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摘要
摘要
玻璃磨邊機(jī)是玻璃深加工必須的專用設(shè)備，其作用是根據(jù)需要將玻璃邊部磨
削成特定的形狀。本文論述了基于S7-226PLC實現(xiàn)的玻璃磨邊機(jī)設(shè)計。文章首先
介紹了玻璃磨邊機(jī)的現(xiàn)狀及其在設(shè)計中要實現(xiàn)的磨削花型。其磨削花型分別是:
磨直線斜邊、磨靠邊基本波浪邊、磨直線波浪邊、磨雙直線波浪邊、磨樹葉型波
浪邊、磨直線樹葉波浪邊。隨后介紹了玻璃磨邊機(jī)控制系統(tǒng)的設(shè)計情況。其硬件
設(shè)計采用S7-226PLC作為控制核心，加上相應(yīng)的接口電路、通訊裝置和智能化軟
件設(shè)計，由其高速計數(shù)裝置并通過旋轉(zhuǎn)編碼器檢測電機(jī)轉(zhuǎn)速，通過PLC輸出控制
磨輪進(jìn)給電機(jī)和磨輪旋轉(zhuǎn)電機(jī)進(jìn)而控制磨削不同花型:PLC的程序完成了各種開
關(guān)量信號的采集，磨輪旋轉(zhuǎn)角度和磨輪進(jìn)給參數(shù)的采集，磨輪旋轉(zhuǎn)角度和磨輪進(jìn)
給參數(shù)的計算、輸出控制等功能，文章對其進(jìn)行了分析。作者選用了PWS1711人
機(jī)界面對玻璃磨邊機(jī)進(jìn)行實時監(jiān)視和參數(shù)設(shè)置，文章介紹了玻璃磨邊機(jī)人機(jī)界面
軟件設(shè)計，包括主畫面、磨直線斜邊子畫面、參數(shù)設(shè)置畫面、控制畫面、手動調(diào)
整畫面、調(diào)試畫面等。為進(jìn)一步提高磨削精度，作者將原方案中控制磨輪進(jìn)給的
普通電機(jī)改由伺服電機(jī)來完成，文章最后對其控制思想進(jìn)行了討論，并給出了基
于PLC實現(xiàn)的模糊PID程序設(shè)計。
關(guān)鍵詞:PLC;玻璃磨邊機(jī);人機(jī)界面:PID;磨輪
緒論
1緒論
1.，課題來源及意義
上世紀(jì)80年代隨著交通、建筑和旅游業(yè)的迅速發(fā)展，對深加工玻璃的需求越
來越多，使玻璃深加工行業(yè)得到了較快的發(fā)展，玻璃深加工的產(chǎn)量上升較快。大批
浮法玻璃生產(chǎn)線的建成投產(chǎn)，給玻璃深加工提供了優(yōu)質(zhì)玻璃原片:建筑業(yè)、交通業(yè)
發(fā)展的加快和檔次的提高，為深加工玻璃的應(yīng)用開辟了廣闊的市場;但是，由于玻
璃加工機(jī)械水平的影響，大部分玻璃深加工企業(yè)的生產(chǎn)能力并沒有充分發(fā)揮出來。
由于世界主要玻璃生產(chǎn)企業(yè)對平板玻璃以及其它品種的玻璃都在尋求新的利潤增
長點，產(chǎn)品創(chuàng)新、新工藝探索、降低成本、產(chǎn)生高附加值等己成為各大玻璃廠商
發(fā)展的目標(biāo)。因此目前世界上5096-60%的平板玻璃原片均進(jìn)行深加工后再上市，
浮法玻璃原片己不再風(fēng)光，而是向功能型、實用型、裝飾型、安全型、環(huán)保型五
大方向的深加工玻璃發(fā)展，這是21世紀(jì)平板玻璃創(chuàng)新產(chǎn)品不容爭議的目標(biāo)。近年
來，我國玻璃深加工企業(yè)發(fā)展很快，數(shù)量不斷增加，規(guī)模越來越大，玻璃磨邊機(jī)
作為玻璃深加工企業(yè)必須的專用設(shè)備，其市場需求也將越來越多。然而到目前為
止，國內(nèi)玻璃磨邊設(shè)備還不很成熟，大多只適合單件加工，而不能應(yīng)用于批量生
產(chǎn)線。大型玻璃深加工企業(yè)必須采用自動化程度高的智能玻璃磨邊機(jī)。
由于現(xiàn)階段國產(chǎn)玻璃磨邊機(jī)自動化程度較低，難以滿足玻璃深加工行業(yè)快速
發(fā)展的要求，因此安徽理工大學(xué)與方圓玻璃機(jī)械廠合作進(jìn)行智能玻璃磨邊機(jī)研制。
1.2玻玻磨邊機(jī)的主要種類及特點
目前國內(nèi)玻璃深加工企業(yè)使用較多的幾種玻璃磨邊機(jī)如下〔23 [4] [10]
(l)單臂異形磨邊機(jī)(簡稱異形機(jī)或單臂機(jī))
異形機(jī)的最大特點是用途廣泛，異形機(jī)既可以磨直邊，也可磨圓邊、鴨嘴邊，
還可磨斜邊;既可以磨圓形工件，也可磨橢圓及異形工件。在獨立吸盤上裝上靠
模，用異形機(jī)可以磨一些形狀不規(guī)則的工件。
(2)直線磨邊機(jī)
直線磨邊機(jī)的特點有三個:一是用途比較單一，只能磨各類直線邊;二是可
連續(xù)性磨削，生產(chǎn)效率較高:三是可磨削尺寸較大的平板玻璃。
直線磨邊機(jī)是各類磨邊機(jī)中品種、規(guī)格最多的磨邊機(jī)，按能磨削的直線邊的
