616 螺旋壓力機設計【CAD圖+說明書+PPT+中英文翻譯】
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(本科畢業(yè)設計論文)
畢業(yè)設計（論文）外文資料翻譯
附件：1.外文原文2.外文資料翻譯譯文
2014年6月
電動螺旋壓力機的發(fā)展概況
1 概述
螺旋壓力機是一種歷史悠久的鍛壓設備，具有較人的能容量，結構簡單、調整和維護簡便、沒有固定的下死點，能保證模鍛件精度的穩(wěn)定性。廣泛應用于金屬模鍛、精壓、沖壓工藝以及耐火材料、陶瓷等非金屬材料的壓力加工。螺旋壓力機的設備投資、模具和鍛件成本比模鍛錘和熱模鍛壓力機便宜一半，加工余量小、鍛件精度高?，F(xiàn)代螺旋壓力機相繼采用了超載保護、力能顯示、能量預選及先進的計算機控制系統(tǒng)和自動送料、模具更換等輔助裝置。理論和實踐都證明螺旋壓力機工藝適應性廣、生產(chǎn)率適中、勞動條件好，己成為現(xiàn)代鍛壓生產(chǎn)優(yōu)選設備之一。國內外相關企業(yè)都十分重視螺旋壓力機的開發(fā)與應用。
青島青鍛鍛壓機械有限公司開發(fā)研制了80MN摩擦螺旋壓力機，經(jīng)查證為目前國內外最大規(guī)格的同類設備。由于摩擦壓力機傳動效率低、功率損耗較大和結構上的限制，規(guī)格發(fā)展受到了影響。隨著科學水平的不斷提高，螺旋壓力機的結構形式及傳動形式己經(jīng)有了很大的改進。除了機械式摩擦傳動以外，又采用了新的傳動形式，如離合器式螺旋壓力機、液壓螺旋壓力機和電動螺旋壓力機等。這不僅提高了螺旋壓力機的實用性、工作速度、生產(chǎn)率和可靠性，打擊力和能量也得到了很大的發(fā)展。如電動螺旋壓力機打擊力己達到320MN,能量達到5000kJ以上。電動螺旋壓力機自上世紀40年代研制成功以來，在國內外得到了廣泛響應。我國上世紀80年代由青島青鍛鍛壓機械有限公司與山東工業(yè)人學成功研制生產(chǎn)出了J58- 160型1.6MN電機直驅式電動螺旋壓力機，但因當時電力條件和控制技術的限制而中斷了進一步的研發(fā)工作，十分可惜。
近年來，隨著科技發(fā)展，變頻技術和電子數(shù)控技術的不斷提高，電動螺旋壓力機的開發(fā)創(chuàng)新、生產(chǎn)制造己全面展開，華中科技人學、青島青鍛鍛壓機械有限公司等，都相繼擁有了自己的技術和產(chǎn)品并迅速地推向市場。電動螺旋壓力機己成為目前最具生命力的螺旋壓力機產(chǎn)品。
2 電動螺旋壓力機的結構原理
2.1 電機直驅式電動螺旋壓力機
電機直驅式電動螺旋壓力機所用的電動機是特制的，其定子殼體坐在壓力機機架的頂端，轉子軸的上端由定子殼體支撐，下端緊固在壓力機飛輪上。飛輪與螺桿采用鍵連接由推力軸承支撐在機架上，飛輪具有超載保護裝置。制動器為抱閘形式，制動飛輪的外緣，通氣松開，斷氣制動。電機的熱量靠壓力機頂部的風扇排走。壓力機的機架結構采用預應力組合機架，由拉桿將上橫梁、立柱和底座預緊為一體，使其具有足夠的剛度。螺母裝在滑塊上，滑塊采用四股導軌與機架立柱上的導軌配合。壓力機可根據(jù)需要配置上下頂料裝置。
電機直驅式壓力機傳動鏈短，電機驅動飛輪旋轉沒有任何傳動損失。工作時，風扇轉動、制動器松開，同時主電機驅動壓力機飛輪使螺桿定軸旋轉，通過安裝在滑塊上的螺母將螺旋運動轉換為直線運動，使滑塊加速下行，主電機達到預先設置的打擊能量所要求的轉速時，利用飛輪儲存的能量做功，使坯件成形。飛輪能量釋放后，主電機反轉，滑塊上行，當滑塊到達設定的位置時電機自身制動，制動器只是在主電機斷電時抱住飛輪，制動力矩很小。
2.2 經(jīng)一級齒輪傳動的電動螺旋壓力機
