數(shù)控車床系統(tǒng)XY工作臺與控制系統(tǒng)設(shè)計
數(shù)控車床系統(tǒng)XY工作臺與控制系統(tǒng)設(shè)計,數(shù)控車床系統(tǒng)XY工作臺與控制系統(tǒng)設(shè)計,數(shù)控車床,系統(tǒng),xy,工作臺,控制系統(tǒng),設(shè)計
數(shù)控車床XY軸工作臺和控制系統(tǒng)設(shè)計摘 要我設(shè)計的是車床XY軸工作臺和控制系統(tǒng),采用單片機控制步進電動機驅(qū)動工作臺。首先確定設(shè)計的總體方案,然后對車床的機械部分進行設(shè)計,其中包括工作臺、滾動導(dǎo)軌、滾珠絲杠、步進電動機的設(shè)計和選用,最后對數(shù)控系統(tǒng)硬件和軟件設(shè)計。新一代的CNC系統(tǒng)這類典型機電一體化產(chǎn)品正朝著高性能、智能化、系統(tǒng)化以及輕量、微型化方向發(fā)展。關(guān)鍵詞:數(shù)控車床 XY工作臺 控制系統(tǒng)前 言一、當今世界數(shù)控技術(shù)及裝備發(fā)展的趨勢及我國數(shù)控裝備技術(shù)發(fā)展和產(chǎn)業(yè)化的現(xiàn)狀在我國對外開放進一步深化的新環(huán)境下 ,發(fā)展我國數(shù)控技術(shù)及裝備、提高我國制造業(yè)信息化水平和國際競爭能力的重要性 ,并從戰(zhàn)略和策略兩個層面提出了發(fā)展我國數(shù)控技術(shù)及裝備的幾點看法。裝備工業(yè)的技術(shù)水平和現(xiàn)代化程度決定著整個國民經(jīng)濟的水平和現(xiàn)代化程度 ,數(shù)控技術(shù)及裝備是發(fā)展新興高新技術(shù)產(chǎn)業(yè)和尖端工業(yè)的使能技術(shù)和最基本的裝備 ,又是當今先進制造技術(shù)和裝備最核心的技術(shù)。數(shù)控技術(shù)是用數(shù)字信息對機械運動和工作過程進行控制的技術(shù) ,而數(shù)控裝備是以數(shù)控技術(shù)為代表的新技術(shù)對傳統(tǒng)制造產(chǎn)業(yè)和新興制造業(yè)的滲透形成的機電一體化產(chǎn)品 ,其技術(shù)范圍覆蓋很多領(lǐng)域。(一)、數(shù)控技術(shù)的發(fā)展趨勢。數(shù)控技術(shù)的應(yīng)用不但給傳統(tǒng)制造業(yè)帶來了革命性的變化 ,使制造業(yè)成為工業(yè)化的象征 ,而且隨著數(shù)控技術(shù)的不斷發(fā)展和應(yīng)用領(lǐng)域的擴大 ,他對國計民生的一些重要行業(yè) IT、汽車、輕工、醫(yī)療等的發(fā)展起著越來越重要的作用。從目前世界上數(shù)控技術(shù)及其裝備發(fā)展的趨勢來看 ,其主要研究熱點有以下幾個方面: (1) 高速、高精加工技術(shù)及裝備的新趨勢 (2) 5 軸聯(lián)動加工和復(fù)合加工機床快速發(fā)展 (3) 智能化、開放式、網(wǎng)絡(luò)化成為當代數(shù)控系統(tǒng)發(fā)展的主要趨勢(二)、對我國數(shù)控技術(shù)及其產(chǎn)業(yè)發(fā)展的基本估計我國數(shù)控技術(shù)起步于 1958 年 ,近 50 年的發(fā)展歷程大致可分為三個階段:第一階段從 1958 年到 1979 年 ,即封閉式發(fā)展階段。在此階段 ,由于國外的技術(shù)封鎖和我國的基礎(chǔ)條件的制 ,數(shù)控技術(shù)的發(fā)展較為緩慢。第二階段是在國家的“六五”、“七五”期間以及“八五”的前期 ,即引進技術(shù) ,消化吸收 ,初步建立起國產(chǎn)化體系階段。在此階段 ,由于改革開放和國家的重視 ,以及研究開發(fā)環(huán)境和國際環(huán)境的改善 ,我國數(shù)控技術(shù)的研究、開發(fā)以及在產(chǎn)品的國產(chǎn)化方面都取得了長足的進步。第三階段是在國家的“八五”的后期和“九五”期間 ,即實施產(chǎn)業(yè)化的研究 ,進入市場競爭階段??v觀我國數(shù)控技術(shù)近 50 年的發(fā)展歷程 ,特別是經(jīng)過 4 個 5 年計劃的攻關(guān) ,總體來看取得的成績還是不小。(三)、對我國數(shù)控技術(shù)和產(chǎn)業(yè)化發(fā)展的戰(zhàn)略思考(1) 戰(zhàn)略考慮。我國是制造大國 ,在世界產(chǎn)業(yè)轉(zhuǎn)移中要盡量接受前端而不是后端的轉(zhuǎn)移 ,所以 ,我們應(yīng)站在國家安全戰(zhàn)略的高度來重視數(shù)控技術(shù)和產(chǎn)業(yè)問題。首先從社會安全看 ,因為制造業(yè)是我國就業(yè)人口最多的行業(yè) ,制造業(yè)發(fā)展不僅可提高人民的生活水平 ,而且還可緩解我國就業(yè)的壓力 ,保障社會的穩(wěn)定;其次從國防安全看 ,西方發(fā)達國家把高精尖數(shù)控產(chǎn)品都列為國家的戰(zhàn)略物質(zhì) ,對我國實現(xiàn)禁運和限制 ,“東芝事件”和“考克斯報告”就是最好的例證。(2)發(fā)展策略。從我國基本國情的角度出發(fā) ,以國家的戰(zhàn)略需求和國民經(jīng)濟的市場需求為導(dǎo)向 ,以提高我國制造裝備業(yè)綜合競爭能力和產(chǎn)業(yè)化水平為目標 ,用系統(tǒng)的方法 ,選擇能夠主導(dǎo) 21 世紀初期我國制造裝備業(yè)發(fā)展升級的關(guān)鍵技術(shù)以及支持產(chǎn)業(yè)化發(fā)展的支撐技術(shù)、配套技術(shù)作為研究開發(fā)的內(nèi)容 ,實現(xiàn)制造裝備業(yè)的跨躍式發(fā)展。強調(diào)市場需求為導(dǎo)向 ,即以數(shù)控終端產(chǎn)品為主 ,以整機如量大面廣的數(shù)控車床、銑床、高速高精高性能數(shù)控機床、曲型數(shù)字化機械、重點行業(yè)關(guān)鍵設(shè)備等 帶動數(shù)控產(chǎn)業(yè)的發(fā)展。重點解決數(shù)控系統(tǒng)和相關(guān)功能部件 數(shù)字化伺服系統(tǒng)與電機、高速電主軸系統(tǒng)和新型裝備的附件等 的可靠性和生產(chǎn)規(guī)模問題。沒有規(guī)模就不會有高可靠性的產(chǎn)品;沒有規(guī)模就不會有價值低廉而富有競爭力的產(chǎn)品;當然 ,沒有規(guī)模中國的數(shù)控裝備最終難有出頭之日。一、畢業(yè)設(shè)計的目的、意義機電一體化系統(tǒng)設(shè)計畢業(yè)設(shè)計是培養(yǎng)學(xué)生設(shè)計能力的重要實踐性教學(xué)環(huán)節(jié)之一,是綜合運用所學(xué)過的機械、電子、自動控制、計算機等知識進行的基本設(shè)計訓(xùn)練。其目的是:能夠正確運用機電一體化系統(tǒng)設(shè)計課程的基本理論和相關(guān)知識,掌握機電一體化系統(tǒng)(產(chǎn)品)的功能構(gòu)成、特點和設(shè)計思想、設(shè)計方法,了解設(shè)計方案的擬定、比較、分析和計算,培養(yǎng)學(xué)生分析問題和解決問題的能力,使學(xué)生具有機電一體化系統(tǒng)設(shè)計的初步能力;通過機械部分設(shè)計,掌握機電一體化系統(tǒng)典型機械零部件和執(zhí)行元件的計算、選型和結(jié)構(gòu)設(shè)計方法和步驟;通過測試及控制系統(tǒng)方案設(shè)計,掌握機電一體化系統(tǒng)控制系統(tǒng)的硬件組成、工作原理,和軟件編程思想;通過畢業(yè)設(shè)計提高學(xué)生應(yīng)用手冊、標準及編寫技術(shù)說明書的能力,促進學(xué)生在科學(xué)態(tài)度、創(chuàng)新精神、專業(yè)技能等方面綜合素質(zhì)的提高。二、畢業(yè)設(shè)計的內(nèi)容(一)畢業(yè)設(shè)計題目:單片機控制步進電機驅(qū)動的多用XY工作臺。已知條件:定位精度:0.01mm,滾珠絲杠及導(dǎo)軌使用壽命:T=15000h,中等沖擊工作臺的有效行程為 快速進給速度 和工作載荷三、數(shù)控系統(tǒng)總體方案的確定數(shù)控系統(tǒng)總體方案設(shè)計的內(nèi)容包括:系統(tǒng)運動方式的確定,執(zhí)行機構(gòu)及傳動方案的確定,伺服電機類型及調(diào)速方案確定,計算機控制系統(tǒng)的選擇。進行方案的分析、比較和論證。(一)系統(tǒng)運動方式的確定該系統(tǒng)要求工作臺沿各坐標軸的運動有精確的運動關(guān)系因此采用連續(xù)控制方式。(二)伺服系統(tǒng)的選擇開環(huán)伺服系統(tǒng)在負載不大時多采用功率步進電機作為伺服電機.開環(huán)控制系統(tǒng)由于沒有檢測反饋部件,因而不能糾正系統(tǒng)的傳動誤差。但開環(huán)系統(tǒng)結(jié)構(gòu)簡單,調(diào)整維修容易,在速度和精度要求不太高的場合得到廣泛應(yīng)用。考慮到運動精度要求不高,為簡化結(jié)構(gòu),降低成本,宜采用步進電機開環(huán)伺服系統(tǒng)驅(qū)動。(三)計算機系統(tǒng)的選擇采用MCS-51系列中的8031單片機擴展控制系統(tǒng)。MCS-51單片機的主要特點是集成度高,可靠性好,功能強,速度快,性價比高??刂葡到y(tǒng)由微機部分、鍵盤及顯示器、I/O接口及光電隔離電路、步進功率放大電路等組成。系統(tǒng)的工作程序和控制命令通過鍵盤操作實現(xiàn)。顯示器采用數(shù)碼管顯示加工數(shù)據(jù)和工作狀態(tài)等信息。(四) XY工作臺的傳動方式為保證一定的傳動精度和平穩(wěn)性以及結(jié)構(gòu)的緊湊,采用滾珠絲杠螺母傳動副。為提高傳動剛度和消除間隙,采用有預(yù)加載荷的結(jié)構(gòu)。由于工作臺的運動部件重量和工作載荷不大,故選用滾動直線導(dǎo)軌副,從而減小工作臺的摩擦系數(shù),提高運動平穩(wěn)性。考慮電機步距角和絲杠導(dǎo)程只能按標準選取,為達到分辨率的要求,以及考慮步進電機負載匹配,采用齒輪減速傳動。系統(tǒng)總體框圖如下:計算機光電隔離功率放大步進電機X向工作臺光電隔離功率放大步進電機Y向工作臺圖3-1四、機械部分設(shè)計機械部分設(shè)計內(nèi)容包括:確定系統(tǒng)脈沖當量,運動部件慣性的計算,選擇步進電機,傳動及導(dǎo)向元件的設(shè)計、計算與選擇,繪制機械部分裝配圖等。(一 )確定系統(tǒng)脈沖當量脈沖當量p是一個進給指令時工作臺的位移量,應(yīng)小于等于工作臺的位置精度,由于定位精度為0.01mm因此選擇脈沖當量為0.01mm。(二)工作臺外形尺寸及重量初步估算根據(jù)給定的有效行程,畫出工作臺簡圖,估算X向和Y向工作臺承載重量WX和WY。