工件 另外 產品 周期的縮短也要求加工機床能夠隨時調整和適應新的變化 滿足各種各樣產品的加工需 求然而更關鍵的是 現代 通信技術在機床裝備中的應用 信息通信技術的引進使得現代 機床的自動化程度進一步提高 操作者可以通過 網絡 或手機對機床的程序進行遠程修 改 對運轉狀況進行監(jiān)控并積累有關數據 通過網絡對遠程的設備進行維修和檢查 提 供售后服務等 在這些方面我國就先進國家還有相當大的差距 因此我國組合機床生產 線高速度 高精度 柔性化 模塊化 可調可變 任意加工性以及通信技術的應用將是 今后的發(fā)展方向 從以上論述可以看出我國目前的機械加工生產線在節(jié)拍時間 柔性化進展 加工精 度 綜合自動化程度 可靠性和利用率等方面都有了長足的進步和發(fā)展 控制技術也由 集中控制方式轉向分散控制方式 未來將向高速 高精 柔性及數字方向發(fā)展