加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)5張CAD圖
加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)5張CAD圖,加工,中心,鏈?zhǔn)?控制系統(tǒng),設(shè)計(jì),CAD
畢業(yè)設(shè)計(jì)（論文）要求及原始數(shù)據(jù)（資料）:
1、原始數(shù)據(jù)（資料）：
在加工中心中，刀庫(kù)和換刀機(jī)械手組成自動(dòng)換刀裝置（ATC）,它是加工中心的關(guān)鍵部件之一，?自動(dòng)換刀裝置的好壞將直接影響到加工中心的好壞。
本設(shè)計(jì)為加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)
技術(shù)參數(shù)：
1、刀座數(shù)：40
2、選刀時(shí)間：3S??
3、刀套線速度：25m/min
4、刀柄號(hào)：BT50
5、刀具最大重量25kg
2、畢業(yè)設(shè)計(jì)（論文）要求：
（1）、任務(wù)要求
根據(jù)畢業(yè)設(shè)計(jì)任務(wù)書(shū)技術(shù)要求，擬定鏈?zhǔn)降稁?kù)機(jī)械傳動(dòng)方案，完成機(jī)械關(guān)鍵零部件設(shè)計(jì)與計(jì)算、繪制裝配圖、和部分零件圖；完成刀庫(kù)控制系統(tǒng)設(shè)計(jì)，繪制控制系統(tǒng)原理圖。?同時(shí)根據(jù)機(jī)械部分設(shè)計(jì)計(jì)算，電機(jī)及關(guān)鍵零部件選型計(jì)算，控制系統(tǒng)設(shè)計(jì)等完成畢業(yè)設(shè)計(jì)設(shè)計(jì)說(shuō)明書(shū)。主要任務(wù)如下：
????①畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告；
②文獻(xiàn)綜述和外文翻譯；
③?加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)裝配圖，部分關(guān)鍵零件圖，刀庫(kù)控制系統(tǒng)電氣原理圖；
④畢業(yè)設(shè)計(jì)說(shuō)明書(shū)。
畢業(yè)設(shè)計(jì)（論文）主要內(nèi)容1、設(shè)計(jì)圖樣要求：
設(shè)計(jì)原理正確，運(yùn)用相關(guān)標(biāo)準(zhǔn)、查閱相關(guān)手冊(cè)，正確處理好圖、數(shù)字、符號(hào)、標(biāo)準(zhǔn)等的關(guān)系，圖樣完整準(zhǔn)確?？傮w設(shè)計(jì)完整、圖紙表達(dá)清晰、標(biāo)注采用國(guó)家最新標(biāo)準(zhǔn)；完成整機(jī)裝配圖紙?jiān)O(shè)計(jì)，保證結(jié)構(gòu)方案確定最優(yōu)化；完成部件圖設(shè)計(jì)及傳動(dòng)系統(tǒng)設(shè)計(jì)；完成零件圖設(shè)計(jì)，完成控制系統(tǒng)電氣原理圖設(shè)計(jì)。
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2、畢業(yè)設(shè)計(jì)說(shuō)明書(shū)：
設(shè)計(jì)依據(jù)可靠，參數(shù)選用合理，結(jié)構(gòu)設(shè)計(jì)強(qiáng)度及剛度校核、計(jì)算準(zhǔn)確，內(nèi)容完整，中英文摘要與科技論文必須做到準(zhǔn)確無(wú)誤。對(duì)主要傳動(dòng)方案進(jìn)行比較和選擇、并可行性論證。對(duì)主要的零部件進(jìn)行動(dòng)力的計(jì)算，強(qiáng)度、剛度的校核；對(duì)電氣原理圖設(shè)計(jì)的說(shuō)明。
畢業(yè)設(shè)計(jì)說(shuō)明書(shū)參考文獻(xiàn)15篇以上，原則上所涉及的參考文獻(xiàn)論文資料為近5年出版發(fā)表。
學(xué)生應(yīng)交出的設(shè)計(jì)文件（論文）設(shè)計(jì)成果要求：提交紙質(zhì)資料（打印和部分手工繪制圖紙）和電子文檔資料。圖紙使用AutoCAD軟件繪制，文件為*.dwg格式。設(shè)計(jì)說(shuō)明書(shū)資料為*.doc格式。
1、畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告。
2、畢業(yè)設(shè)計(jì)說(shuō)明書(shū)1份，字?jǐn)?shù)2-2.5萬(wàn)字。按《山西能源學(xué)院本科畢業(yè)設(shè)計(jì)（論文）撰寫規(guī)范》執(zhí)行。
3、圖紙：
(1)?鏈?zhǔn)降稁?kù)裝配圖（A0）1張；
(2)?刀庫(kù)關(guān)鍵零件圖（圖紙大小根據(jù)零件尺寸和復(fù)雜程度定）3-5張；
(3)?控制系統(tǒng)電氣原理圖（A1號(hào)）1張；
4、文獻(xiàn)綜述與外文翻譯：按《山西能源學(xué)院本科畢業(yè)設(shè)計(jì)（論文）撰寫規(guī)范》執(zhí)行。
(1)?文獻(xiàn)綜述：字?jǐn)?shù)不少于3000字；
(2)?外文翻譯：外文翻譯必須與畢業(yè)設(shè)計(jì)課題相關(guān)，字?jǐn)?shù)不少于5000字，并標(biāo)明文章出處。