取X向?qū)к壷武撉虻闹行木酁?10mm,Y向?qū)к壷武撉虻闹行木酁?00mm,設(shè)計工作臺簡圖如下:工作臺簡圖圖4-1X向拖板(上拖板)尺寸為: 長*寬*高=420*410*50重量:按重量=體積*材料比重估算為: = Y向拖板(下拖板)尺寸為: 重量=上導(dǎo)軌(含電機)重量為夾具及工件重量:約155NX-Y工作臺運動部分總重量為:(三)滾動導(dǎo)軌副的計算、選擇根據(jù)給定的工作載荷Fz和估算的Wx和Wy計算導(dǎo)軌的靜安全系數(shù)fSL=C0/P,式中:C0為導(dǎo)軌的基本靜額定載荷,kN;工作載荷P=0.5(Fz+W); fSL=1.03.0(一般運行狀況),3.05.0(運動時受沖擊、振動)。根據(jù)計算結(jié)果查有關(guān)資料初選導(dǎo)軌:因系統(tǒng)受中等沖擊,因此取根據(jù)計算額定靜載荷初選導(dǎo)軌:選擇漢機江機床廠HJG-D系列滾動直線導(dǎo)軌,其型號為:HJG-D25基本參數(shù)如下: 表4-1額定載荷/N靜態(tài)力矩/N*M滑座重量導(dǎo)軌重量導(dǎo)軌長度動載荷靜載荷L(mm)17500260001981982880.603.1760滑座個數(shù)單向行程長度每分鐘往復(fù)次數(shù)M40.64導(dǎo)軌的額定動載荷N依據(jù)使用速度v(m/min)和初選導(dǎo)軌的基本動額定載荷 (kN)驗算導(dǎo)軌的工作壽命Ln:額定行程長度壽命: (4-1)導(dǎo)軌的額定工作時間壽命: (4-2)導(dǎo)軌的工作壽命足夠.(四)滾珠絲杠計算、選擇初選絲杠材質(zhì):CrWMn鋼,HRC5860,導(dǎo)程:l0=5mm強度計算絲杠軸向力:(N) (4-3)其中:K=1.15,滾動導(dǎo)軌摩擦系數(shù)f=0.0030005;在車床車削外圓時:Fx=(0.10.6)Fz,F(xiàn)y=(0.150.7)Fz,可取Fx=0.5Fz,F(xiàn)y=0.6Fz計算。取f=0.004,則:壽命值:,其中絲杠轉(zhuǎn)速(r/min) (4-4)最大動載荷:式中:fW為載荷系數(shù),中等沖擊時為1.21.5;fH為硬度系數(shù),HRC58時為1.0。查表得中等沖擊時則:根據(jù)使用情況選擇滾珠絲杠螺母的結(jié)構(gòu)形式,并根據(jù)最大動載荷的數(shù)值可選擇滾珠絲杠的型號為: CM系列滾珠絲桿副,其型號為:CM2005-5。其基本參數(shù)如下:圖4-2其額定動載荷為14205N 足夠用.滾珠循環(huán)方式為外循環(huán)螺旋槽式,預(yù)緊方式采用雙螺母螺紋預(yù)緊形式.滾珠絲杠螺母副的幾何參數(shù)的計算如下表表4-2名稱計算公式結(jié)果公稱直徑20mm螺距mm接觸角鋼球直徑3.175mm螺紋滾道法向半徑1.651mm偏心距0.04489mm螺紋升角螺桿外徑19.365mm螺桿內(nèi)徑16.788mm螺桿接觸直徑17.755mm螺母螺紋外徑23.212mm螺母內(nèi)徑(外循環(huán))20.7mm傳動效率計算絲杠螺母副的傳動效率為: (4-5)式中:=10,為摩擦角;為絲杠螺旋升角。穩(wěn)定性驗算絲杠兩端采用止推軸承時不需要穩(wěn)定性驗算。剛度驗算滾珠絲杠受工作負載引起的導(dǎo)程變化量為:(cm) (4-6)Y向所受牽引力大,故用Y向參數(shù)計算絲杠受扭矩引起的導(dǎo)程變化量很小,可忽略不計。導(dǎo)程變形總誤差為E級精度絲杠允許的螺距誤差 =15m/m。(五)齒輪計算、設(shè)計 因步進電機步距角滾珠絲杠螺距t=5mm,要實現(xiàn)脈沖當量,在傳動系統(tǒng)中應(yīng)加一對齒輪降速傳動.齒輪傳動比: ,步進電機步距角:= 1.5/step。 (4-7) 取小齒輪齒數(shù) 則大齒輪齒數(shù)大小齒輪材料均為45鋼由于軟齒面齒輪工藝簡單、生產(chǎn)率高,故選擇軟齒面齒輪。因傳遞的扭距較小,取模數(shù)m=1mm則:分度圓直徑: 齒頂圓直徑: 齒根圓直徑: 齒寬: 取 中心距: 分度圓壓力角: 大小齒輪均采用漸開線標準圓柱齒輪小齒輪采用兩片薄齒輪錯齒排列以消除間隙.雙片齒輪錯齒消隙結(jié)構(gòu)圖如下:1、2-薄齒輪, 3彈簧, 4、8凸耳, 5調(diào)節(jié)螺釘, 6、7螺母雙片齒輪錯齒消隙結(jié)構(gòu)圖圖4-3(六)步進電機慣性負載的計算根據(jù)等效轉(zhuǎn)動慣量的計算公式,有: (1)等效轉(zhuǎn)動慣量的計算折算到步進電機軸上的等效負載轉(zhuǎn)動慣量為: (4-8)式中:為折算到電機軸上的慣性負載;為步進電機軸的轉(zhuǎn)動慣量;為齒輪的轉(zhuǎn)動慣量;為齒輪的轉(zhuǎn)動慣量;為滾珠絲杠的轉(zhuǎn)動慣量;為移動部件的質(zhì)量。對鋼材料的圓柱零件可以按照下式進行估算: (4-9)式中為圓柱零件直徑,為圓柱零件的長度。所以有:電機軸的轉(zhuǎn)動慣量很小,可以忽略,所以有:(七)步進電機的選用()步進電機啟動力矩的計算設(shè)步進電機的等效負載力矩為,負載力為,根據(jù)能量守恒原理,電機所做的功與負載力所做的功有如下的關(guān)系:式中為電機轉(zhuǎn)角,為移動部件的相應(yīng)位移,為機械傳動的效率。若取,則,且。所以: (4-10)式中:為移動部件負載(N),G為移動部件質(zhì)量(N),為與重力方向一致的作用在移動部件上的負載力(N),為導(dǎo)軌摩擦系數(shù),為步進電機的步距角(rad),T為電機軸負載力矩(N.cm)。取=0.3(淬火鋼滾珠導(dǎo)軌的摩擦系數(shù)),.8,=279.23??紤]到重力影響,向電機負載較大,因此1200,所以有:考慮到啟動時運動部件慣性的影響,則啟動轉(zhuǎn)矩: (4-11)取系數(shù)為.,則: 對于工作方式為三相拍的步進電機: () 步進電機的最高工作頻率為使電機不產(chǎn)生失步空載啟動頻率要大于最高運行頻率,同時電機最大靜轉(zhuǎn)矩要足夠大,查表選擇兩個90BF001型三相反應(yīng)式步進電機.電機有關(guān)參數(shù)如下: 表4-3型號主要技術(shù)參數(shù)相數(shù)步距角電壓(V)相電流(A)最大靜轉(zhuǎn)矩(n.m)空載啟動頻率空載運行頻率分配方式90BF00140.98073.92200080004相8拍外形尺寸(mm)重量kg轉(zhuǎn)子轉(zhuǎn)動慣量Kg.m外直徑長度軸直徑9014594.51764五、數(shù)控系統(tǒng)硬件電路設(shè)計(一)數(shù)控系統(tǒng)的硬件電路由以下幾部分組成:1、主控制器。即中央處理單元CPU2、總線。包括數(shù)據(jù)總線,地址總線,控制總線。3、存儲器。包括只讀可編程序存儲器和隨機讀寫數(shù)據(jù)存儲器。4、接口。即I/O輸入輸出接口。數(shù)控系統(tǒng)的硬件框圖如下所示:圖5-1(二)主控制器的選擇系列單片機是集中,端口及部分等為一體的功能性很強的控制器。只需增加少量外圍元件就可以構(gòu)成一個完整的微機控制系統(tǒng),并且開發(fā)手段齊全,指令系統(tǒng)功能強大,編程靈活,硬件資料豐富。本次設(shè)計選用芯片作為主控芯片。(三)存儲器擴展電路設(shè)計(1)程序存儲器的擴展單片機應(yīng)用系統(tǒng)中擴展用的程序存儲器芯片大多采用芯片。其型號有:2716,2732,2764,27128,27258,其容量分別為k,4k,8k,16k32k。在選擇芯片時要考慮與時序的匹配。所能讀取的時間必須大于所要求的讀取時間。此外,還需要考慮最大讀出速度,工作溫度以及存儲器容量等因素。在滿足容量要求時,盡量選擇大容量芯片,以減少芯片數(shù)量以簡化系統(tǒng)。綜合以上因素,選擇芯片作為本次設(shè)計的程序存儲器擴展用芯片。于8031芯片的口是分時傳送低8位地址線和數(shù)據(jù)線的,故8031擴展系統(tǒng)中一定要有地址鎖存器,常用的地址鎖存器芯片是742S373。(2)數(shù)據(jù)存儲器的擴展由于8031芯片內(nèi)部RAM只有128字節(jié)供用戶使用,遠不能滿足系統(tǒng)需要,因此需要擴展片外的數(shù)據(jù)存儲器(RAM)。常用的數(shù)據(jù)存儲器有6116(2Kx8),6264(8Kx8)等,這里我選用6264(8Kx8)。(3)譯碼電路由于這里擴展的容量較大,擴展多個外圍芯片。因此,這里使用譯碼法來進行編址。譯碼電路可使用現(xiàn)有的譯碼芯片,這里我們選用3-8譯碼器(74LS138)。這種芯片,輸入端占用3根最高位地址線,剩余的13根低位地址線可作為片內(nèi)地址線,74LS138譯碼器的8根輸出線分別對應(yīng)8個8K字節(jié)的地址空間。(4)擴展電路設(shè)計(a).通用可編程接口芯片單片機共有個位并行接口,但供用戶使用的只有1口及部分3 口線。因此要進行口的擴展。與微機接口較簡單,是微機系統(tǒng)廣泛使用的接口芯片。(四)步進電機驅(qū)動電路設(shè)計(1)脈沖分配器步進電機的控制方式由脈沖分配器實現(xiàn),其作用是將數(shù)控裝置送來的一系列指令脈沖按一定的分配方式和順序輸送給步進電機的各相繞組,實現(xiàn)電機正反轉(zhuǎn)。數(shù)控系統(tǒng)中通常使用集成脈沖分配器和軟件脈沖分配器。本設(shè)計采用集成脈沖分配器YB013。(2)光電隔離電路在步進待年紀驅(qū)動電路中,一般在接口電路與功率放大器之間家上光電隔離電路,實現(xiàn)電氣隔離,通常使用光電偶合器作為光電隔離電路。(3)功率放大器環(huán)型分配器的輸出脈沖很小,還遠不能滿足步進電機的要求,不許將它放大,以產(chǎn)生足夠大的功率驅(qū)動步進電機正常運轉(zhuǎn),這里采用的功率放大電路如下圖所示:圖5-2功率放大器(五)其它輔助電路設(shè)計()的時鐘電路單片機的時鐘可由內(nèi)部方式產(chǎn)生,內(nèi)部方式利用芯片內(nèi)部的振蕩電路,在XTA,XTA引腳上外接定時元件。如下圖所示圖5-3時鐘電路()復(fù)位電路單片機的復(fù)位電路都是靠外部電路實現(xiàn),在時鐘電路工作后,只要在引腳上出現(xiàn)10ms 以上高電平,單片機便實現(xiàn)狀態(tài)復(fù)位,以后單片機便從0000單元開始執(zhí)行程序圖5-4復(fù)位電路六、系統(tǒng)控制軟件的設(shè)計(一)系統(tǒng)控制軟件的主要內(nèi)容數(shù)控系統(tǒng)是按照事先編好的控制程序來實現(xiàn)各種控制功能。按照功能可將數(shù)控系統(tǒng)的控制軟件分為以下幾個部分:(1)系統(tǒng)管理程序:它是控制系統(tǒng)軟件中實現(xiàn)系統(tǒng)協(xié)調(diào)工作的主體軟件。其功能主要是接受操作者的命令,執(zhí)行命令,從命令處理程序到管理程序接收命令的環(huán)節(jié),使系統(tǒng)處于新的等待操作狀態(tài)。(2)零件加工源程序的輸入處理程序。該程序完成從外部I/O設(shè)備輸入零件加工源程序的任務(wù)。(3)插補程序。根據(jù)零件加工源程序進行插補,分配進給脈沖。(4)伺服控制程序。根據(jù)插補運算的結(jié)果或操作者的命令控制伺服電機的速度,轉(zhuǎn)角以及方向。(5)診斷程序。包括移動不見移動超界處理,緊急停機處理,系統(tǒng)故障診斷,查錯等功能。(6)機床的自動加工及手動加工控制程序。