不同，它又可分為如下三種:
1)直線磨邊機(jī)(簡稱直邊機(jī))
直邊機(jī)只能磨削玻璃的平底邊及兩棱角，按磨頭數(shù)分，有三、五、八、九、
十、十三、十四磨頭等數(shù)種機(jī)型。一般來說，磨頭數(shù)越多，則磨削精度和生產(chǎn)效
率越高，相應(yīng)地機(jī)器的價格也越高。而電腦控制的直邊機(jī)(一般磨頭數(shù)都在十或
十以上)價格更高。
近些年來，國內(nèi)市場上又出現(xiàn)一種既可磨平底邊，又可磨45度底邊的兩用直
邊機(jī)，用量也比較多。另外還有可磨一組或兩組互成角度底邊的磨邊機(jī)，叫多級
磨邊機(jī)。這種機(jī)型磨頭較多，一般為計算機(jī)控制。
2)直線圓(簡稱圓邊機(jī))
圓邊機(jī)可以磨削玻璃的圓邊、鴨嘴邊等，在家具、玻璃的加工中用的較多。
圓邊機(jī)也有三、五、六、七、八、九磨頭等數(shù)種機(jī)型。
3)直線斜邊機(jī)(簡稱斜邊機(jī))
斜邊機(jī)一般用于磨削玻璃3-20度的斜邊。現(xiàn)在，有的斜邊機(jī)也可磨削45
度的斜邊。斜邊機(jī)按磨頭數(shù)分，也有七、八、九、十、十一、十四磨頭等機(jī)型。
近些年來又出現(xiàn)一種能在玻璃斜邊上磨出各種波浪花紋的斜邊機(jī)，叫波浪斜邊機(jī)。
(3)靠模磨邊機(jī)(簡稱靠模機(jī)仿形機(jī))
靠模機(jī)利用模板準(zhǔn)確定位，可精確磨削圓形或異形玻璃的直邊、圓邊、鴨嘴
邊、斜邊等，這種磨邊機(jī)磨出的玻璃形狀準(zhǔn)確，尺寸統(tǒng)一，生產(chǎn)效率較高。
使用靠模磨邊機(jī)需要制作專門的模板，當(dāng)生產(chǎn)品種較多時，不但制作模板費
用較高，而且管理、更換模板也較麻煩，因此這種機(jī)型適用于生產(chǎn)品種不多，但
生產(chǎn)批量很大的玻璃加工。
(4)內(nèi)圓磨邊機(jī)(簡稱內(nèi)圓機(jī))
內(nèi)圓機(jī)的特點是結(jié)構(gòu)簡單，價格低廉，但用途比較單一，主要適于加工圓周
邊(可以是正圓，也可是橢圓或異形圓)?，F(xiàn)國內(nèi)有些廠生產(chǎn)的內(nèi)圓機(jī)，擺臂較長，
使磨頭的擺動范圍加大。這種機(jī)型不但可磨內(nèi)圓，也可兼磨外圓，又稱為內(nèi)外圓
磨邊機(jī)。
(5)直線雙邊磨邊機(jī)(簡稱雙邊磨機(jī))
雙邊磨機(jī)的特點是可同時磨削玻璃的兩條對邊，加工精度好，生產(chǎn)效率高，
適用于大批量的玻璃磨邊生產(chǎn)。
雙邊磨機(jī)按使用性能分有雙直邊磨邊機(jī)和雙圓邊磨邊機(jī)兩種，其中雙直邊磨
邊機(jī)用的較多。
雙邊磨機(jī)按磨削玻璃寬度的不同可分為中小型和大型兩種。最大磨削寬度在
兩米以下的稱為中、小型雙邊磨機(jī)，磨頭配置有四、六、八、十二磨頭等。最大
磨削寬度在兩米及兩米以上的稱為大型雙邊磨機(jī)，磨頭配置有十六、二十、二十
二磨頭等。大型雙邊磨機(jī)一般為電腦控制，自動化程度較高，適于磨削大尺寸平
板玻璃，但是，這種設(shè)備的價格比較昂貴。
(6)其他磨邊機(jī)及專用磨邊機(jī)
除以上介紹的磨邊機(jī)以外，還有一些結(jié)構(gòu)簡單、用途單一的磨邊機(jī)，如倒角
機(jī)、小圓片機(jī)、拋光機(jī)等。另外還有一些專門加工某種產(chǎn)品的專用磨邊機(jī)，如汽
車后視鏡磨邊機(jī)、洗手盆磨邊機(jī)等。
1.3國內(nèi)外發(fā)展與應(yīng)用情況
目前玻璃磨邊機(jī)設(shè)備不少是進(jìn)口的，進(jìn)口磨邊機(jī)主要來自意大利生產(chǎn)，另外
還有來自韓國、美國、臺灣等地的磨邊機(jī)用的也較多〔日。進(jìn)口機(jī)的質(zhì)量、精度、
生產(chǎn)效率和使用壽命都要比國內(nèi)機(jī)好，但進(jìn)口機(jī)價格昂貴，一般為國內(nèi)同類機(jī)價
格的3-10倍。玻璃磨邊機(jī)目前仍以進(jìn)口設(shè)備為主，雖然國外這方面的技術(shù)和設(shè)備
都很成熟，在國際市場上也應(yīng)用廣泛，但完全依賴進(jìn)口設(shè)備的缺點也是明顯的，
首先進(jìn)口設(shè)備價格昂貴，需花費大量的外匯;其次它的定貨周期、購買備品備件的
周期長，對正常生產(chǎn)造成一定的影響，特別是設(shè)備的控制軟件部分，由于保密性
強(qiáng)而無從深入了解，功能擴(kuò)展性差，一旦出現(xiàn)問題就必須等國外的專家來維護(hù)和
調(diào)試，對正常生產(chǎn)有很大的影響，故研制和開發(fā)國產(chǎn)的智能玻璃磨邊機(jī)的重要性
是顯而易見的，不僅能夠提高玻璃加工技術(shù)水平和市場競爭力，而且隨著玻璃深
