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6ES75225FF000AB0
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電鍍之后版輥的粗細(xì)不均勻，必須用磨削機(jī)經(jīng)過(guò)幾次磨削把它磨成粗細(xì)均勻的產(chǎn)品，而且磨削的精度要控制在0.01mm到0.05mm之間，加工時(shí)，刀具作快速直線運(yùn)動(dòng)來(lái)掃描版輥表面，同時(shí)版輥在不斷旋轉(zhuǎn)，就可以加工出有一定錐度的表面，采用磨削加工，既能用簡(jiǎn)單刀具實(shí)現(xiàn)高效切削，又能簡(jiǎn)化系統(tǒng)結(jié)構(gòu)。國(guó)外生產(chǎn)的磨削機(jī)是用復(fù)雜的繼電器控制的，存在可靠性差、可塑性差、接線復(fù)雜、自動(dòng)化程度低等一系列缺點(diǎn)，并且為了在日益激烈的競(jìng)爭(zhēng)中提高市場(chǎng)競(jìng)爭(zhēng)力，選用PLC作為控制單元是較為合適的方案。本文提出了利用變頻器和PLC定位控制單元的伺服系統(tǒng)構(gòu)成磨削機(jī)的見(jiàn)解與方法，給出了控制系統(tǒng)軟、硬件結(jié)構(gòu)的設(shè)計(jì)方案。
1 工藝流程
一上電，拖板和控制進(jìn)刀距離的伺服歸零，接著為了實(shí)現(xiàn)合適的進(jìn)刀距離開(kāi)始檢測(cè)，檢測(cè)完畢開(kāi)始真正的磨削過(guò)程。磨削機(jī)控制系統(tǒng)中，通過(guò)3臺(tái)變頻器來(lái)控制用于拖板移動(dòng)，刀盤(pán)轉(zhuǎn)動(dòng)，版輥轉(zhuǎn)動(dòng)的電機(jī)，刀盤(pán)主軸進(jìn)給系統(tǒng)應(yīng)用PLC(可編控制器)定位伺服控制系統(tǒng)，通過(guò)伺服來(lái)實(shí)現(xiàn)一定的進(jìn)刀距離，磨削出所要求的版輥，永宏FBs-MN系列PLC高速輸入讀取檢測(cè)時(shí)探頭的讀數(shù)。光電接近開(kāi)關(guān)裝在轉(zhuǎn)動(dòng)輪上，把拖板的長(zhǎng)度轉(zhuǎn)化為脈沖信號(hào)，利用可編程控制器的計(jì)數(shù)器進(jìn)行計(jì)數(shù)，當(dāng)計(jì)數(shù)值達(dá)到設(shè)定值時(shí)，控制拖板停止移動(dòng)，橫向移動(dòng)控制精度要求不高，用PLC內(nèi)部計(jì)數(shù)器來(lái)實(shí)現(xiàn)即可，節(jié)約了成本。噴霧閥在機(jī)器運(yùn)行時(shí)，給版輥噴灑冷卻液，來(lái)保證成形輥不受磨損及型材表面的光潔度。為了提高生產(chǎn)線使用的安全性、運(yùn)行的可靠性、維護(hù)的方便性、操作的靈活性、故障診斷的智能性、磨削的準(zhǔn)確性，設(shè)計(jì)的控制系統(tǒng)采用自動(dòng)(包括粗切、精切)/手動(dòng)控制方式。在選擇手動(dòng)操作時(shí)，通過(guò)觸摸屏上的軟按鈕實(shí)現(xiàn)設(shè)備啟、停控制，操作手柄控制伺服的進(jìn)或退點(diǎn)動(dòng)，便于設(shè)備調(diào)試維修。在選擇自動(dòng)操作時(shí)，在觸摸屏上設(shè)置版輥直徑、版輥長(zhǎng)度、切削量，顯示檢測(cè)時(shí)的版輥直徑最大值，最小值和平均值等信息和檢測(cè)到的故障信息，從而也提高了控制便利性。改變變頻器的設(shè)定頻率，可改變拖板移動(dòng)速度;版輥旋轉(zhuǎn)速度和刀盤(pán)旋轉(zhuǎn)速度。
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