(7)鍵盤操作和顯示處理程序。包括監(jiān)視鍵盤操作,顯示加工程序、機床工作狀態(tài)、操作命令等信息。(二)系統(tǒng)控制功能分析數(shù)控X-Y工作臺的控制功能包括:(1)、系統(tǒng)初始化。如對I/O接口8155,8255A進行必要的初始化工作,預(yù)置接口工作方式控制字。(2)、工作臺復(fù)位。開機后工作臺應(yīng)該自動復(fù)位,亦可手動復(fù)位。(3)、輸入和顯示加工程序。(4)、監(jiān)視按鍵,鍵盤及開關(guān)。如監(jiān)視緊急停機鍵及行程開關(guān),鍵盤掃描等功能。(5)、工作臺超程顯示與處理。工作臺位移超過規(guī)定值時應(yīng)該立即停止工作臺的運動,并顯示相應(yīng)的指示字符。(6)、工作臺的自動控制。(7)、工作臺的手動控制。(8)、工作臺的聯(lián)動控制。(三)系統(tǒng)管理程序控制管理稱許是系統(tǒng)的主程序,開機后即進入管理程序。其主要功能是接受和執(zhí)行操作者的命令。在設(shè)計管理程序時,應(yīng)確定接收命令的形式,系統(tǒng)的各種操作功能等。數(shù)控X-Y工作臺的基本操作功能有:輸入加工程序,自動加工,刀位控制,工作臺位置控制,手動操作,緊急停機等。(四)自動加工程序設(shè)計(1)機床在自動加工時的動作順序:工作臺移動到位刀具快速進給加工退刀工作臺運動到下一位置;(2)計算機在加工過程中的操作:讀取刀具軌跡,控制機床完成加工;結(jié)束語畢業(yè)設(shè)計是我在大學(xué)里的最后一門課程。通過這次畢業(yè)設(shè)計,我學(xué)會了如何查閱現(xiàn)有的技術(shù)資料、如何舉一反三、如何通過改進并加入自己的想法與觀點,使之成為自己的東西。并且結(jié)合生產(chǎn)知識,培養(yǎng)理論聯(lián)系實際以及分析和解決工程實際問題的才能,并使大學(xué)三年所學(xué)的知識得到進一步鞏固、深化和擴展。在此,我對我的論文指導(dǎo)老師沈丁琦老師表示衷心的感謝,感謝他對我的嚴格要求,感謝他的監(jiān)督和指導(dǎo)。其次我要感謝這三年里給我授課的所有老師。感謝你們傳給我知識。最后還要感謝參考文獻中所列書籍、文章及資料的作者。參考資料1、 高鐘毓 機電控制工程M 清華大學(xué)出版社 20022、 劉助柏 知識創(chuàng)新思維方法論J機械工業(yè)出版社 19993、 宋云奪 宋云奪 光機電一體化產(chǎn)業(yè)的未來J 光機電信息 2003 (12)4、 丁連紅 機電一體化技術(shù)發(fā)展趨勢和現(xiàn)狀分析J 中國科技信息 2007 (12)5、 張鵬萬 孫劍峰 李占平 機電一體化中的接口技術(shù)J礦業(yè)工程 2005 (06)6、 王寶敏 談機電一體化技術(shù)的發(fā)展趨勢J 大眾科技 2006 (05)7、 王維剛 淺談機電一體化技術(shù)的發(fā)展趨勢J黑龍江科技信息 2007 (02)8、 楊春光 我國機電一體化技術(shù)的現(xiàn)狀和發(fā)展趨勢J 科技促進發(fā)展 2007 (03)9、 毅剛 單片機原理與應(yīng)用M高等教育出版社 200310、 張大明 彭旭昀 尚靜基.單片微機控制應(yīng)用技術(shù)M機械工業(yè)出版社 200611、 付家才 單片機控制工程實踐技術(shù)M化學(xué)工業(yè)出版社 200412、 陳小忠 黃寧 趙小俠 單片機接口技術(shù)實用子程序M 人民郵電出版社 200525目 錄摘 要1前 言2一、畢業(yè)設(shè)計的目的、意義4二、畢業(yè)設(shè)計的內(nèi)容4(一)畢業(yè)設(shè)計題目:單片機控制步進電機驅(qū)動的多用XY工作臺。4三、數(shù)控系統(tǒng)總體方案的確定4(一)系統(tǒng)運動方式的確定4(二)伺服系統(tǒng)的選擇4(三)計算機系統(tǒng)的選擇5(四) XY工作臺的傳動方式5四、機械部分設(shè)計5(一)確定系統(tǒng)脈沖當量5(二)工作臺外形尺寸及重量初步估算6(三)滾動導(dǎo)軌副的計算、選擇7(四)滾珠絲杠計算、選擇8(五)齒輪計算、設(shè)計11(六)步進電機慣性負載的計算12(七)步進電機的選用13五、數(shù)控系統(tǒng)硬件電路設(shè)計15(一)數(shù)控系統(tǒng)的硬件電路由以下幾部分組成:15(二)主控制器的選擇15(三)存儲器擴展電路設(shè)計15(四)步進電機驅(qū)動電路設(shè)計16(五)其它輔助電路設(shè)計17六、系統(tǒng)控制軟件的設(shè)計18(一)系統(tǒng)控制軟件的主要內(nèi)容18(二)系統(tǒng)控制功能分析18(三)系統(tǒng)管理程序控制19(四)自動加工程序設(shè)計19結(jié)束語20參考資料21 黃河科技學(xué)院畢業(yè)設(shè)計(文獻翻譯) 第10 頁 單位代碼 0 2 學(xué) 號 080105655 分 類 號 TH6 密 級 秘密 畢業(yè)設(shè)計文獻翻譯院(系)名稱工學(xué)院機械系 專業(yè)名稱機械設(shè)計制造及其自動化 學(xué)生姓名金賀 指導(dǎo)教師薛東彬 2012年 3 月 10 日針對不同的數(shù)控機床一個基于互聯(lián)網(wǎng)的機床檢查計劃Dong-ttoon Kim情報和精密機械部門,韓國機械和材料研究所,大田305 - 343,韓國Sun-Ho Kim機電工程專業(yè)本科工程,東義大學(xué),Busan 614 - 714釜山、韓國Kwang-SIK KOH電氣工程和計算機科學(xué)學(xué)院,慶北國立大學(xué),大邱廣域市702-701,韓國摘要本文提出了一個基于互聯(lián)網(wǎng)的機床檢查與數(shù)字控制機床(CNC)技術(shù)。根據(jù)其體系結(jié)構(gòu)的不同,數(shù)控機床分為兩種類型:一種是封閉式控制結(jié)構(gòu)(CAC),它是傳統(tǒng)的數(shù)控機床;一種是開放式控制結(jié)構(gòu)(OAC),這是最近推出的PC-based控制器。由于CAC有一個封閉的架構(gòu),所以它依賴于數(shù)控機床供應(yīng)商制定的規(guī)格。而因為這一點,它的應(yīng)用程序很難在數(shù)控領(lǐng)域為用戶所實現(xiàn)。近日,傳統(tǒng)的數(shù)控機床已被基于PC的開放式數(shù)控機床所取代。然而,現(xiàn)在還有很多傳統(tǒng)的數(shù)控機床在OAC配備不足的車間工作。對于CAC和OAC數(shù)控機床基于互聯(lián)網(wǎng)的檢查,一個合適的系統(tǒng)環(huán)境是必要的。通過這項研究,對包括CAC和OAC在內(nèi)的各種CNC在專業(yè)化生產(chǎn)系統(tǒng)進行全球化管理,對各種CNC基于互聯(lián)網(wǎng)的檢查設(shè)計一個合適的環(huán)境,并對CAC和OAC檢查方法作比較。這項研究成果可作為一個數(shù)控機床集成制造系統(tǒng)的全球監(jiān)測和遠程控制的基本模型。在本研究中定義的檢查點分為兩類:結(jié)構(gòu)性點和操作點。前者包括軸承的振動,主軸單元的溫度,和其他期刊管理點,而后者則包括油檢查,夾具鎖/開鎖,加工開/關(guān)狀態(tài)。關(guān)鍵詞:基于Internet的檢查方法,變式數(shù)控,CAC,0AC1導(dǎo)言電腦和互聯(lián)網(wǎng)的廣泛使用,導(dǎo)致一個基于Internet的數(shù)控機床的控制和監(jiān)測的全球化管理在專業(yè)化生產(chǎn)系統(tǒng)的需求不斷增加。在過去,利用可編程邏輯控制器(PLC)的接觸點,監(jiān)測做為數(shù)控機床和制造系統(tǒng)外圍設(shè)備的I / O信號。但是,這個程序已經(jīng)被限制到CNC內(nèi)部信息的監(jiān)測。它很難執(zhí)行用戶在數(shù)控領(lǐng)域定義的程序,這個程序包括檢查有關(guān)CNC的各種監(jiān)測數(shù)據(jù),外圍設(shè)備和其他外部單位(Rober and Shin, 1995;Lee et.al.,2004)。而所需的用戶自定義程序是數(shù)控機床監(jiān)測與遠程站點的通信應(yīng)用程序模塊。近日,基于PC的開放式結(jié)構(gòu)數(shù)控機床取代了傳統(tǒng)的數(shù)控機床,從而提供了一個方便的環(huán)境來實現(xiàn)用戶定義的用于遠程監(jiān)視和控制的數(shù)控程序(Rober and Shin, 1995;Kwon et.al.,2000;Hong et.al.,2003)。然而,很多傳統(tǒng)的數(shù)控機床在OAC配備不足的車間工作。為了做到對這種變式數(shù)控機床遠程檢查,應(yīng)對每個CAC和OAC構(gòu)建合適的環(huán)境?,F(xiàn)在,我們簡要的概述下相關(guān)的研究。關(guān)于機床的開放式數(shù)控制造系統(tǒng)管理的研究,已經(jīng)快速的實現(xiàn)了在柔性制造系統(tǒng)和自動配置(Wright,1995)和動態(tài)重新配置(Oldknow and Yellowley,2001)的研究。一個開關(guān)函數(shù)發(fā)生器的研究解決了在開放式結(jié)構(gòu)機床的維修機制(Kim et al.,2002)。機床的遠程控制和監(jiān)測客戶端 - 服務(wù)器環(huán)境也一直被研究(Oldknow and Yellowley,2003)。這種關(guān)于遠程服務(wù)的代表性例子是由CNC供應(yīng)商開發(fā)的工廠窗口和遠程系統(tǒng)(Kim et al.,2000;Kang and Kang,1999)。然而,這些系統(tǒng)的特點是當?shù)氐挠颦h(huán)境提高基本的技術(shù)支持。此外,這些研究還包括基于互聯(lián)網(wǎng)的機床管理,CNC故障診斷的實現(xiàn)和基本的遠程服務(wù)(Kim et al.,2003)。在柔性制造系統(tǒng)中基于Web的監(jiān)控也進行了研究(Jung et al.,2001)。此外,還研究了維護數(shù)控機床的公共交換電信電話網(wǎng)(PSTN)和數(shù)字I / O模塊(Hyun et al.,1998)。然而,這些研究都集中在CAC機除外的OAC機上,而研究的大多數(shù)的服務(wù)功能是通過電話線或外部網(wǎng)絡(luò)(如Internet)傳輸?shù)谋O(jiān)測數(shù)據(jù)。盡管是基于互聯(lián)的應(yīng)用程序,仍要安裝一個開發(fā)商依賴的特殊的客戶端,因為大多數(shù)情況下是基于客戶-服務(wù)器的配置。在某些特殊情況下,一個額外的內(nèi)核是必需的。此外,優(yōu)越的數(shù)控廠商,如西門子的第三方支持通過互聯(lián)網(wǎng)的網(wǎng)絡(luò)服務(wù)。然而,在這情況下,非常困難的是服務(wù)的功能往往不適合車間修改功能。