主要參考文獻(xiàn)（資料）: 1] 廉元國(guó)等編．加工中心設(shè)計(jì)與應(yīng)用[M]. 北京：機(jī)械工業(yè)出版社，1995
[2] 黃鶴汀主編．機(jī)械制造裝陪備[M]. 北京：機(jī)械工業(yè)出版社，2017
[3] 杜國(guó)臣主編．機(jī)床數(shù)控技術(shù)[M]. 北京：機(jī)械工業(yè)出版社，2016
[4] 劉偉主編．?dāng)?shù)控技術(shù)[M]. 北京：機(jī)械工業(yè)出版社，2019
[5] 機(jī)械設(shè)計(jì)手冊(cè)[M]. 北京：化學(xué)工業(yè)出版社，2010
[6] 成大先主編．機(jī)械設(shè)計(jì)手冊(cè)（第4卷）．第四版[M].北京：化學(xué)工業(yè)出版社．2002
[7] 車洪麟、張素輝．非標(biāo)準(zhǔn)機(jī)械設(shè)計(jì)（第一版）[M].北京：機(jī)械工業(yè)出版社，2011；
[8] 葉玉駒、焦永和、張彤．機(jī)械制圖手冊(cè)（第5版）[M]. 北京：機(jī)械工業(yè)出版社，2019；
[9] 屈波．互換性與技術(shù)測(cè)量[M]. 北京：機(jī)械工業(yè)出版社，2014；
[10] 孫桓、陳作模，機(jī)械原理（第七版）[M].北京：高等教育出版社，2005；
[11] 濮良貴、紀(jì)名剛．機(jī)械設(shè)計(jì)（第八版）[M].北京：高等教育出版社，2005；
[12] 于永泗、齊民．機(jī)械工程材料（第七版）[M].大連：大連理工大學(xué)出版社，2007；
[13] 黃鶴汀主編.金屬切削機(jī)床設(shè)計(jì). 北京：機(jī)械工業(yè)出版社，2015；
[14] 成大先，機(jī)械設(shè)計(jì)手冊(cè)，單行本[M].北京：化學(xué)工業(yè)出版社，2004；
[15] 劉宏新主編；機(jī)電一體化技術(shù). 北京：機(jī)械工業(yè)出版社，2019；
畢業(yè)設(shè)計(jì)（論文）題目：加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)畢業(yè)設(shè)計(jì)（論文）要求及原始數(shù)據(jù)（資料）：
1、原始數(shù)據(jù)（資料）：
在加工中心中，刀庫(kù)和換刀機(jī)械手組成自動(dòng)換刀裝置（ATC）,它是加工中心的關(guān)鍵部件之一， 自動(dòng)換刀裝置的好壞將直接影響到加工中心的好壞。
本設(shè)計(jì)為加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)技術(shù)參數(shù)：
1、刀座數(shù)：40
2、選刀時(shí)間：3S
3、刀套線速度：25m/min
4、刀柄號(hào)：BT50
5、刀具最大重量 25kg
2、畢業(yè)設(shè)計(jì)（論文）要求：
（1）、任務(wù)要求
根據(jù)畢業(yè)設(shè)計(jì)任務(wù)書(shū)技術(shù)要求，擬定鏈?zhǔn)降稁?kù)機(jī)械傳動(dòng)方案，完成機(jī)械關(guān)鍵零部件設(shè)計(jì)與計(jì)算、繪制裝配圖、和部分零件圖；完成刀庫(kù)控制系統(tǒng)設(shè)計(jì)，繪制控制系統(tǒng)原理圖。 同時(shí)根據(jù)機(jī)械部分設(shè)計(jì)計(jì)算，電機(jī)及關(guān)鍵零部件選型計(jì)算， 控制系統(tǒng)設(shè)計(jì)等完成畢業(yè)設(shè)計(jì)設(shè)計(jì)說(shuō)明書(shū)。主要任務(wù)如下：
①畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告；
②文獻(xiàn)綜述和外文翻譯；
③ 加工中心鏈?zhǔn)降稁?kù)及控制系統(tǒng)設(shè)計(jì)裝配圖，部分關(guān)鍵零件圖，刀庫(kù)控制系統(tǒng)電氣原理圖；
④畢業(yè)設(shè)計(jì)說(shuō)明書(shū)。
（2）、時(shí)間進(jìn)度要求
序號(hào)
時(shí)間
周次
設(shè)計(jì)工作及要求
1
2021.3.22-2021.3.28
第 1 周
選擇畢業(yè)設(shè)計(jì)題目,領(lǐng)取任務(wù)書(shū)
2
2021.3.29-2021.4.4
第 2 周
查閱文獻(xiàn)資料，完成文獻(xiàn)綜述和外文
3
2021.4.5-2021.4.11
第 3 周
撰寫開(kāi)題報(bào)告及答辯
4
2021.4.12-2021.5.9
第 4-7 周
方案設(shè)計(jì)、計(jì)算及圖紙繪制
5
2021.5.10-2021.5.16
第 8 周
畢業(yè)設(shè)計(jì)中期檢查
6
2021.5.17-2021.5.30
第 9-10 周
圖紙進(jìn)一步繪制、論文編寫
7
2021.5.31-2021.6.6
第 11 周
論文查重、修改
8
2021.6.7-2021.6.13
第 12 周
打印裝訂、指導(dǎo)老師與評(píng)閱老師評(píng)閱
畢業(yè)設(shè)計(jì)（論文）主要內(nèi)容：
1、設(shè)計(jì)圖樣要求：