電動壓力機的另一種形式是經(jīng)一級齒輪傳動，即電機軸上裝有一個小齒輪驅動大齒輪正反旋轉，大齒輪(即飛輪)與螺桿連接作定軸轉動，帶動裝在滑塊上的螺母使滑塊做上卜直線運動實現(xiàn)打擊。這種形式的壓力機可由多臺電機同時驅動大齒輪，因此可做到規(guī)格很大，目前世界最大噸位達320MN，遠遠大于其他模鍛設備的噸位，受到鍛造業(yè)的青睞。目前，這種壓力機采用的電機種類和控制尚不統(tǒng)一，應用比較多的是ABB變頻器控制三相異步交流電動機，運用直接轉矩控制。國內用電動機人致有三類:一類是變頻器控制交流異步電動機，另一類是變頻器控制交流伺服電動機，都是運用矢量控制技術，但兩種變頻器不一樣。
還有采用開關磁阻電動機的，但需匹配專用的控制器。上述變頻器控制交流伺服電動機成本偏高，在大噸位壓力機上極少使用。
3 電動螺旋壓力機的控制系統(tǒng)
電動螺旋壓力機的優(yōu)點是能量大小可調。飛輪角速度直接影響能量，因此，在打擊過程中，控制能量的大小也就是控制角速度的大小。青鍛公司采用日本安川變頻器控制特制交流異步電動機，運用矢量控制技術，電機采用編碼器反饋，速度控制精度提高，從而控制能量更加精確。矢量控制技術可在極短時間內讓電機達到額定轉矩，適應電動螺旋壓力機低速大扭矩的要求?？赏ㄟ^輸入010V的電壓信號或4mAmA的電流信號對應電動機速度，從而控制能量大小 。
(1)硬件設計
控制系統(tǒng)以可編程序控制器K7M- DR40U為核心，輔以數(shù)字量輸入/輸出、模擬量輸入/輸出擴展模塊，再加上外圍的控制電路和控制對象。CPU模塊通過通訊接口與觸摸屏進行通訊，觸摸屏負責數(shù)據(jù)的顯示和必要的參數(shù)設定;開關量輸入/輸出模塊主要負責一些開關信號的控制，模擬量輸入/輸出模塊主要負責打擊力的控制;模擬量模塊產(chǎn)生打擊力指令信號，打擊力通過觸摸屏顯示出來，變頻器采用矢量控制方式控制電機運轉，電動機通過傳動機構帶動壓力機滑塊實現(xiàn)上下往復運動。控制系統(tǒng)運行時，通過安裝在機身上的接近開關檢測滑塊的位置，并根據(jù)各接近開關信號發(fā)出一系列控制指令，滿足各種操作要求。
( 2)軟件結構
軟件系統(tǒng)在KGL -WC環(huán)境下采用梯形圖編寫。根據(jù)螺旋壓力機控制系統(tǒng)的要求，將主程序分化為多個子程序模塊，各模塊實現(xiàn)各個功能，以便識別和修改。控制程序對手動和運行分別進行控制。下行打擊時，變頻器正向運行觸點閉合，電動機以設定好的加速時間使其達到設置的速度，此時滑塊加速運行，達到打擊工件所需的能量(根據(jù)不同工件調節(jié)安裝在機身上接近開關的位置)，切斷變頻器正向運行觸點，滑塊自由下滑打擊工件，并在打擊完畢后接受同程接近開關發(fā)出的信號;如果下行打擊工件尚未達到所需能量，此時滑塊己到達下死點，為保護設備及變頻器必須斷開運行信號。程序接受到滑塊同程信號后，變頻器反向運行觸點閉合，電動機以設定好的速度加速反向運行，到達一定的位置斷開變頻器反向使能，剎車制動，一次打擊完成。
4 電動螺旋壓力機的特點
電機直接驅動形式的電動螺旋壓力機，不存在電機與飛輪傳動損失。除此之外，無論哪種驅動形式的電動螺旋壓力掃L都具有以下特點: ①結構簡單、緊湊，傳動鏈短，操作維修方便，檢修工作量小，節(jié)約工時和維修費用，運行安全;②打擊能量可精確控制，可根據(jù)鍛件成形工藝調整打擊力和打擊能量，鍛件成形精度高，模具應力小，模具使用壽命長;③采用先進的電動機驅動電氣控制技術，壓力機工作時，不會對電網(wǎng)產(chǎn)生沖擊和影響其他設備的正常運行;④滑塊靜止時，主電機不工作，電量消耗低，節(jié)約能源;⑤無固定下死點，不必調整模具高度，不會產(chǎn)生悶車現(xiàn)象;⑥可方便地調整行程高度，同程位置準確;⑦與液壓螺旋壓力機相比，不需復雜的液壓驅動設備，不存在液壓油泄漏污染環(huán)境和出現(xiàn)液壓故障問題;⑧與摩擦螺旋壓力機相比，無摩擦盤、橫軸等中間傳動裝置和摩擦帶易損件，零部件少，可靠性高，精度好。
5 結束語