在國內(nèi),甚至有部分數(shù)控廠商無法服務(wù)一般商用的基于互聯(lián)網(wǎng)的檢查服務(wù),如通過lnternet的監(jiān)測。出現(xiàn)這種情況是因為大部分的運營商和數(shù)控廠商都集中在國內(nèi)數(shù)控市場的穩(wěn)定性和原創(chuàng)能力上面。也就是說,大部分的數(shù)控廠商都害怕數(shù)控機床因過載而崩潰或因故障造成額外軟件安裝或升級,所以他們支持遠程服務(wù)功能??傊?,雖然對OAC有一些研究,但是少有滿意的設(shè)計,而對CAC的研究更是非常缺乏。尤其是,基于互聯(lián)網(wǎng)的檢查與CAC和OAC的變種數(shù)控機床沒有得到充分的研究報告,由于不便開發(fā)環(huán)境和較差的軟件可移植性。本文調(diào)查申請的方法是基于互聯(lián)網(wǎng)的檢查技術(shù),對OAC和CAC兩個變式數(shù)控機床進行比較。通過這項研究建議通過基于Internet檢查變式數(shù)控機床的有效計劃。首先,遠程檢查和控制與CAC的機床和零部件相關(guān)的數(shù)字信號,通過使用I / O的嵌入式模塊介紹網(wǎng)頁;其次,本文認為模擬和數(shù)字遠程檢查OAC的機器通過實施相關(guān)的信號用戶定義的應(yīng)用程序能夠接口與外部服務(wù)器的數(shù)控域,并通過數(shù)據(jù)采集單元(DAU),能夠獲得與連接的數(shù)據(jù)機及周邊設(shè)備的聯(lián)系點。CAC有一個封閉的架構(gòu),它是依賴數(shù)控協(xié)力廠商規(guī)范。由于這一點,就已經(jīng)很困難,為用戶實施在數(shù)控應(yīng)用程序。因此,一個特殊的,額外的模塊需要基于互聯(lián)網(wǎng)的應(yīng)用程序(塞納科技,2002年)。對于這一點,一個網(wǎng)絡(luò)的I / O嵌入式模塊適用于本研究基于互聯(lián)網(wǎng)的檢查。模塊直接連接到TCP/ IP網(wǎng)絡(luò)與遠程通信網(wǎng)站。為了獲得監(jiān)測數(shù)據(jù)數(shù)控機床,模塊的I / O信號在數(shù)控被分配到PLC的I / O信號。另一方面,OAC有一個基于PC的開放式架構(gòu),運作獨立于數(shù)控供應(yīng)商的規(guī)范并沒有額外的模塊是必要的,用于連接遠程站點。正因為如此,一個簡單的DAU,這是不直接連接到OAC的主要電路板,而不是直接影響到數(shù)控穩(wěn)定,用于信號傳感和數(shù)據(jù)通過RS232/422行收購無需額外通信設(shè)備模塊。基于Internet的遠程機器檢查與OAC,用戶定義的守護進程的工具通信和應(yīng)用程序Web服務(wù)的形式實現(xiàn)OAC和內(nèi)部功能內(nèi)外部服務(wù)器?;ヂ?lián)網(wǎng)通信之間進行數(shù)控領(lǐng)域的守護程序外部服務(wù)器和網(wǎng)絡(luò)腳本程序。2基于Internet檢查OAC的方法在OAC的情況,不需要網(wǎng)絡(luò)支持附加設(shè)備模塊,OAC有一個方便的結(jié)構(gòu),可以實現(xiàn)網(wǎng)絡(luò)應(yīng)用程序。檢查和獲得機床I / O信號的數(shù)據(jù),只需要信號處理板或外部的DAU數(shù)據(jù)采集。由于大多數(shù)OAC是基于單板計算機上的DAU一個緊湊的結(jié)構(gòu),比板型(Advantech,2002)更有效可以簡單地連接I / O信號。試圖通過監(jiān)測加工狀態(tài),應(yīng)用程序通過DAU零部件溫度和振動的檢查方法,可以通知檢查時間和零部件的更換時間。通過這個應(yīng)用,數(shù)控機床及周邊設(shè)備的模擬和數(shù)字接觸點監(jiān)測使用的DAU。在實驗中,使用外部的I / O的DAU模塊,以減少硬件設(shè)備的大小,并盡量減少負荷?;贗nternet的檢查OAC機床配置使用的DAU如圖1RS485通訊內(nèi)部通過RS232/485轉(zhuǎn)換規(guī)范。0V至1.5V的范圍內(nèi)分配一個采樣周期為每秒10次,以獲取模擬傳輸值。為獲取軸承的振動和主軸溫度的實驗,傳輸?shù)哪M值在OAC和DAU之間的通信協(xié)議實時監(jiān)控,如圖2所示Subsequently,也進行檢查開/關(guān)狀態(tài)的石油和鉗的基本實驗,如圖3所示功能的應(yīng)用程序代碼,實現(xiàn)在OAC數(shù)控域的內(nèi)部功能。基于Internet的檢查應(yīng)用,通訊發(fā)達的守護程序在數(shù)控領(lǐng)域?qū)嵤谕獠糠?wù)器由Web服務(wù)的Web scr.ipt方案實施,使用vbscrip,JavaScript和活動服務(wù)器頁面(ASP),如圖4守護程序之間的網(wǎng)絡(luò)通信可以在數(shù)控域和外部Web腳本程序。因此,多個客戶端可以監(jiān)控檢查的數(shù)據(jù)和機器的狀態(tài),通過收購數(shù)字和模擬數(shù)據(jù)傳輸從外部數(shù)據(jù)庫的OAC。數(shù)控通信服務(wù)程序采用標準的開放式數(shù)據(jù)庫連接(ODBC)和數(shù)據(jù)處理,利用結(jié)構(gòu)化查詢語言(SQL)查詢。通過這個過程,檢查數(shù)據(jù)傳輸相關(guān)的表中的信息構(gòu)建在數(shù)據(jù)庫表中。在互聯(lián)網(wǎng)環(huán)境下的遠程檢查,實現(xiàn)了通過設(shè)計的應(yīng)用程序,如圖5所示結(jié)果表明,這種檢查方法是有利的,在其方便的開發(fā)環(huán)境在軟件方面,可以很容易地實現(xiàn)用戶定義的應(yīng)用程序。圖1基于互聯(lián)網(wǎng)的檢查OAC的機器配置使用的DAU圖2通信協(xié)議之間的OAC的DAU模圖3模擬輸入(0-1.5V的范圍)的收購和數(shù)字輸入(8位直接投資)圖4 OAC和應(yīng)用程序之間的接口網(wǎng)站SEVER圖5 檢查OAC的機器所使用的DAU和應(yīng)用程序3基于Internet的檢查計劃和變式數(shù)控機床的例子基于互聯(lián)網(wǎng)的檢查的計劃變型數(shù)控機床的建議圖6CAC機區(qū)旨在檢查通過下載腳本代碼的數(shù)字數(shù)據(jù)和嵌入式設(shè)備服務(wù)器的I / O接口機制。在OAC機區(qū)檢查所使用的DAU和應(yīng)用程序,如數(shù)據(jù)采集模塊,通信守護進程模塊,和一個web腳本模塊的模擬數(shù)據(jù)和數(shù)字數(shù)據(jù)。基于互聯(lián)網(wǎng)的變種數(shù)控機床的遠程檢查,通過擬議的計劃表見圖7在CAC的機床的情況下,一個Java applet被編碼和下載,以檢查機床的I / O數(shù)據(jù)和通過網(wǎng)絡(luò)瀏覽器向客戶提供檢查結(jié)果。在I / O地址的Java applet代碼和真正的I / O點的機床之間分配,監(jiān)視和控制遠程站點。展示的內(nèi)容是對監(jiān)測結(jié)果 I / O的接觸點與當前加工/關(guān)狀態(tài)。 CAC的機床運作周期的啟動按鈕正在網(wǎng)頁瀏覽器上。在OAC機床的情況下,收購的DAU監(jiān)測數(shù)據(jù)傳送到在遠程站點,外部服務(wù)器和通信守護進程服務(wù)。它通過網(wǎng)絡(luò)瀏覽器激活油傳感器,主軸溫度是0.0007(這是從0至1.5 V范圍內(nèi)的模擬值)。結(jié)果表明,在前一種情況下,CAC是有利的,它可以很容易地利用網(wǎng)絡(luò)功能的嵌入式設(shè)備,在硬件實現(xiàn)基于lnternet的檢查系統(tǒng)。然而,用戶定義的應(yīng)用程序和下載數(shù)據(jù)的最大尺寸被限制在512字節(jié);后者的情況下,在其方便的開發(fā)環(huán)境,可以方便地實現(xiàn)在數(shù)控領(lǐng)域的許多不同的應(yīng)用程序,無需額外設(shè)備的優(yōu)點。然而,用戶定義的應(yīng)用程序編程工作需要比在前者的情況下實施通信和網(wǎng)絡(luò)服務(wù)。圖6基于互聯(lián)網(wǎng)的檢查環(huán)境變異數(shù)控機床圖7 例如基于互聯(lián)網(wǎng)的遠程檢查變種數(shù)控機床4結(jié)論本文提出了一種新的研究基于Internet檢查傳統(tǒng)的CAC和最近推廣的OAC兩種變式數(shù)控機床。為了實現(xiàn)基于互聯(lián)網(wǎng)高效的檢查CAC機,使用信號檢測方法,通過網(wǎng)絡(luò)I / O嵌入式設(shè)備模塊,可以支持互聯(lián)網(wǎng)應(yīng)用環(huán)境,因為在CAC的環(huán)境執(zhí)行用戶定義的應(yīng)用程序,是依賴于數(shù)控廠商規(guī)范了的數(shù)控領(lǐng)域。為了實現(xiàn)基于互聯(lián)網(wǎng)檢查OAC機床,數(shù)字和模擬信號的檢查方法,它不需要額外的網(wǎng)絡(luò)I / O的互聯(lián)網(wǎng)應(yīng)用的嵌入式設(shè)備,有人建議,因為數(shù)控域執(zhí)行用戶定義的應(yīng)用程序很容易因方便OAC的環(huán)境。這種方法只需利用的DAU取得的I / O硬件方面的數(shù)據(jù)和采集到的數(shù)據(jù)傳送到外部服務(wù)器通過在遠程站點上的網(wǎng)頁瀏覽器的遠程檢查。隨后,對CAC和OAC機的檢查方法進行了比較。通過這項研究,為數(shù)控機床與數(shù)控變種的CAC和OAC在制造系統(tǒng),基于互聯(lián)網(wǎng)的變型數(shù)控機床的檢查,被設(shè)計為一體的綜合經(jīng)營的一個合適的環(huán)境,如建筑的全球管理。這項研究的結(jié)果可能是一個全球監(jiān)測和遠程控制在變種數(shù)控機床集成制造系統(tǒng)的基本模型。在今后的工作中應(yīng)解決以下問題:首先,研究人員應(yīng)該調(diào)查優(yōu)越的遠程檢查環(huán)境的設(shè)計和實現(xiàn),可以在嵌入式設(shè)備利用足夠的上下載的代碼;其次,還需要進一步研究,可以更簡單地對集成和經(jīng)營變式數(shù)控機床的標準化和優(yōu)化應(yīng)用程序進行開發(fā)。感謝感謝工業(yè)改造技術(shù)項目(商務(wù)部,工業(yè)和能源)提供的財政支持。