設(shè)計(jì)原理正確，運(yùn)用相關(guān)標(biāo)準(zhǔn)、查閱相關(guān)手冊(cè)，正確處理好圖、數(shù)字、符號(hào)、標(biāo)準(zhǔn)等的關(guān)系，圖樣完整準(zhǔn)確。總體設(shè)計(jì)完整、圖紙表達(dá)清晰、標(biāo)注采用國(guó)家最新標(biāo)準(zhǔn)；完成整機(jī)裝配圖紙?jiān)O(shè)計(jì)，保證結(jié)構(gòu)方案確定最優(yōu)化；完成部件圖設(shè)計(jì)及傳動(dòng)系統(tǒng)設(shè)計(jì)；完成零件圖設(shè)計(jì)，完成控制系統(tǒng)電氣原理圖設(shè)計(jì)。
2、畢業(yè)設(shè)計(jì)說(shuō)明書(shū)：
設(shè)計(jì)依據(jù)可靠，參數(shù)選用合理，結(jié)構(gòu)設(shè)計(jì)強(qiáng)度及剛度校核、計(jì)算準(zhǔn)確，內(nèi)容完整，中英文摘要與科技論文必須做到準(zhǔn)確無(wú)誤。對(duì)主要傳動(dòng)方案進(jìn)行比較和選擇、并可行性論證。對(duì)主要的零部件進(jìn)行動(dòng)力的計(jì)算，強(qiáng)度、剛度的校核；對(duì)電氣原理圖設(shè)計(jì)的說(shuō)明。
畢業(yè)設(shè)計(jì)說(shuō)明書(shū)參考文獻(xiàn) 15 篇以上，原則上所涉及的參考文獻(xiàn)論文資料為
近 5 年出版發(fā)表。
學(xué)生應(yīng)交出的設(shè)計(jì)文件（論文）：
設(shè)計(jì)成果要求：提交紙質(zhì)資料（打印和部分手工繪制圖紙）和電子文檔資料。圖紙使用 AutoCAD 軟件繪制，文件為*.dwg 格式。設(shè)計(jì)說(shuō)明書(shū)資料為*.doc 格式。
1、畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告。
2、畢業(yè)設(shè)計(jì)說(shuō)明書(shū) 1 份，字?jǐn)?shù) 2-2.5 萬(wàn)字。按《山西能源學(xué)院本科畢業(yè)設(shè)計(jì)（論文）撰寫規(guī)范》執(zhí)行。
3、圖紙：
(1) 鏈?zhǔn)降稁?kù)裝配圖（A0）1 張；
(2) 刀庫(kù)關(guān)鍵零件圖（圖紙大小根據(jù)零件尺寸和復(fù)雜程度定）3-5 張；
(3) 控制系統(tǒng)電氣原理圖（A1 號(hào)）1 張；
4、文獻(xiàn)綜述與外文翻譯：按《山西能源學(xué)院本科畢業(yè)設(shè)計(jì)（論文）撰寫規(guī)范》執(zhí)行。
(1) 文獻(xiàn)綜述：字?jǐn)?shù)不少于 3000 字；
(2) 外文翻譯：外文翻譯必須與畢業(yè)設(shè)計(jì)課題相關(guān)，字?jǐn)?shù)不少于 5000 字， 并標(biāo)明文章出處。
主要參考文獻(xiàn)（資料）：
[1] 廉元國(guó)等編．加工中心設(shè)計(jì)與應(yīng)用[M]. 北京：機(jī)械工業(yè)出版社，1995
[2] 黃鶴汀主編．機(jī)械制造裝陪備[M]. 北京：機(jī)械工業(yè)出版社，2017
[3] 杜國(guó)臣主編．機(jī)床數(shù)控技術(shù)[M]. 北京：機(jī)械工業(yè)出版社，2016
[4] 劉偉主編．?dāng)?shù)控技術(shù)[M]. 北京：機(jī)械工業(yè)出版社，2019
[5] 機(jī)械設(shè)計(jì)手冊(cè)[M]. 北京：化學(xué)工業(yè)出版社，2010
[6] 成大先主編．機(jī)械設(shè)計(jì)手冊(cè)（第 4 卷）．第四版[M].北京：化學(xué)工業(yè)出版社．2002
[7] 車洪麟、張素輝．非標(biāo)準(zhǔn)機(jī)械設(shè)計(jì)（第一版）[M].北京：機(jī)械工業(yè)出版社，2011；
[8] 葉玉駒、焦永和、張彤．機(jī)械制圖手冊(cè)（第 5 版）[M]. 北京：機(jī)械工業(yè)出版社，2019；
[9] 屈波．互換性與技術(shù)測(cè)量[M]. 北京：機(jī)械工業(yè)出版社，2014；
[10] 孫桓、陳作模，機(jī)械原理（第七版）[M].北京：高等教育出版社，2005；
[11] 濮良貴、紀(jì)名剛．機(jī)械設(shè)計(jì)（第八版）[M].北京：高等教育出版社， 2005；
[12] 于永泗、齊民．機(jī)械工程材料（第七版）[M].大連：大連理工大學(xué)出版社，2007；
[13] 黃鶴汀主編.金屬切削機(jī)床設(shè)計(jì). 北京：機(jī)械工業(yè)出版社，2015；
[14] 成大先，機(jī)械設(shè)計(jì)手冊(cè)，單行本[M].北京：化學(xué)工業(yè)出版社，2004；
[15] 劉宏新主編；機(jī)電一體化技術(shù). 北京：機(jī)械工業(yè)出版社，2019； ；
指 導(dǎo) 教 師 簽 字 日期
教研室主任審查簽字 日期
系主任批準(zhǔn)簽字 日期
Applied Mechanics and Materials Vols 271-272 (2013) pp 461-465 Online: 2012-12-27
? (2013) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMM.271-272.461
Reliability Evaluation of Chain-type Tool Magazine and ATC
Xiaohong Lua, Pengzhuo Hanb,Wenyi Wuc
Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian 116024, China.