加工行業(yè)的迅猛發(fā)展，該設(shè)備的應(yīng)用前景也是很廣闊的。
1.4本文的主要工作
玻璃磨邊機(jī)的作用是根據(jù)需要將玻璃邊部磨削成特定的形狀。其機(jī)械結(jié)構(gòu)主
要由磨削進(jìn)給系統(tǒng)和加工工作臺兩部分構(gòu)成。加工工作臺上放置被加工的玻璃，
玻璃靠普通交流電機(jī)驅(qū)動在加工工作臺上移動，磨削砂輪的轉(zhuǎn)動也由普通交流電
機(jī)驅(qū)動.，磨削進(jìn)給系統(tǒng)也采用普通交流電機(jī)驅(qū)動，用以控制磨削砂輪的運動軌跡，
以便將玻璃邊部磨削成不同的形狀。這也是應(yīng)方圓玻璃機(jī)械有限公司的要求而設(shè)
計的方案，本文第3章與第5章對其進(jìn)行了詳細(xì)介紹。為了進(jìn)一步提高磨削精
度，
作者對上述方案進(jìn)行了改進(jìn)，將普通電機(jī)的工作改由伺服電機(jī)完成，本文第6章
給予了分析。本文主要工作包括:
玻璃磨邊機(jī)的總體設(shè)計
玻璃磨邊機(jī)的電氣控制部分硬件設(shè)計
可編程控制器的選型、模塊設(shè)計
旋轉(zhuǎn)編碼器及高速計數(shù)器分析
人機(jī)界面選型、設(shè)計
PLC與人機(jī)界面的程序設(shè)計
基于PLC的模糊PID設(shè)計等。
1.5本章小結(jié)
本章對課題的來源和意義、玻璃磨邊機(jī)的結(jié)構(gòu)組成、玻璃磨邊機(jī)的主要種類
及特點、目前國內(nèi)外應(yīng)用情況、玻璃磨邊機(jī)的主要參數(shù)以及本文的主要工作等做
了簡要介紹。
本科畢業(yè)設(shè)計開題報告
課題名稱 玻璃磨邊機(jī)
一、課題來源及意義
上世紀(jì)80年代隨著交通、建筑和旅游業(yè)的迅速發(fā)展，對深加工玻璃的需求越來越多，使玻璃深加工行業(yè)得到了較快的發(fā)展，玻璃深加工的產(chǎn)量上升較快。大批浮法玻璃生產(chǎn)線的建成投產(chǎn)，給玻璃深加工提供了優(yōu)質(zhì)玻璃原片:建筑業(yè)、交通業(yè)發(fā)展的加快和檔次的提高，為深加工玻璃的應(yīng)用開辟了廣闊的市場;但是，由于玻璃加工機(jī)械水平的影響，大部分玻璃深加工企業(yè)的生產(chǎn)能力并沒有充分發(fā)揮出來。由于世界主要玻璃生產(chǎn)企業(yè)對平板玻璃以及其它品種的玻璃都在尋求新的利潤增長點，產(chǎn)品創(chuàng)新、新工藝探索、降低成本、產(chǎn)生高附加值等己成為各大玻璃廠商發(fā)展的目標(biāo)。因此目前世界上50%-60%的平板玻璃原片均進(jìn)行深加工后再上市，浮法玻璃原片己不再風(fēng)光，而是向功能型、實用型、裝飾型、安全型、環(huán)保型五大方向的深加工玻璃發(fā)展，這是21世紀(jì)平板玻璃創(chuàng)新產(chǎn)品不容爭議的目標(biāo)。近年來，在很多行業(yè)，特別是在建筑行業(yè)，對玻璃的需求增長很快同時對玻璃的加工質(zhì)量和加工效率也有了很高的要求，傳統(tǒng)意義上的砂布磨邊己滿足不了生產(chǎn)工藝和建筑市場的要求，生產(chǎn)效率低，生產(chǎn)成本高。隨著工業(yè)的高速發(fā)展，我國玻璃深加工企業(yè)發(fā)展很快，數(shù)量不斷增加，規(guī)模越來越大，玻璃磨邊機(jī)作為玻璃深加工企業(yè)必須的專用設(shè)備，其市場需求也將越來越多。玻璃直線磨邊機(jī)可以通過粗磨、精磨、粗拋光、細(xì)拋光等工序一次可同時磨削平板玻璃的邊，該機(jī)用于磨削各種規(guī)格的平板玻璃。磨削玻璃的直線平底邊、垂直邊倒角及拋光可一次完成。產(chǎn)品完全能夠滿足生產(chǎn)節(jié)能、安全、環(huán)保玻璃的前處理要求和建筑市場對玻璃的要求，改善了傳統(tǒng)的玻璃磨邊方式，降低生產(chǎn)成本，提高加工精度和提高生產(chǎn)效率。
二、玻玻磨邊機(jī)的主要種類及特點
目前國內(nèi)玻璃深加工企業(yè)使用較多的幾種玻璃磨邊機(jī)如下
1、單臂異形磨邊機(jī)(簡稱異形機(jī)或單臂機(jī))
異形機(jī)的最大特點是用途廣泛，異形機(jī)既可以磨直邊，也可磨圓邊、鴨嘴邊，還可磨斜邊;既可以磨圓形工件，也可磨橢圓及異形工件。在獨立吸盤上裝上靠模，用異形機(jī)可以磨一些形狀不規(guī)則的工件。
2、直線磨邊機(jī)
直線磨邊機(jī)的特點有三個:一是用途比較單一，只能磨各類直線邊;二是可連續(xù)性磨削，生產(chǎn)效率較高:三是可磨削尺寸較大的平板玻璃。直線磨邊機(jī)是各類磨邊機(jī)中品種、規(guī)格最多的磨邊機(jī)，按能磨削的直線邊的不同，它又可分為如下三種:
1）直線磨邊機(jī)(簡稱直邊機(jī))