Journal of Mechanical Science and Technology, Vol. 19, No. 1, pp. 97-105, 2005 97 A Scheme for an Internet-based Checking Method of Machine-Tools with Variant CNC Architecture Dong-ttoon Kim* Department of Intelligence and Precision Machines, Korea Institute of Machinery and Materials, Daejeon 305-343, Korea Sun-Ho Kim Mechatronics Engineering Major, College of Engineering, Dong-Eui University, Busan 614-714, Korea Kwang-Sik Koh School of Electrical Engineering and Computer Science, Kyungpook National University, Daegu 702-701, Korea This paper proposes an Internet-based checking technique for machine-tools with variant Computerized Numerical Controller (CNC). According to its architecture, CNC is classified into one of two types : Closed Architecture Controller (CAC), which is the conventional CNC, or Open Architecture Controller (OAC), which is a recently introduced PC-based controller. Since CAC has a closed architecture, it is dependent on CNC vender specification. Because of this, it has been very difficult for users to implement application programs in the CNC domain. Recently, the conventional CNC of machine-tools has been replaced by a PC-based open architecture CNC. However, now many conventional CAC machines are being operated together with OAC machines in inadequately equipped shop floors. For Internet-based checking for variant CNC machines with CAC and OAC, a suitable systematic environment is necessary. Through this research, for the global management of variant CNC machines both a CAC and an OAC in the manufacturing system, a suitable environment for Internet-based checking of variant CNC machines was designed, and the checking methods for CAC and OAC machines were compared. The results of this research may serve as a base model for global monitoring and remote control in an integrated manufacturing system with variant CNC machines. Checking points defined in this research are classified into two categories: structured point and opera- tional point. The former includes the vibration of bearing, temperature of spindle unit, and other points of periodical management, while the latter includes oil checking, clamp locking/ unlocking, and machining on/off status. Key Words : Internet-Based Checking Method, Variant CNC, CAC, 0AC I. Introduction Widespread use of computers and the Internet * Corresponding Author, E-mail : kdh680 kimm.re.kr TEL : -t-82-42-868-7148; FAX : -t-82-42-868-7150 9 Department of Intelligence and Precision Machines, Korea Institute of Machinery and Materials, Daejeon 305-343, Korea 9 (Manuscript Received June 11, 2004; Revised October 25, 2004) have led to a continuously increasing demand for Internet-based control and monitoring of CNC machines for distributed global management in manufacturing systems. In the past, the contact points of Programmable Logic Controller (PLC) were utilized for the monitoring of I/O signals associated with CNC machines and peripheral equipment in manufacturing systems. However, this solution has been limited to the monitoring of CNC internal information. It has Copyright (C) 2005 NuriMedia Co., Ltd. 98 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh been difficult to check various monitoring data regarding the CNC, peripheral equipment, and other external units by implementing user-defin- ed programs to the CNC domain (Rober and Shin, 1995 ; Lee et. al., 2004). The required user- defined programs are application modules for the monitoring of CNC machines and for com- munication with a remote site. Recently, a conve- nient environment able to implement user-defin- ed programs to a CNC domain for remote moni- toring and control has been provided, since the conventional CNC of machine-tools has been replaced by a PC-based open architecture CNC (Rober and Shin, 1995 ; Kwon et. al., 2000 ; Hong et. al., 2003). However, many conventional CAC machines are now being operated in inadequately equipped shop floors. In order to do a remote check on such variant CNC machines, a suitable environment for each case of the CAC and the OAC should be constructed. We will now briefly outline the related re- search. Regarding research on the management of machine-tools with open architecture CNC in manufacturing systems, there have been studies on rapid part realization in flexible factory sys- tems (Wright, 1995) and on automatic configura- tion and dynamic reconfiguration (Oldknow and Yellowley, 2001). A study on switching function generators addressed the maintenance mechanism of machine-tools with open architecture CNC (Kim et al., 2002). Remote control and monitoring of machine tools by client-server environments has also been investigated (Oldknow and Yellowley, 2001; Kim et al., 2003). The representative examples for such remote services are factory windows and remote systems that are developed by a com- mercial CNC vendor (Kim et al., 2000 ; Kang and Kang, 1999). However, these systems are char- acterized by basic technical support in local domain environments. Besides of this, as for re- search on Internet-based management of mac- hine-tools, CNC-implemented fault diagnosis and basic remote services were reported (Kim et al., 2003). Web-based