a lxhdlut@dlut.edu.cn, b hanpengzhuo@mail.dlut.edu.cn, c wuwenyiwwy@mail.dlut.edu.cn
Keywords: Chain-type tool magazine, ATC, Reliability, Mean tool change numbers between failures, Mean time to repair
Abstract. As the tool magazine and automatic tool changer (ATC) are the important function units to reserve and change tools for the machining center, the tool-changing rate affects their reliability life which directly influences the performance level of the machining center. However, the reliability of the tool magazine and ATC has not yet got a reasonable evaluation index. Directing at the features of the tool magazine and ATC system, the mean tool change numbers between failures evaluation index is proposed, which is used to calculate the mean time to repair and estimate the collected failure data of the chain-type tool magazine and ATC. It can be seen that the tool magazine with continuous tool-changing adopts the mean tool change numbers between failures as the reliability evaluation index.
Introduction
Reliability evaluation is the one of the most important section of the reliability study on CNC machine tool. The purpose of it is to master the status of the tool, put forward the goals and tasks of the reliability design work and make a direction to the further studies on reliability. In studies of CNC machine tool reliability evaluation, Huazhong University of Science and Technology[1,2] and Tianjin Vocational and Technical Normal University proposed a reliability assessment based on performance degradation data. Shanghai Jiaotong University[3,4] research the reliability evaluation about the time-terminated test on a variety of CNC machine tool in use of Weibull mixture model and then put forward some model of time-terminated test on CNC machine tool as well as parameter estimation of time between failures' methods. Jilin University and Dalian University of Technology[5,6] took the fuzzy theory into the research on reliability of CNC machine tool and came up with a comprehensive fuzzy reliability allocation method oh CNC machine tool. Wang Guiping[7] studied the machining center failure analysis methods which are faced on reliability and green, evaluation methods and growth strategy.
As the tool magazine and automatic tool changer (ATC) are the important function units to reserve and exchange tools for the machining center, their tool-changing rate affect their reliability life which directly influences the performance level of the machining center. However, the reliability has not yet get a reasonable evaluation index. The tool-changing rate of the tool magazine and ATC affects their reliability life greatly. To the same product, its lifetime difference is great between in one processing with changing tools frequently and in another with changing tools seldom. It can’t evaluate the property of the tool magazine and ATC product only by adopting MTBF (Mean Time between Failures) as the reliability evaluation index. Therefore, based on the science and technology major projects “The Development Study of the Large Chain-type Tool Magazine, the High-speed Disk-type Tool Magazine and the Automatic Tool Changer” in the
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462 Frontiers of Manufacturing and Design Science III
national “High-grade NC machine tools and basic manufacturing equipment”, this paper summarizes and analyses the study of reliability evaluation to the domestic and overseas CNC and their key function units. Through the laboratory accelerated test on the large-scale chain-type tool magazine and ATC, the tool-changing times is recorded, and their reliability is evaluated based on the MTCNBF (mean tool change numbers between failures) and MTTR (Mean Time to Repair). This paper explored the reliability evaluation methods on the large-scale chain-type tool magazine and ATC, expecting to provide reference for the development of the CNC and their function units’ reliability level.
Reliability Evaluation of Chain-Type Tool Magazine and Automatic Tool Changer
Chain-type tool magazine and ATC system includes tool magazine, ATC, CNC system and simulation spindle, shown as Fig.1. The operation of tool magazine is realized by servomotor, planetary reduction gear drives chain wheel and chain to choose the tool. In the ATC of tool magazine, the exchange of the tool and the switch motion of protective door is achieved through the chain drives roller type of rotor cambered surface multiple mounted cam. The power producer of chain driving comes from gear motor, transducer controls the rate of manipulator tool changing, and time of tool changing can be adjusted. In the reliability test of tool magazine system, the tool changing time of tool- to-tool is 3.0 seconds. The process of tool changing includes choosing the tool, tool cylinder sends separating cover and tool to the location of tool changing. The technical parameters of the studied chain-type tool magazine and ATC system are in Table.1.
Fig. 1 The chain-type tool magazine and ATC for testing
Table 1 The technical parameters of the studied chain-type tool magazine system
Item The technical parameters Tool warehouse capacity 40/60[T]
Largest cutter length 500[mm]
Maximum tool weight 25[kg] Tool- to-tool changing time 3.0[s]
The largest knife storage capacity 600/900[kg]
Applied Mechanics and Materials Vols. 271-272 463
The failure data of Table 2 comes from the accelerate reliability test of MDH-80 Chain-type tool magazine system in Dalian Golden CNC Group CORP... According to the sampling principle, 3 chain-type tool magazine and ATC system is chosen to perform the accelerate reliability test, the testing time of each chain-type tool magazine and ATC is 30 days, and 8 hours per day, in total, the circle of tool changing is 60 circles, changing tool 80 times per circle. So the tool changing times is 4800 in one day, equally, tool changing 10 times per minute. 14 failure data have been gotten.