電動螺旋壓力機作為一種高效、節(jié)能、環(huán)保的新型鍛壓設備，已在高精度發(fā)動機、汽輪機的葉片，齒輪等重要零件的毛壞鍛造和精密鍛造中得到廣泛應用。 現(xiàn)代螺旋壓力機相繼采用了超載保護、力能顯示、能量預選及先進的計算機控制系統(tǒng)和自動送料、模具更換等輔助裝置。理論和實踐都證明螺旋壓力機工藝適應性廣、生產(chǎn)率適中、勞動條件好，已成為現(xiàn)代鍛壓生產(chǎn)優(yōu)選設備之一。
隨著汽車、船舶、航空、航天等工業(yè)的發(fā)展，電動螺旋壓力機的應用領域還會不斷擴展。電動螺旋壓力機雖已發(fā)展到了一個良好的階段，但其理論系統(tǒng)尚未完善，控制技術也在不斷探索，相信在業(yè)內開發(fā)機構和生產(chǎn)企業(yè)的不斷創(chuàng)新努力下，電動螺旋壓力機的發(fā)展前景一定會更加光明。近年來，隨著科技發(fā)展，變頻技術和電子數(shù)控技術的不斷提高，電動螺旋壓力機的開發(fā)創(chuàng)新、生產(chǎn)制造已全面展開，華中科技人學、青島青鍛鍛壓機械有限公司等，都相繼擁有了白己的技術和產(chǎn)品并迅速地推向市場。電動螺旋壓力機已成為目前最具生命力的螺旋壓力機產(chǎn)品。 進一步提高螺旋壓力機的自動化程度，使打擊力、速度、位置等參數(shù)的控制更加準確、方便、將是螺旋壓力機今后繼續(xù)發(fā)展的方向。
The development of the electric screw press
1 Overview
Screw press is a kind of forging equipment with a long history, has the person's capacity, simple structure, easy adjustment and maintenance, have no fixed bottom dead center, can guarantee the stability of precision die forgings. Widely used in metal forging, precision pressure, stamping process and refractories, ceramics and other non-metallic materials of pressure processing. The screw press equipment investment, the mold and the forging costs half cheaper than die forging hammer and hot die forging press, small machining allowance, high precision forgings. Modern screw press that have adopted the overload protection, force can display, primary energy, and advanced computer control system and the replacement of the automatic feeding, die and other auxiliary equipment. The theory and practice prove that screw press technology of wide adaptability, productivity is moderate, good working conditions, has become one of the preferred equipment for the production of modern forging. Relevant enterprises at home and abroad have attached great importance to the development and application of screw press.