直邊機(jī)只能磨削玻璃的平底邊及兩棱角，按磨頭數(shù)分，有三、五、八、九、十、十三、十四磨頭等數(shù)種機(jī)型。一般來說，磨頭數(shù)越多，則磨削精度和生產(chǎn)效率越高，相應(yīng)地機(jī)器的價格也越高。而電腦控制的直邊機(jī)(一般磨頭數(shù)都在十或十以上)價格更高。
近些年來，國內(nèi)市場上又出現(xiàn)一種既可磨平底邊，又可磨45度底邊的兩用直邊機(jī)，用量也比較多。另外還有可磨一組或兩組互成角度底邊的磨邊機(jī)，叫多級磨邊機(jī)。這種機(jī)型磨頭較多，一般為計算機(jī)控制。
2）直線圓(簡稱圓邊機(jī))
圓邊機(jī)可以磨削玻璃的圓邊、鴨嘴邊等，在家具、玻璃的加工中用的較多。圓邊機(jī)也有三、五、六、七、八、九磨頭等數(shù)種機(jī)型。
3）直線斜邊機(jī)(簡稱斜邊機(jī))
斜邊機(jī)一般用于磨削玻璃3-20度的斜邊?，F(xiàn)在，有的斜邊機(jī)也可磨削45度的斜邊。斜邊機(jī)按磨頭數(shù)分，也有七、八、九、十、十一、十四磨頭等機(jī)型。近些年來又出現(xiàn)一種能在玻璃斜邊上磨出各種波浪花紋的斜邊機(jī)，叫波浪斜邊機(jī)。
3、靠模磨邊機(jī)(簡稱靠模機(jī)仿形機(jī))
靠模機(jī)利用模板準(zhǔn)確定位，可精確磨削圓形或異形玻璃的直邊、圓邊、鴨嘴邊、斜邊等，這種磨邊機(jī)磨出的玻璃形狀準(zhǔn)確，尺寸統(tǒng)一，生產(chǎn)效率較高。使用靠模磨邊機(jī)需要制作專門的模板，當(dāng)生產(chǎn)品種較多時，不但制作模板費用較高，而且管理、更換模板也較麻煩，因此這種機(jī)型適用于生產(chǎn)品種不多，但生產(chǎn)批量很大的玻璃加工。
4、內(nèi)圓磨邊機(jī)(簡稱內(nèi)圓機(jī))
內(nèi)圓機(jī)的特點是結(jié)構(gòu)簡單，價格低廉，但用途比較單一，主要適于加工圓周邊(可以是正圓，也可是橢圓或異形圓)?，F(xiàn)國內(nèi)有些廠生產(chǎn)的內(nèi)圓機(jī)，擺臂較長，使磨頭的擺動范圍加大。這種機(jī)型不但可磨內(nèi)圓，也可兼磨外圓，又稱為內(nèi)外圓磨邊機(jī)。
5、直線雙邊磨邊機(jī)(簡稱雙邊磨機(jī))
雙邊磨機(jī)的特點是可同時磨削玻璃的兩條對邊，加工精度好，生產(chǎn)效率高適用于大批量的玻璃磨邊生產(chǎn)。雙邊磨機(jī)按使用性能分有雙直邊磨邊機(jī)和雙圓邊磨邊機(jī)兩種，其中雙直邊磨邊機(jī)用的較多。雙邊磨機(jī)按磨削玻璃寬度的不同可分為中小型和大型兩種。最大磨削寬度在兩米以下的稱為中、小型雙邊磨機(jī)，磨頭配置有四、六、八、十二磨頭等。最大磨削寬度在兩米及兩米以上的稱為大型雙邊磨機(jī)，磨頭配置有十六、二十、二十二磨頭等。大型雙邊磨機(jī)一般為電腦控制，自動化程度較高，適于磨削大尺寸平板玻璃，但是，這種設(shè)備的價格比較昂貴。
6、其他磨邊機(jī)及專用磨邊機(jī)
除以上介紹的磨邊機(jī)以外，還有一些結(jié)構(gòu)簡單、用途單一的磨邊機(jī)，如倒角機(jī)、小圓片機(jī)、拋光機(jī)等。另外還有一些專門加工某種產(chǎn)品的專用磨邊機(jī)，如汽車后視鏡磨邊機(jī)、洗手盆磨邊機(jī)等。
三、國內(nèi)外發(fā)展與應(yīng)用情況
自20世紀(jì)90年代以來，由于材料科學(xué)的重大創(chuàng)新和突破，人們利用納米材料技術(shù)、表面處理技術(shù)和復(fù)合雜化技術(shù)等高新技術(shù)開發(fā)出了各種環(huán)保節(jié)能型、環(huán)保型、智能型等新型深加工玻璃，賦予了玻璃新的機(jī)械、電氣、光學(xué)、化學(xué)等功能，增加了玻璃的使用效果，改善了人類的工作與生活環(huán)境。雖然我國深加工玻璃的生產(chǎn)技術(shù)在某些領(lǐng)域接近或達(dá)到國外先進(jìn)國家水平，但是，深加工玻璃的整體生產(chǎn)技術(shù)與國外相比有很大差距，尚未形成規(guī)模的專業(yè)產(chǎn)品研究與生產(chǎn)線，某些產(chǎn)品的產(chǎn)業(yè)化仍是空白。