Description of the failure Number Failure start
Failure end
Failure
Failure
Failure repair
date
date
start time
end time
time[min]
The tool magazine stalls 1
2011.12.05
2011.12.05
14:35
14:40
5
The abnormal noise appears in 1
2011.12.14
2011.12.14
7:40
9:20
100
The tool falls in ATC 1
2011.12.18
2011.12.18
8:10
8:30
20
Tool magazine stuck 1
2011.12.23
2011.12.23
9:45
12:10
145
Splined shaft and bushing wear 1
2011.12.28
2011.12.28
9:30
12:00
150
Tool magazine stop turning 2
2012.02.04
2012.02.04
10:00
10:05
5
Grasping tool is not in place 2
2012.02.10
2012.02.10
13:20
13:35
15
Inserting tool is not in place 2
2012.02.20
2012.02.20
15:55
16:15
20
Pocket impact is too large 2
2012.02.27
2012.02.27
14:50
18:40
230
Inserting the tool is not in place 3
2012.03.08
2012.03.08
13:05
13:30
25
Pocket is stuck 3
2012.03.19
2012.03.19
9:30
12:00
150
The tool falls in ATC 3
2012.03.21
2012.03.21
15:30
15:35
5
Splined shaft and bushing wear 3
2012.03.26
2012.03.26
10:40
12:50
130
The abnormal noise appears in 3
2012.03.30
2012.03.30
9:00
10:30
90
Table 2 The failure data of MDH-80 chain-type tool magazine system
ATC
and tear
and tear ATC
Mean Tool Change Numbers between Failures
MTCNBF (Mean Tool Change Numbers between Failures) is proposed as a reliability evaluation index of the tool magazine and automatic tool changer, which indicates the average number of tool change between the adjacent two failures. It calculates as follows:
MTCNBF = k
n
?S j j =1
n
?rj
j =1
(1)
n:number of samples, Sj: the cumulative tool change number of the j set sample in an assessment cycle, rj: the cumulative fault number of the j set sample in an assessment cycle, k: Correction factor and its value is as follows in Table.3
Cumulative times of tool change for each chain-type tool magazine and ATC can be drawn from the processed and calculated failure data in Table 2.
464 Frontiers of Manufacturing and Design Science III
Table 3 The correction factor of MTCNBF
Cumulative times of tool changes of the first chain-type tool magazine and ATC:
Serial Number
Maximum Weight of tool [Kg]
Tool Magazine Capacity [T]
Tool Change Time [s]
k
1
≤20
≤60
≥3
1.1
2
≤20
≤60
<3
1.0
3
≤20
>60
≥3
1.0
4
≤20
>60
<3
0.9
5
>20
≤60
≥3
1.0
6
>20
≤60
<3
0.9
7
>20
>60
≥3
0.9
8
>20
>60 <3 0.8
S = 30 ′ 4800 - (5 + 100 + 20 + 145 + 150（′10 = 139800
（
1
S = 30 ′ 4800 - (5 + 15 + 20 + 230)
)
（
Cumulative times of tool changes of the second chain-type tool magazine and ATC:
′10 = 141300
2
S = 30′ 4800 - (25 +150 + 5 +130 + 90
Cumulative times of tool changes of the third chain-type tool magazine and ATC:
3 ) ′10 = 140000
According to the data in Table 2, a total of 14 failures in 3 chain-type tool magazines, the sample number is 3, the correction factor is 1.0. S1=139800, S2=141300, S3=140000, bringing them into Eq. 1:
MTCNBF =
1 3 S
?
j
14 j=1
= 1 (139800 + 141300 + 140000) = 30078
14
Take 9 sets chain-type tool magazine and ATC developed by Dalian Golden CNC Group Corp. for example, the average tool change times of the studied chain-type tool magazine and ATC is about 30000 applied on horizontal machining center. It will last one more year to obtain the MTCNBR, if the user evaluates the reliability in the course of machining. However, by exposing the weak spots of the chain-type tool magazine and ATC based on reliability tests, it will only last one month. Consequently this characteristic provides timely reference for the design of reliability growth of chain-type tool magazine and ATC.
Mean Time To Repair
Traditional MTTR (Mean Time To Repair) indicates the average time interval from the beginning of failure to maintenance end. It calculates as follows.
MTTR = 1
N
n
?Ti =
n
?Ti
i =1
n
(2)
0 i =1
?ri
i =1
N0: Cumulative fault frequency of system in an assessment cycle, n: Sample number of system, Ti: Corrective maintenance time of the i system in an assessment cycle, ri: fault frequency of the i system in an assessment cycle.
According to the data in Table 2, the cumulative corrective maintenance time for each chain-type tool magazine and ATC can be calculated: T1= 7 [h], T2= 4.5 [h], T3= 6.7 [h]. There are 14 failures in 3 chain-type tool magazines. Bringing them into Eq. 2, the MTTR is 1.30 [h]. It can be concluded that the MTTR is about 1.3 [h] of the studied chain-type tool magazine and ATC.