Qingdao green forging forging machinery co., LTD. 80 MN friction screw press is developed, the verification for the biggest specifications of similar equipment at home and abroad. Because of its high friction press transmission efficiency is low, the power loss and the limitation of the structure, specification development are affected. With the continuous improvement of scientific level, the structure of screw press and form has had the very big improvement. In addition to the mechanical friction drive, and adopted a new form of transmission, such as clutch screw press, hydraulic screw press, electric screw press and so on. This not only improves the practicability of screw press, the working speed, productivity, and reliability, it has received a lot of force and energy development. Such as electric screw press force of 320 mn, energy reaches more than 5000 kj. Successfully developed the electric screw press since the 1940 s, both at home and abroad has been widely response. In China in the 1980 s by Qingdao green forging forging machinery co., LTD and shandong industrial production out of the humanism developed J58-160 1.6 MN motor direct driving type electric screw press, but due to the limitation and control technology of power condition at that time and interrupt the further research and development work, great pity.
In recent years, with the development of science and technology, frequency conversion technology and electronic numerical control technology unceasing enhancement, the development innovation, production of electric screw press manufacture already in full swing, Huazhong science and technology study, Qingdao green forging forging machinery co., LTD., etc., have had their own technologies and products and to market quickly. Current of electric screw press has become the most vitality of the screw press product.
2 The structure and principles of the electric screw press
2.1 Motor direct driving type electric screw press
Motor direct drive motor used in the electric screw press is special, sitting in the stator shell press the top of the frame, with the top of the rotor shaft is supported by the stator shell, bottom fastening on the press flywheel. Flywheel and screw adopt the key connection is supported by thrust bearing on the rack, the flywheel has overload protection device. Form of brake for the brake, brake wheel rim, ventilation to loosen, barely able to brake. Motor heat with press at the top of the fan. Press the frame structure of prestressed composite frame, the rod will be preloaded beams, columns, and on the base as a whole, has the enough rigidity. Nut on the slider, the slider adopt four guide cooperate with the guide rail of the frame column. Press up and down according to need to configure the device.
Motor direct driving type press short transmission chain, motor drive the flywheel rotating no transmission losses. Work, fan rotation, brake loosen, at the same time, the main motor driven press flywheel rotating screw fixed axis, by installing the nut on the slider will spiral movement into linear motion, make the slider to accelerate downward, main motor reaches preset strike energy when the required speed, use energy from the flywheel storage work, make the forming ware. Flywheel energy release, the main motor reversal, slider uplink, when the slider to set the position of the motor brake itself, embrace a flywheel brake only when the main motor power, braking torque is small.
2.2 The primary gear drive electric screw press
Another form of electric screw press is the level of gear drive, the motor shaft is equipped with a big gear and small gear drive rotation, big gear (i.e., the flywheel) connected to the screw fixed axis rotation, drive mounted on the slider nut on the slider do linear motion realization hit. This type of press can be made of more than one motor driven wheel at the same time, so can do the specification is very big, is the world's largest tonnage of 320 mn, far more than other forging equipment tonnage, get the favour of the forging industry. At present, the press by the types of motor and control are not unified, the application is more ABB inverter control three phase asynchronous ac motor, using the direct torque control. Domestic motor to have three kinds: one kind is the inverter control of ac asynchronous motor, another kind is the inverter ac servo motor control, vector control technology is used, but is not the same as the two kind of frequency converter.
And in the case of switched reluctance motor, but need to match a dedicated controller. The inverter control, ac servo motor higher cost in large tonnage presses rarely used.
3 Electric screw press control system
The advantage of electric screw press is energy size is adjustable. Flywheel angular velocity affect energy directly, therefore, in the process of blow, the size of the control energy, that is, control the size of the angular velocity. Green forging company USES Japan AnChuan inverter control the special ac asynchronous motor, using the vector control technology, the motor with encoder feedback, speed control precision, thus more accurate control energy. Vector control technology can achieve in a very short time to let motor rated torque, adapt to the requirement of low speed high torque electric screw press. By 010 v input voltage signal or 4 mama current signal corresponding to the motor speed, to control the size of the energy.