monitoring has been stu- died in a flexible manufacturing system (Jung et al., 2001). Furthermore, Public Switched Tele- Copyright (C) 2005 NuriMedia Co., Ltd. phone Network (PSTN) and digital I/O modules were utilized for research on the maintenance of CNC machines (Hyun et al., 1998). However, these researches have focused on only OAC machines except CAC machines and the most service function is to transmit moni- toring data via telephone line or external net- work such as Internet. Although in the case of Internet-based application, a special client-ter- minal program, which is dependent of developer, has to be installed because the most cases are based on client-server configuration. In some special cases, an additional kernel is optionally required. Besides, the third-party of superior CNC vendor such as Siemens supports partially the web services via Internet. However, in this case, the service functions are not often suitable to the shop-floor and the modification of the functions is very difficult. In domestic case, even representative CNC vendor can not service gen- erally and commercially the Internet-based chec- king services such as conditions monitoring via lnternet. The cause of such actual circumstance mentioned above is because most operators and CNC vendors have focused on the stability and original ability of CNC in domestic CNC market. That is, most CNC vendors are afraid of the breakdown of CNC machine-tools due to over- load and faults resulting from additional soft- ware installation or upgrade for the purpose of supporting the functions such as remote services. In short, although there are some researches av- ailable for machines with OAC, satisfied applica- tion cases are rare yet and the studies on machines with CAC have been very deficient. Especially, research on Internet-based checking for variant CNC machines with a CAC and an OAC has not been sufficiently reported due to the inconvenient development environment and inferior software- portability. This paper investigates methods for applying Internet-based checking techniques to variant CNC machines with OAC and CAC, and the two types of CNC are compared. And an efficient scheme for Internet-based checking for variant CNC machines is suggested through this study. First, remote checking and control of the digital A Scheme for an lnternet-based Checking Method of Machine-Tools with Variant CNC Architecture 99 signals associated with CAC machines and com- ponent parts by using a web I/O embedded mo- dule are introduced. Second, this paper consi- ders the remote checking of analog and digital signals associated with OAC machines by imple- menting user-defined application programs able to interface with an external server to the CNC domain, and by using a Data Acquisition Unit (DAU) able to acquire data connected with the contact points of machines and peripheral equi- pments. CAC has a closed architecture which is depen- dent on CNC vender specification. Because of this, it has been very difficult for users to imple- ment an application program in CNC. Therefore, a special, additional module is required for Internet-based application (Sena Technologies, 2002). For this, a web I/O embedded module was applied for Internet-based checking in this re- search. The module is directly attached to the TCP/IP network for communication with a re- mote site. In order to obtain the monitoring data of CNC machines, the I/O signals of the module were assigned to PLC I/O signals within CNC. On the other hand, OAC has a PC-based open architecture that operates independent of CNC vendor specification and no additional module is necessary for connection with a remote site. Because of this, a simple DAU, which is not directly attached to OAC main-board and not directly affects to CNC stability, is used for signal sensing and data acquisition via RS232/422 line without additional communication device mo- dule. For Internet-based remote checking of ma- chine-tools with OAC, a user-defined daemon for communication and application programs for web services were implemented in the form of internal function within OAC and an external server. Internet communication is performed be- tween the daemon program of the CNC domain and web script programs of the external server. 