Applied Mechanics and Materials Vols. 271-272 465
Summary
Directing at the features of the chain-type tool magazine and ATC system, the mean tool change numbers between failures evaluation index is proposed. It is adopted to evaluate the failure data received by experimenting on type MDH-80 chain-type tool magazine and ATC whose MTTR are calculated. It can be seen that the mean tool change numbers between failures is a reasonable evaluation index to describe the reliability of the tool magazine and ATC. The failure data of the tool magazine without tool-changing times should be evaluated by the traditional method. While in the experiment on continuous tool-changing or in the circumstance that the tool magazine has a counter, the reliability can be evaluated based on the mean tool change numbers between failures.
Acknowledgments
The research is supported by the high-grade CNC machine tool and the basic equipment manufacturing industry major science and technology project (No. 2011ZX04011-022) and Dalian science and technology project (No. 2010A16GX091).
References
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[2] Bin Li, Hailong Lu, Methods of Reliability Estimation for Numerical Control Machine Tool Based on Performance Parameters [J]. 2011 2nd International Conference on Mechanic Automation and Control Engineering, MACE 2011-Proceedings, p 4144-4147, 2011.
[3] Wang Zhiming, Yang Jianguo, Reliability assessment of numerical control machine tools using Weibull mixture models [J]. Advanced Materials Research, v 181-182, p 161-165, 2011, Advanced Materials Science and Technology.
[4] Wang Zhiming, Yang Jianguo, Wang Guoqiang, Zhang Genbao, Reliability evaluation of multiple NC machine tools with time truncation [J]. Harbin Gongye Daxue Xuebao/ Journal of Harbin Institute of Technology, v 43, n 3, p 85-89, March 2011.
[5] Yang Zhaojun, Hao Qingbo, Chen Fei, Xu Binbin, Li Xiaobing, Zhao Hongwei, A comprehensive fuzzy reliability allocation method of NC machine tools based on interval analysis [J]. Beijing Gongye Daxue Xuebao/ Journal of Beijing University of Technology, v 37, n 3, p 321-329, March 2011.
[6] Yang Zhaojun, Zhu Xiaocui, Jia Yazhou, Wang Liding, Xu Binbin, Li Xiaobing, Lu Jianwei, Fuzzy-comprehensive evaluation of use reliability of CNC machine tools [J]. Key Engineering Materials, v 464, p 374-378, 2011.
[7] Wang Guiping. Study on Evaluation System and Increasing Technology of Reliability and Green in CNC Machining Center[D]. Changchun: Jilin University, 2008.in Chinese.
Frontiers of Manufacturing and Design Science III
10.4028/www.scientific.net/AMM.271-272
Reliability Evaluation of Chain-Type Tool Magazine and ATC
10.4028/www.scientific.net/AMM.271-272.461
鏈?zhǔn)降稁?kù)和ATC的可靠性評(píng)估盧曉紅a，彭卓漢b，吳文義c
教育部精密非傳統(tǒng)加工技術(shù)重點(diǎn)實(shí)驗(yàn)室，大連理工大學(xué)，大連116024。