(1) Hardware design
Control system with programmable controller K7M - DR40U as the core, supplemented by digital quantity input/output, analog input/output module, combined with peripheral control circuit and the control object. CPU module to communicate through communication interface and touch screen, touch screen is responsible for data display and the necessary parameters set; Switch input/output module is mainly responsible for some of the switch signal control, analog input/output module is mainly responsible for the control of the force; Force command signal analog module, force through the touch screen display, inverter adopts vector control method of controlling the motor running, the motor through a transmission mechanism drives the press ram to realize reciprocating movement up and down. Control system is running, by means of the proximity switch installed in the fuselage detect the position of the slider, and according to the proximity switch signal is a series of control instruction, meet the requirements of various operations.
(2) Software architecture
The software system in KGL - WC environment using ladder diagram. According to requirements of the control system of screw press, the differentiation is the main program subroutine modules, each module implements the function, in order to identify and modify. Control programs and operation control, respectively. Downward blow when the inverter is running contact closure, motor to set speed up time to set up, the slider acceleration run, reach the amount of energy needed to crack down on workpiece installation (according to the different artifacts on the fuselage close to the position of switch), cut off contact inverter is running, the slider free falling against the workpiece, and in the fight against after the completion of acceptance with the signal from the proximity switch; If the downward blow artifact has yet to reach the needed energy, at this point the slider has reached the bottom dead center, to protect the equipment and frequency converter must be disconnected operation signal. Program receive the slider with signal process, the reverse operation contact closure, frequency converter motor to set the speed to accelerate the reverse operation, to disconnect the inverter can reverse the certain position, brake, completed a blow
4 The characteristics of the electric screw press
Motor driven directly in the form of electric screw press, there is no motor and the flywheel transmission losses. In addition, in the form of either drive electric spiral pressure and L have the following features: (1) simple and compact structure, transmission chain is short, convenient operation and maintenance, and maintenance workload small, save time and maintenance cost, safe operation; (2) energy can accurate control, force can be adjusted according to forging forming process and the fight against energy, high precision forging forming, die stress is small, mould service life is long; (3) the use of advanced motor drive electric control technology, press work, will not impact and influence on power grid normal operation of other equipment; (4) the slider stops, the main motor does not work, low power consumption, save energy; (5) there is no fixed bottom dead center, don't need to adjust the mould height, won't produce stuffy car phenomenon; 6, stroke height can be adjusted conveniently, and the position accurately; Cruelly compared with hydraulic screw press, does not need complex hydraulic equipment, there is no leakage of hydraulic oil pollution of environment and hydraulic failure problem; Was compared with friction screw press, no friction plate, the horizontal axis and so on intermediate transmission device and friction belt wearing parts, spare parts, high reliability, good accuracy.
5 Conclusion
Electric screw press as a kind of high efficiency, energy saving, environmental protection new forging equipment, has been in high precision engine, turbine blades, gear and other important parts of MAO bad is widely used in forging and precision forging. Modern screw press that have adopted the overload protection, force can display, primary energy, and advanced computer control system and the replacement of the automatic feeding, die and other auxiliary equipment. The theory and practice prove that screw press technology of wide adaptability, productivity is moderate, good working conditions, has become one of modern forging production optimization equipment.
As the automobile, shipbuilding, aviation, aerospace and other industrial development, the application field of the electric screw press will be expanded. Electric screw press has been developed at a good stage, but its theory system has not yet perfect, the control technology is also in constant exploration, believe in the industry in the development of institutions and production enterprises of innovation efforts, the development prospect of the electric screw press will be more bright. In recent years, with the development of science and technology, frequency conversion technology and electronic numerical control technology unceasing enhancement, the development innovation, production of electric screw press manufacture is in full swing, Huazhong science and technology study, such as green forging forging machinery co., LTD., Qingdao has successively have missile technology and products and to market quickly. Electric screw press has become the most vitality of the screw press product. To further enhance the automation of screw press, make the force, speed and position control parameters, such as more accurate, convenient, will be the developing direction of the screw press next to continue.
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