2. Structure of Variant CNC Machines and Remote Checking Directions As mentioned above, the implementation of a Copyright (C) 2005 NuriMedia Co., Ltd. user-defined application program is much more difficult in the CAC than in the OAC due to the inconvenient development environment of the CAC. Because the CAC is fully dependent on the CNC vendor, as shown in Fig. 1 (a), the CAC cannot support the application of user-functions that can connect with the network and remotely check CNC machines in the CNC domain. How- ever, as shown in Fig. 1 (b), it is convenient for users to implement the application programs for remote checking in the OAC domain because the OAC has an open architecture based on a PC. For Internet-based remote checking of these two CNC machines that are operated together in a manufacturing system, a suitable system environ- ment must be constructed according to the struc- ture characters of the variant CNC. The conven- tional CAC with closed architecture can effi- ciently use the network-supported unit with em- bedded web server functions because connecting the I/O signals of the applied unit with the I/O signals of CNC machines is possible. This method has an relatively simple system architecture for users, but its fatal flaw is that it cannot manage multiple CNC machines simultaneously with a single server and web script program ; this meth- od, using web-server functions embedded in the device, requires that an individual Internet Pro- tocol (IP) address be associated with each ma- chine. For the recently popularized OAC with a (a) CNC with closed architecture controller (b) CNC with open architecture controller Fig. 1 Structure of variant CNC machines 100 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh PC-based open architecture environment, instead of using network-supported units that require additional unique IP addresses, a suitable method is as follows. First, a DAU is utilized in order to acquire I/O data. Then the application program for data acquisition is implemented in order to check I/O contact signals through the DAU, and the interface daemon program, that can transmit the acquired data from a CNC domain to an external server, is implemented in the CNC do- main. A particularly outstanding merit of this system is that a lot of CNC machines can be monitored and managed simultaneously without an additional device with embedded web-server functions. This method also has good expansi- bility. 3. Definition of Checking Points As shown in Table 1, the checking points defined in this research are classified into two categories : structured point and operational point. The former includes the vibration of bear- ing, and the temperature of the spindle unit and other specific units, while the latter includes oil checking, clamp locking/unlocking, and other digital checking points associated with machine operations. Table 1 Definition of checking point Structured Conditions Operational Conditions Vibration of bearings Machining On Temperature of spindle Machining Off Vibration of bearing2 Fault (No Ready) Temperature of spindle2 Oil checking Vibration of bearing3 Clamp lock/unlock Temperature of spindle3 Sub unit on/off 4. Internet-Based Checking Method for CAC Machines This section describes the application of an Internet-based checking method for CAC mac- Fig. 2 hines. In remote monitoring of checked results Copyright (C) 2005 NuriMedia Co., Ltd. and related information with CAC machines, the application program implementation and the program running environment in the CNC do- main are more limited than in an OAC environ- ment that can easily implement software func- tions. Because an additional device module is necessary, we utilized the I/O module with em- bedded minimum operating system and web ser- ver functions, as shown in Fig. 2. By applying this module, the control and monitoring of CNC machines were remotely performed in the experi- ment. The applied device module supports a total of 32 I/O contact points in order to interface with external devices. The contact points were connected with the PLC I/O signals of the CAC machine. Through these points, the machine sta- tus such as cycle start, stop, emergency stop, and machining on/off status can actually be moni- tored in a web environment. The procedure for the application test is as follows. The icons associated with the I/O device module are first designed in default html source by using the supplied device utility, and then the icons properties are assigned to specific I/O addresses. Next, network-supported java class is inserted in default html source and the source codes are compiled by the utility compiler. After that, coded web script files are transferred to the specific file index format so that they can be interpreted by the device module engine (Sena CAC Machine .q D PLC/PMC Z 176 I,. N ooo ooo _ Digital tlO Connection (Digital I/0 Interface Method) .: l Browser Ethernet cable I Hub/SwitCh t Internet-based checking configuration using embedded web I/O device for CAC machine A Scheme for an Internet-based Checking Method of Machine-Tools with Variant CNC Architecture 101 Technologies, 2002). The transferred file, that is in the form of a specific format, is a single image file format that is downloaded to flash memory, as shown in Fig. 3. In order to assign the phy- sical I/O device addresses in application source codes, the real I/O addresses are mapped with the icon properties in web script sources such as html, vbscript, and javascript, as shown in Fig. 4. Fig. 5 shows that the status of the CAC ma- chine is now checked as