關(guān)鍵詞：鏈?zhǔn)降稁?kù)，ATC，可靠性，故障間平均刀具變化數(shù)，平均修復(fù)時(shí)間
摘要
由于刀庫(kù)和自動(dòng)換刀器(ATC)是為加工中心儲(chǔ)備和更換刀具的重要功能單元， 換刀率影響其可靠性壽命，直接影響加工中心的性能水平。 然而，刀庫(kù)和ATC 的可靠性還沒(méi)有得到合理的評(píng)價(jià)指標(biāo)。 針對(duì)刀庫(kù)和ATC系統(tǒng)的特點(diǎn)，提出了故障評(píng)價(jià)指標(biāo)之間的平均工具變化數(shù)，用于計(jì)算鏈?zhǔn)降稁?kù)和ATC收集的故障數(shù)據(jù)的平均修復(fù)和估計(jì)時(shí)間。 可以看出，具有連續(xù)換刀的刀具雜志采用故障間的平均刀具變化數(shù)作為可靠性評(píng)價(jià)指標(biāo)。
導(dǎo)言
可靠性評(píng)價(jià)是數(shù)控機(jī)床可靠性研究的重要內(nèi)容之一。 目的是掌握該工具的現(xiàn)狀，提出可靠性設(shè)計(jì)工作的目標(biāo)和任務(wù)，為可靠性的進(jìn)一步研究指明方向。 在數(shù)控機(jī)床可靠性評(píng)估研究中，華中科技大學(xué)[1,2]和天津職業(yè)技術(shù)師范大學(xué)提出了基于性能退化數(shù)據(jù)的可靠性評(píng)估。上海交通大學(xué)[3,4]利用威布爾混合模型對(duì)多種數(shù)控機(jī)床進(jìn)行時(shí)間終止試驗(yàn)的可靠性評(píng)價(jià)進(jìn)行了研究，并提出了數(shù)控機(jī)床時(shí)間終止試驗(yàn)的一些模型以及故障間時(shí)間的參數(shù)估計(jì)方法。 吉林大學(xué)和大連理工大學(xué)[5,6]將模糊理論引入到數(shù)控機(jī)床可靠性研究中，提出了一種綜合模糊可靠性分配方法。 王貴平[7]研究了加工中心失效分析方法的可靠性和綠色化、評(píng)價(jià)方法和增長(zhǎng)策略。
由于刀庫(kù)和自動(dòng)換刀器(ATC)是加工中心儲(chǔ)備和交換刀具的重要功能單元，其換刀率影響其可靠性壽命，直接影響加工中心的性能水平。 但可靠性尚未得到合理的評(píng)價(jià)指標(biāo)。 刀具雜志和ATC的換刀率對(duì)其可靠性壽命有很大影響。 對(duì)于同一種產(chǎn)品，它的壽命差異很大，在一個(gè)經(jīng)常更換工具的加工過(guò)程中，在另一個(gè)很少更換工具的加工過(guò)程中。 采用MTBF（平均故障時(shí)間）作為可靠性評(píng)價(jià)指標(biāo)， 不能對(duì)刀庫(kù)和ATC產(chǎn)品的性能進(jìn)行評(píng)價(jià)。 因此，基于科技重大項(xiàng)目“大鏈?zhǔn)降毒唠s志、高速盤式刀具雜志和自動(dòng)換刀器的發(fā)展研究”在本文對(duì)國(guó)內(nèi)外數(shù)控及其關(guān)鍵功能單元的可靠性評(píng)價(jià)研究進(jìn)行了總結(jié)和分析。 通過(guò)對(duì)大型鏈型刀庫(kù)和ATC 的實(shí)驗(yàn)室加速試驗(yàn)，記錄了換刀時(shí)間，并根據(jù)MTCNBF（故障間的平均刀具變化數(shù)） 和MTTR（平均修復(fù)時(shí)間)對(duì)其可靠性進(jìn)行了評(píng)價(jià)）。 本文探討了大型鏈?zhǔn)降毒唠s志和ATC的可靠性評(píng)價(jià)方法，以期為數(shù)控系統(tǒng)及其功能單元的可靠性水平的發(fā)展
提供參考。
鏈型刀庫(kù)和自動(dòng)換刀器的可靠性評(píng)估
鏈?zhǔn)降稁?kù)和ATC系統(tǒng)包括刀庫(kù)、ATC、數(shù)控系統(tǒng)和仿真主軸，如圖所示。 1. 通過(guò)伺服電機(jī)，行星減速齒輪帶動(dòng)鏈輪和鏈條來(lái)選擇刀具來(lái)實(shí)現(xiàn)刀庫(kù)的操作。 在刀庫(kù)的ATC中，通過(guò)轉(zhuǎn)子形成面多安裝凸輪的鏈條驅(qū)動(dòng)滾子式實(shí)現(xiàn)刀具的交換和保護(hù)門的開(kāi)關(guān)運(yùn)動(dòng)。 鏈條傳動(dòng)的動(dòng)力源來(lái)自齒輪電機(jī)，換能器控制機(jī)械手換刀速度，換刀時(shí)間可調(diào)節(jié)。 在刀庫(kù)系統(tǒng)可靠性測(cè)試中，刀庫(kù)換刀時(shí)間為3.0秒。 換刀過(guò)程包括選擇刀具，刀缸將分離蓋和刀具送至換刀位置。 所研究的鏈型刀庫(kù)和ATC系統(tǒng)的技術(shù)參數(shù)見(jiàn)表 1.
圖1 鏈?zhǔn)降稁?kù)和ATC進(jìn)行測(cè)試
表1所研究的鏈?zhǔn)降稁?kù)系統(tǒng)的技術(shù)參數(shù)
表2故障數(shù)據(jù)來(lái)自大連金數(shù)控集團(tuán)公司MDH-80鏈型刀庫(kù)系統(tǒng)加速可靠性試驗(yàn)... 根據(jù)采樣原理，選擇3個(gè)鏈型刀庫(kù)和ATC系統(tǒng)進(jìn)行加速可靠性測(cè)試，每個(gè)鏈型刀庫(kù)和ATC的測(cè)試時(shí)間為30天，每天8小時(shí)，總共換刀圈為60圈，換刀80次/圈。因此，一天內(nèi)工具更換次數(shù)為4800次，平均每分鐘更換工具10次。 已獲得14個(gè)故障數(shù)據(jù)
表2 MDH-80鏈?zhǔn)降稁?kù)系統(tǒng)的故障數(shù)據(jù)
Description of the failure
Number
Failure start
date
Failure end date
Failure start time
Failure end time
Failure repair time[min]
The tool magazine stalls
1
2011.12.05
2011.12.05
14:35
14:40
5
The abnormal noise appears in
1
2011.12.14
2011.12.14
7:40
9:20
100
The tool falls in ATC
1
2011.12.18
2011.12.18
8:10
8:30
20
Tool magazine stuck
