1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
通常機(jī)床主軸電動機(jī)制動時,采用的是能耗制動方式,使電動機(jī)AB相輸入直流電源。
采用能耗制動方式使主軸電動機(jī)停止,主軸在低檔位低速旋轉(zhuǎn)時,大約需要0.5s,在高檔位高速旋轉(zhuǎn)時,大約需要2.5s。目前,采用的主軸電動機(jī)制動方法如圖1所示,先斷開KM1,再閉合開關(guān)KM2,從而斷開三相交流電源,接通直流電源,延時2.5s,認(rèn)定主軸電動機(jī)停止旋轉(zhuǎn),然后進(jìn)行換刀或其它動作。
主軸以不同的速度旋轉(zhuǎn)時,采用能耗制動方式使主軸停止所需要的時間不同,采用同樣的能耗制動時間,延長無意義的加工輔助時間,降低了機(jī)床工作效率。另外,一旦開關(guān)KM2不能可靠閉合,或者直流電源保險斷開不能正常提供直流電,則主軸電動機(jī)只能在摩擦力的作用下減速,制動時間需要很長,但延時2.5s后,機(jī)床數(shù)控系統(tǒng)仍然認(rèn)定主軸電動機(jī)已經(jīng)停止旋轉(zhuǎn),此時機(jī)床進(jìn)行換刀或其它動作容易造成事故。
因此,我們對機(jī)床主軸制動控制方式進(jìn)行了改進(jìn)設(shè)計,判斷主軸旋轉(zhuǎn)狀態(tài),不采用延時2.5s,即認(rèn)定主軸電動機(jī)停止旋轉(zhuǎn)的控制方式,而是實時監(jiān)控主軸旋轉(zhuǎn)狀態(tài),當(dāng)主軸旋轉(zhuǎn)低于一定轉(zhuǎn)速時,立即發(fā)出主軸停止完了信號。
2 主軸轉(zhuǎn)速監(jiān)測方案
在電動機(jī)的同步傳動軸上安裝一塊條形鐵片,和電動機(jī)同步旋轉(zhuǎn),由接近開關(guān)對其檢測,每轉(zhuǎn)檢測到兩個脈沖信號,通過對脈沖信號的檢測而得知其轉(zhuǎn)速。檢測脈沖信號有兩種方案。
第一方案:在一定周期Tp內(nèi)讀取脈沖信號的個數(shù)N,PLC是一種順序控制器,它的程序是由前到后一步一步執(zhí)行,每執(zhí)行完一遍為一個掃描周期,然后從頭開始循環(huán)執(zhí)行。假如程序有2000步,每步執(zhí)行時間周期為30μs,則程序的掃描周期約60ms,掃描頻率約16Hz,能夠準(zhǔn)確檢測出的脈沖頻率應(yīng)低于8Hz,當(dāng)轉(zhuǎn)速的脈沖頻率大于16Hz,即轉(zhuǎn)速n≥480r/min時,PLC受其掃描頻率的影響,不能準(zhǔn)確檢測出脈沖的個數(shù),情況不好時,會出現(xiàn)高速時檢測的脈沖個數(shù)很少,誤判為電動機(jī)基本停止而進(jìn)行下面動作,造成事故。此種方案只適用于主軸低速旋轉(zhuǎn)狀態(tài)的監(jiān)測。
第二種方案:檢測脈沖信號持續(xù)為“0”或“1”的時間T,當(dāng)n<60r/min時,發(fā)出主軸停止完了信號。由于PLC程序執(zhí)行過程的延時,數(shù)控系統(tǒng)收到主軸停止信號,并執(zhí)行下面動作時,主軸已完全停止旋轉(zhuǎn),n=60r/min所對應(yīng)脈沖信號持續(xù)為“0”或“1”的時間T為0.25s,因此我們把檢測脈沖信號的計時器設(shè)定為0.25s。同樣高速時也會出現(xiàn)脈沖測不準(zhǔn)的情況,但不管情況多壞,在0.25s的時間內(nèi)“0”或“1”至少變化一次,因此可以準(zhǔn)確地判斷主軸是否停止旋轉(zhuǎn)。此方案可以適用于主軸高速或低速旋轉(zhuǎn)時主軸制動狀態(tài)的檢測。在實際應(yīng)用中,我們采用了此方案。
3 PLC實現(xiàn)主軸能耗制動的控制方法
PLC設(shè)計程序中,X20.0為轉(zhuǎn)速脈沖信號的輸入,M05為主軸停止信號,Y50.0為主軸停止完了信號。
兩個計時器TM1、TM2分別判斷X20.0脈沖信號持續(xù)為“0”或“1”的時間是否達(dá)到設(shè)定的時間,只要有一個時間到達(dá),即R100.1或R100.2變“1”,導(dǎo)致R100.3變“1”,此時M05為“1”,導(dǎo)致Y50.0輸出“1”,則發(fā)出主軸制動完了信號,實現(xiàn)了主軸停止的準(zhǔn)確判斷。
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DCS集散式控制系統(tǒng)、PLC可編程控制器、數(shù)控系統(tǒng)、
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