玻璃磨邊機(jī)設(shè)備國外在上世紀(jì)九十年代末期發(fā)展起來，目前比利時、意大利生產(chǎn)的磨邊機(jī)加工精度較高、生產(chǎn)效率高、操作方便，設(shè)備技術(shù)成熟，運行穩(wěn)定，可靠;我國已引進(jìn)一些進(jìn)口設(shè)備，每臺設(shè)備在80-90萬元以上，設(shè)備價格比較昂貴。我國從2001年以后才開始發(fā)展該項技術(shù)設(shè)備，目前存在的主要是玻璃的對角線誤差、玻璃加工尺寸精度問題.從調(diào)研情況來看磨邊機(jī)設(shè)備目前仍以進(jìn)口設(shè)備為主，國產(chǎn)機(jī)上處于研制開發(fā)階段，其性能與進(jìn)口設(shè)備相比仍有較大差距。隨著我國數(shù)控技術(shù)的發(fā)展，數(shù)控機(jī)床的應(yīng)用，相信我們的設(shè)備完全可以替代進(jìn)口設(shè)備，開發(fā)出能夠滿足國內(nèi)建筑市場需求的設(shè)備。玻璃磨邊機(jī)這項技術(shù)國外在上世紀(jì)九十年代末期發(fā)展起來;但設(shè)備價格比較昂貴。而國產(chǎn)機(jī)尚處于起步階段.目前玻璃磨邊機(jī)設(shè)備不少是進(jìn)口的，進(jìn)口磨邊機(jī)主要來自意大利生產(chǎn)，另外還有來自韓國、美國、臺灣等地的磨邊機(jī)用的也較多。進(jìn)口機(jī)的質(zhì)量、精度、生產(chǎn)效率和使用壽命都要比國內(nèi)機(jī)好，但進(jìn)口機(jī)價格昂貴，一般為國內(nèi)同類機(jī)價格的3-10倍。玻璃磨邊機(jī)目前仍以進(jìn)口設(shè)備為主，雖然國外這方面的技術(shù)和設(shè)備都很成熟，在國際市場上也應(yīng)用廣泛，但完全依賴進(jìn)口設(shè)備的缺點也是明顯的，首先進(jìn)口設(shè)備價格昂貴，需花費大量的外匯;其次它的定貨周期、購買備品備件的周期長，對正常生產(chǎn)造成一定的影響，特別是設(shè)備的控制軟件部分，由于保密性強(qiáng)而無從深入了解，功能擴(kuò)展性差，一旦出現(xiàn)問題就必須等國外的專家來維護(hù)和調(diào)試，對正常生產(chǎn)有很大的影響，故研制和開發(fā)國產(chǎn)的智能玻璃磨邊機(jī)的重要性是顯而易見的，不僅能夠提高玻璃加工技術(shù)水平和市場競爭力，而且隨著玻璃深加工行業(yè)的迅猛發(fā)展，該設(shè)備的應(yīng)用前景也是很廣闊的。
四、研究方案
玻璃磨邊機(jī)的作用是根據(jù)需要將玻璃邊部磨削成特定的形狀。其機(jī)械結(jié)構(gòu)主要由磨削進(jìn)給系統(tǒng)和加工工作臺兩部分構(gòu)成。加工工作臺上放置被加工的玻璃，玻璃靠普通交流電機(jī)驅(qū)動在加工工作臺上移動，磨削砂輪的轉(zhuǎn)動也由普通交流電機(jī)驅(qū)動.，磨削進(jìn)給系統(tǒng)也采用普通交流電機(jī)驅(qū)動，用以控制磨削砂輪的運動軌跡，以便將玻璃邊部磨削成不同的形狀。為了進(jìn)一步提高磨削精度，將普通電機(jī)的工作改由伺服電機(jī)完成，解決加工玻璃厚度變化時，其夾持機(jī)構(gòu)的調(diào)整問題，保證玻璃直線運行，不跑偏；完成對直邊的粗磨、半精磨、精磨;粗拋、半精拋、精拋、倒角精磨、拋光等工序一次完成。利用PLC通訊，使其運行狀態(tài)及各種故障報警顯示；系統(tǒng)具有自我診斷、報警功能，維護(hù)方便。
五、工作計劃
1-2周 調(diào)研，查資料，匯總資料
第2 周 計算總體尺寸 計算出總體尺寸，寫開題報告
3-4周 畫總裝圖
5-8周 畫零件圖
9-1周 撰寫論文
12 周 論文答辯
六、參考文獻(xiàn)
[1] 鞏云鵬，田萬祿主編 《機(jī)械設(shè)計課程設(shè)計》 東北大學(xué)出版社
[2] 張玉，劉平 《幾何量公差與測量技術(shù)》 東北大學(xué)出版1999
[3] 盧秉恒主編 《機(jī)械制造技術(shù)基礎(chǔ)》 機(jī)械工業(yè)出版社
[4] 王國良，楊晶編著 《信息資源檢索與利用》 兵器工業(yè)出版社
[5] 熊詩波，黃長藝主編 《機(jī)械工程測試技術(shù)基礎(chǔ)》機(jī)械工業(yè)出版社
[6] 濮良貴，紀(jì)名剛主編 《機(jī)械設(shè)計》 高等教育出版社
[7] 教育部組編 《畫法幾何及機(jī)械制圖》高等教育出版社，
[8] 東北大學(xué)《機(jī)械零件設(shè)計手冊》編寫組 《機(jī)械零件設(shè)計手冊》（第三版）冶金工業(yè)出版社
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Waste Management 25 (2005) 733–736
www.elsevier.com/locate/wasman
Composite materials based on wastes of ?at glass processing
A.V. Gorokhovsky a,*, J.I. Escalante-Garcia a, G.Yu. Gashnikova b, L.P. Nikulina b, S.E. Artemenko b