1
2011.12.23
2011.12.23
9:45
12:10
145
Splined shaft and bushing wear
1
2011.12.28
2011.12.28
9:30
12:00
150
Tool magazine stop turning
2
2012.02.04
2012.02.04
10:00
10:05
5
Grasping tool is not in place
2
2012.02.10
2012.02.10
13:20
13:35
15
Inserting tool is not in place
2
2012.02.20
2012.02.20
15:55
16:15
20
Pocket impact is too large
2
2012.02.27
2012.02.27
14:50
18:40
230
Inserting the tool is not in place
3
2012.03.08
2012.03.08
13:05
13:30
25
Pocket is stuck
3
2012.03.19
2012.03.19
9:30
12:00
150
The tool falls in ATC
3
2012.03.21
2012.03.21
15:30
15:35
5
Splined shaft and bushing wear 3
2012.03.26
2012.03.26
10:40
12:50
130
The abnormal noise appears in 3
2012.03.30
2012.03.30
9:00
10:30
90
平均工具改變數(shù)字之間的失敗
提出了一種刀庫(kù)和自動(dòng)換刀器的可靠性評(píng)價(jià)指標(biāo)MTCNBF（故障間平均刀具變化數(shù)），它表示相鄰兩次故障之間刀具變化的平均次數(shù)。 計(jì)算如下：
n：樣本數(shù)，Sj評(píng)估周期中j集樣本的累積工具變化數(shù)rj評(píng)估周期中j集樣本的累積故障數(shù)k：校正因子及其值如表3所示。
每個(gè)鏈型刀庫(kù)和ATC的刀具變化累積時(shí)間可以從表2中處理和計(jì)算的故障數(shù)據(jù)中提取。
表3 MTCNBF的校正因子
Serial Number
Maximum Weight of tool [Kg]
Tool Magazine Capacity [T]
Tool Change Time [s]
k
1
≤20
≤60
≥3
1.1
2
≤20
≤60
<3
1.0
3
≤20
>60
≥3
1.0
4
≤20
>60
<3
0.9
5
>20
≤60
≥3
1.0
6
>20
≤60
<3
0.9
7
>20
>60
≥3
0.9
8
>20
>60
<3
0.8
第一鏈型刀庫(kù)和ATC的刀具變化累積次數(shù)：
S,= 30×4800-(5+100+20+145+150)(×10=139800
第二鏈型刀庫(kù)和ATC的刀具變化累積次數(shù)：
S, =30×4800-(5+15 +20+230)(×10 =141300
第二鏈型刀庫(kù)和ATC的刀具變化累積次數(shù)：
S; = 30×4800-(25+150＋5+130＋90)(×10= 140000
根據(jù)表2中的數(shù)據(jù)，3個(gè)鏈?zhǔn)降稁?kù)共發(fā)生14次故障，樣本數(shù)為3，修正因子為1.0。
s1=1398002=1413003=140000，把他們帶到等式1
以大連金控集團(tuán)公司開(kāi)發(fā)的9套鏈型刀庫(kù)和ATC為例，研究的鏈型刀庫(kù)和ATC在水平加工中心上的平均換刀次數(shù)約為30000次。如果用戶在加工過(guò)程中對(duì)可靠性進(jìn)行評(píng)估，則獲得MTCNBR將再持續(xù)一年。 然而，通過(guò)基于可靠性測(cè)試的鏈?zhǔn)降稁?kù)和ATC的弱點(diǎn)暴露出來(lái)，它只會(huì)持續(xù)一個(gè)月。 因此，這一特點(diǎn)為鏈?zhǔn)降稁?kù)和ATC 的可靠性增長(zhǎng)設(shè)計(jì)提供了及時(shí)的參考。
同時(shí)修理
傳統(tǒng)的MTTR（平均維修時(shí)間）表示從故障開(kāi)始到維修結(jié)束的平均時(shí)間間隔。它計(jì)算如下。
n0評(píng)估周期內(nèi)系統(tǒng)的累積故障頻率，n：系統(tǒng)樣本數(shù)，Ti*i系統(tǒng)在評(píng)估周期內(nèi)的糾正維修時(shí)間，ri評(píng)估周期內(nèi)i系統(tǒng)的故障頻率。
根據(jù)表2中的數(shù)據(jù)，可以計(jì)算出每個(gè)鏈型刀庫(kù)和ATC的累計(jì)糾正維護(hù)時(shí)間：
T1=7[h]，T2=4.5[h]，T3=6.7[h]。 在3個(gè)鏈?zhǔn)降稁?kù)中有14個(gè)故障。 把他們帶到情商里。 2、MTTR為1.30[h]。 它可以得出結(jié)論，MTTR約為1.3[h]的研究鏈型刀庫(kù)和 ATC。
摘要
針對(duì)鏈?zhǔn)降稁?kù)和ATC系統(tǒng)的特點(diǎn)，提出了故障評(píng)價(jià)指標(biāo)間的平均刀具變化數(shù)。通過(guò)對(duì)MDH-80 型鏈型工具庫(kù)和ATC型工具庫(kù)的試驗(yàn)，對(duì)所接收的失效數(shù)據(jù)進(jìn)行了計(jì)算。 可以看出，故障間的平均刀具變化數(shù)是描述刀具雜志和ATC可靠性的合理評(píng)價(jià)指標(biāo)。 采用傳統(tǒng)方法對(duì)無(wú)換刀次數(shù)的刀庫(kù)失效數(shù)據(jù)進(jìn)行評(píng)價(jià)。 在連續(xù)換刀實(shí)驗(yàn)中，或在刀庫(kù)有計(jì)數(shù)器的情況下，可以根據(jù)故障間的平均換刀次數(shù)來(lái)評(píng)價(jià)可靠性。
致謝
本課題研究以高檔數(shù)控機(jī)床和基礎(chǔ)裝備制造業(yè)重大科技項(xiàng)目（No. 2011ZX04011-022)和大連科技項(xiàng)目(No. 2010A16GX091)為支撐。
參考文獻(xiàn)
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