machining-on when the cycle-start button is selected through a web browser. And through additional analog checking experiment for structured conditions, bearing vi- bration and spindle temperature were monitored in real time. The remote checking model of the CAC machine and its implementation method are relatively simple and convenient, but a database and large-scale script files cannot be loaded. In I User-defined application modules I Cnneetor to Interact Power Supply 16po Sensor nput Conttc Point Fig. 3 Interface between embedded web I/O device and application program detail, a maximum 512 Kbytes application script program can be downloaded to the web I/O embedded device module. However, this method can be very efficient in applications as it uses an I/O board independent of other systems. Here, for remote checking, web script was coded by using java applet and was downloaded to the web I/O embedded device module. For interfacing with the I/O of the CNC machine, I/O contact points were directly connected with each other between the embedded web I/O device and the machine I/ O signals. Test results confirmed that the applica- tion system environment can be easily designed by using this checking method. Table 2 Hardware specification of used web I/O device Item Content CPU 8-bit Microprocessor 512 KB Flesh Memory Memory (User Web File/Parameter App.) Network 10-base T Ethernet (IEEE802.3) Connection External 16 point Digital Input, Connection 16 point Digital Output Internet Protocol HTTP/TCP/UDP/IP/Ethernet Board (Vendor) Dependency, Utility software IP Setting/Web Page Uploading Icons and html implementation by using device utility .1 Icons Property Setting for I/O Address Connection Building Source to Device I Dependent Format I ; Downloading File to Flash Memory I of Embedded Device Server 1 IP Connection of Device and Web . t/O Testing Fig. 4 Address setting and testing of web I/O device Copyright (C) 2005 NuriMedia Co., Ltd. Xltad,i, 808 : ,p Q Fig. 5 Checking for CAC machine by using em- bedded device server 102 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh 5. Internet-Based Checking Method for OAC Machines In the case of the OAC, an additional device module for network support is not required, as the OAC has a convenient structure that can implement network application programs. To check and acquire machine I/O signal data, only a signal processing board or external DAU for data acquisition is needed. As most OAC is based on a single board computer with a compact ar- chitecture, a DAU that can simply Connect I/O signals is more efficient than the board type (Advantech, 2002). The application of a checking method that can notify the checking time and the replacement time of component parts was tried by monitoring of machining status, temperature, and vibration of component parts through the DAU. Through this application, the analog and digital contact points of CNC machines and peripheral units were monitored by using the DAU. In the experiment, an external I/O DAU module was used in order to reduce hardware device sizes and minimize the load. The Internet-based checking configuration using DAU for an OAC machine is shown in Fig. 6. RS485 communication was internally performed through RS232/485 con- version specification. A range of 0V to 1.5V was assigned and a sampling period was assigned as 10 times per second in order to acquire analog transferred values. For the experiment for acqui- ring bearing vibration and spindle temperature, 00007Analog Input Field (MS-SOL Server 7.0) ling SOL Links / ODBC Dtiv (Structured Quer Lan! OAC l!rrm I (PC-base Open Architecture Controller) -DAU (Data Acquisition Unit) . I Model NO: ADAM 4000 Sedes Prolor Digital Input 8 bit oooo coDe Sensors Analog Input 0-1,5V Range I Temperature Inspection I Fig. 9 Interface between OAC and application pro- gram of web sever tion programs, as shown in Fig. 10. Results show that this checking method is advantageous in that its convenient development environment in terms of software can easily implement user-defined application programs. 6. Scheme and Example of Internet- Based Checking for Variant CNC Machines The scheme for Internet-based checking for variant CNC machines is suggested in Fig. 11. The CAC machine area is designed to check digital data by using downloaded script codes and the I/O interface mechanism of the embedded . . . . Digital I a ElIbedded Web II0 Module . ; Closed ArcNter Controller ;._J PenttmCF;U Envlrot=lnent Open Achitecture Colltroller Environment Fig. 11 Internet-based checking environment for variant CNC machines . m o I Remote Digital Input Monitoring r ol Sam4 , : r o= sas Real DI Vals r ol s.r7 / ii r DISB / XH Status= = 0 O!LlCf Fig. 10 I Current AD ? Monitoring?) -Real D Values Checking for OAC machine by using DAU and application program Kill CAC Machine OAC Machine /M,ch,o,oo- ; ,o0 oit / elaine S
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