a Department of Engineering Ceramics, CINVESTAV Unidad Saltillo, Carr. Saltillo-Monterrey km13, AP 663, Saltillo, CP25000 Coahuila, Mexico
b Department of Chemical Technology, Technological Institute of Saratov State Technical University, Pl. Svobody 17, Engels 413100, Russian Federation
Accepted 3 November 2004
Available online 25 December 2004
Abstract
Glass mirrors scrap and poly (vinyl) butiral waste (PVB) obtained from ?at glass processing plants were investigated as raw mate-
rials to produce composites. The emphasis was on studying the in?uence of milled glass mirror waste contents on properties of com- posites produced with PVB. The characterization involved: elongation under rupture, water absorption, tensile strength and elastic modulus tests. The results showed that the composite containing 10 wt% of ?ller powder had the best properties among the com- positions studied. The in?uence of the time of exposure in humid atmosphere on the composite properties was investigated. It was found that the admixture of PVB iso-propanol solution to the scrap of glass mirrors during milling provided stabilization of the properties of the composites produced.
2004 Elsevier Ltd. All rights reserved.
1. Introduction
The use of industrial wastes to produce composite materials is one of the current problems of industry; this provides a means to decrease environmental contamina- tion. Flat glass processing involves the generation of wastes, like scrap of glass mirrors as well as strips of poly (vinyl) butiral ?lm (PVB), from the manufacture of automobile windscreens (Garner, 1996) and safety architectural glass (Lievens, 1995). Clean PVB waste can be recycled on the basis of well-known technological processes; however, about 5–20% of this waste contains contamination, which precludes its recycling. Moreover, in developing countries there is little e?orts or possibility for the recycling of this type of waste. Additionally, waste from glass mirror production (scrap or mirrors not meeting standards) has to be disposed because of the lack of technological processes oriented towards its
* Corresponding author. Tel.: +52 844 438 9600; fax: +52 844 438
9610.
E-mail address: alexande@saltillo.cinvestav.mx (A.V. Gorokhovsky).
utilization (Foss, 1997). The amounts of such waste
can reach 10–15% of commercial production in di?erent plants.
Taking into account that the plants oriented to ?at glass processing, usually produce both types of the aforementioned wastes or are located close by, it was of interest to investigate the possibility of producing glass-polymer composites based on the complex utiliza- tion of such wastes that are inapplicable for recycling. The production of composites based on PVB wastes is especially attractive in developing countries, where their collection as well as transportation into the plants spe- cialized in PVB recycling is economically unpro?table. The high adhesion properties of the PBV to the soda-
lime-silicate glass surface (Garner, 1996; Gopal et al.,
1997) make the composite, based on PVB waste and milled glass, a promising material useful for di?erent applications. The best scheme is that for plants produc- ing both wastes, for example in the manufacturing of di?erent pro?led rods, characterized with high mechan- ical properties stable in conditions of humid atmosphere and temperature changes. However, the presence of
0956-053X/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.wasman.2004.11.007
734 A.V. Gorokhovsky et al. / Waste Management 25 (2005) 733–736
metal particles on the glass surface of milled glass mirror
scrap as well as the use of PVB waste could negatively in?uence the exploitation properties and thus must be investigated.
2. Methodology
Wastes of Saratovsteklo Inc. (Russia) were used for the experiments. The glass used to produce mirrors had the following chemical composition (wt%): 73.1
SiO2; 1.1 Al2O3; 8.6 CaO; 3.6 MgO; 13.6 Na2O. The mirror coating was formed by vacuum sputtering of stainless steel. PVB waste was obtained from the poly- mer ?lm B-17 produced by Monsanto.
In Series 1 of the experiments, the ?ller was produced by dry ball milling of glass mirror scrap, in jars of alu- mina with balls of alumina, to reach a surface area of
4000 ± 100 cm2/g (controlled by LHM-8MD Russian
equipment). The ground glass was then added to PVB waste molten at 115 C, the latter was previously ad- mixed with 0.5 wt% of poly (ethyl) silane (PES-5, Volzh- skii, Russia) to promote the blending of components and increase homogeneity of composition. The ratio of glass powder and molten PVB was varied in the range of 1–30 wt%. The mixtures obtained were used to pro- duce ?lms by quenching, as well as rods by extrusion.
It is well known that water vapor adsorption onto the surface of soda-lime-silicate glasses in?uences their adhesion to polymers (Kawaguchi and Pearson, 2003; Gu et al., 2000; Radhakrishnan and Unde, 1999). It has been shown (Soshko et al., 1989) that the admixtures of some organic polymers into the glass scrap during milling promoted the modi?cation of the glass surface by the products of their thermo-mechanical destruction
(Dhaliwal and Hay, 2000). For this reason, an addi- tional batch of Series 2 was prepared using composites made from the resulting material obtained after joint ball milling of glass mirrors scrap admixed with PVB waste dissolved at room temperature in iso-propanol
(15% solution); the weight ratio of glass scrap and PVB–alcohol solution was 0.05. It was expected that the glass powder thus obtained would have enhanced hydrophobic properties and improved adhesion to PVB. To characterize such surface modi?cation, the ob- tained ?llers were investigated by TGA/DTGA (Perkin Elmer/Seiko Instruments, Japan) for the following types
of glass powder: (a) ‘‘fresh’’ dry milled, (b) dry milled
and exposed to a humid atmosphere for a month, (c) milled with PVB alcohol solution and exposed to a hu- mid atmosphere for a month.
The average tensile mechanical strength of the com- posite articles was measured by testing 18 specimens of each system using the ER-5046-5 Russian equipment. The Young modulus was measured following the E1875-00e1 ASTM standard using UZIS equipment
(LETI, Russia).
Taking into account the in?uence of environmental factors on the properties of materials produced, speci- mens of the two composites, prepared with the ?llers of Series 1 and 2, were exposed for three months at 25
C in air (40% humidity); and the same mechanical tests,
as previously described, were repeated to determine the range of variation in the main characteristics during exploitation.
3. Results and discussion
The main characteristics of composites with di?erent contents of glass powder for Series 1, measured immedi- ately after their production, are presented in Table 1. The introduction of 1–10 wt% of glass powder into the matrix of PVB waste increased the mechanical strength of the composite (by 1.6 times) and decreased its relative elongation under the rupture (by 1.3 times). Further in- crease of glass powder contents decreased the exploita- tion properties.
The in?uence of exposure to a humid atmosphere on the exploitation properties of the composite, made from Series 1 with 10 wt% of glass powder (highest mechani- cal properties), is presented in Figs. 1 and 2. All the tested properties decreased only during the ?rst two months of exposure and then stabilized. The same e?ect was displayed by the results presented in Table 2, show- ing the properties of composites obtained with the
‘‘fresh’’ and ‘‘old’’ (exposed in air for a month) glass powder. Such reduction in the exploitation properties observed, in agreement with published results (Keller and Mortelmans, 1999), can be attributed to the pro- cesses taking place on the surface of glass ?ller before the production of composites: adsorption (condensa- tion) of water vapor from the atmosphere, leaching of sodium ions, and crystallization of Na2CO3 and NaH-
Table 1
The properties of composites obtained by extrusion of samples made of separate dry milling of glass
Properties Contents of glass powder (wt%)
0 1 3 5 10 15 20 25 30
Young module (MPa) 2.3 2.5 2.7 2.9 4.3 3.8 2.7 2.5 2.3
Tensile strength (MPa) 6.8 5.2 7.4 7.9 11.2 8.4 8.5 7.0 5.4
Relative elongation under rupture (%) 318 345 288 271 237 328 295 286 142
A.V. Gorokhovsky et al. / Waste Management 25 (2005) 733–736 735
35
30
25 Relative elongation
60
50
40
1
4 5
6
C
20
15
10
under a rupture
Tensile strength
30
20
10
1
1
2
2
3
B
5 Young
A
0
modulus
0 50 100 150
Exposure, days
0
50 100 150 200 250 300 350 400 450 500
Temperature,?C
Fig. 1. In?uence of exposure to humid atmosphere on properties of
composites produced with powder obtained from Series 1 (continuous lines) and Series 2 (dashed lines): relative elongation under a rupture
(%·10 1), tensile strength (MPa), Young modulus (MPa).
CO3 as a result of the sodium ions interaction with dis- solved CO2. The presence of these crystals and adsorbed water onto the surface of glass ?ller decreased adhesion with PVB. At the same time, modi?cation of the glass powder surface during the milling of glass mirrors scrap with PVB alcohol solution (Series 2) can increase the hydrophobic properties of the glass powder and stabilize the structure of the composite. A comparison of proper- ties for composites from Series 1 and 2 is shown in Figs.
1 and 2; an improvement and increased stability of prop- erties of the composite produced in Series 2 can be noted.
3
2.5
2
1.5
1
0.5
0
0 50 100 150
Exposure, days
Fig. 2. In?uence of exposure in humid atmosphere (dashed lines) and water (continuous lines) on weight of composite rods produced from Series 1 (d) and Series 2 (s).
Fig. 3. DTGA data obtained for di?erent types of ?ller: A – ‘‘fresh’’
dry milled, B – ‘‘old’’ dry milled, C – ‘‘old’’ milled with PVB alcohol solution. 1, 2 – desorption of condensed water, 3 – desorption of chemically adsorbed water, 4 – melting of PVB; 5, 6 – thermal decomposition of PVB and its derivatives formed by milling.
The obtained data of DTGA (Fig. 3) indicates that the ‘‘old’’ glass ?ller, in comparison with the ‘‘fresh’’ ?l- ler obtained by dry ball milling, is characterized by the additional intensive peak at 350–420 C, related to the desorption of chemically adsorbed water (Hench, 1978; Gorokhovsky, 1988). At the same time, this peak is ab- sent for the ?ller milled jointly with the PVB solution in iso-propanol; moreover, the quantity of condensed water is much less. The additional peaks in the thermo- gram of this ?ller are related to the melting and thermal decomposition of PVB (Dhaliwal and Hay, 2000). Thus,
it is possible to propose that the e?ect of stabilization of the mechanical properties, obtained for the composite produced on the base of glass powder with modi?ed sur- face (Series 2), was achieved due to a decreased adsorp- tion of water vapor.
The composite rods of di?erent pro?les, produced by extrusion of the batch based on the PVB wastes and glassy ?ller (10 wt%), obtained by joint ball milling of glass mirrors scrap with PVB waste, dissolved at room temperature in iso-propanol (15% solution), were ap- plied in Salavatsteklo Co. (Salavat, Russia) to manufac- ture the double glazing blocks, as well as bases for the storage and transportation of glass sheets of high thick- ness (weight).
Table 2
Properties of composites, made from Series 1 and with 10 wt% of glass powder, produced immediately after the milling and after one month of glass powder storage in air
Property Type of glass powder applied
4. Conclusions
Composite materials with attractive exploitation properties can be produced on the basis of typical wastes of ?at glass processing: poly (vinyl) butiral ribbons and
One month
after milling
‘‘Fresh’’ powder
glass mirror scrap. The contents about of 10 wt% of
glass powder results in composites with high and stable
Young modulus (MPa) 3.8 4.3
Tensile strength (MPa) 8.2 11.2
mechanical properties. The introduction of PVB alco-
hol solution resulted in the stabilization of properties
Relative elongation before
the rupture (%)
281 237
of the composites in the case of exposure to humid
atmospheres.
736 A.V. Gorokhovsky et al. / Waste Management 25 (2005) 733–736
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