I. Introduction:
C61160 is a large horizontal lathe with digital display function introduced in the early 60s of our factory. It is mainly used for rough machining of turbine rotor components. Due to the rapid development of power electronic devices and the constant renewal of technology, this equipment cannot meet the strategic goals of serialization and rapid development of factory products. Its specific performance is: the original equipment uses relay logic control, the line aging is serious, frequent failures; and many major electrical components are now eliminated, spare parts are difficult to buy and the cycle is long, not easy to maintain; manual human operation, can not achieve control of the processing program The implementation of the goal of sharing resources. Therefore, in order to reasonably integrate the use of factory resources and achieve the goal of digital development of our factory equipment, it has been demonstrated that a comprehensive electrical and mechanical transformation of the horizontal lathe will be carried out. To adapt to the development of nuclear power rotors.
Second, the structure and characteristics of machine tools
C61160 consists of a headstock, a knife holder, a tailstock and a closed center frame to form the main body of the machine. Cooling device, hydraulic device, oil temperature control, etc. are auxiliary equipment for the machine tool.
Before the transformation, the equipment adopts the relay control mode: the speed change of the main shaft is achieved through mechanical shifting; the tool rest is composed of a large carriage, a medium carriage, and a small carriage, and the motion of the large carriage can be driven by the large carriage motor and the main shaft. The light rods are implemented in two ways. The movement of the mid-dragging plate is achieved through the mid-drag motor. The small dragging plate is achieved through the manual rotation of the mechanical gear. The position detection of the tool holder is determined by installing the digital display meter. Tailstock and thimble movements have two motor drives, respectively.
Third, the design proposal:
In order to ensure that the machine tool can achieve rough machining and finish machining without changing the original operation mode, the following reformation program is proposed: 1 Spindle servo (CT) drive control. 2 Tool holders Large carriages, medium carriages are replaced by ball screw drives and are controlled by digital axes. 3 Cancel the small carriage. 4 all the original machine tool movement control from the original relay circuit control to PLC control.
Under the requirements of the above conditions, Siemens’ 802D CNC system has been selected. This system is a digital CNC system introduced by Siemens in recent years. Its standard version of the lathe version comes with a PP72/48 template, which can achieve 72 inputs and 48 points output PLC control, and the drive module is two single-axis power modules, with two linear axes and one analog spindle. Speed ​​feedback and displacement feedback sensors built in the servo motor can form a semi-closed loop control with the host. The system can thus achieve high machine accuracy. And the price is moderate, with a high cost, can meet the requirements of the equipment CNC transformation.
Fourth, hardware configuration and connection:
Because the C61160 lathe is finishing the nuclear rotor, an 802D numerical control system is used to control the movement of the tool holder. All other motion control of the machine tool is controlled by the PLC control unit of the 802D CNC system. The main hardware configuration using the 802D system is:
1, PCU host 1
2, full-function vertical keyboard 1
3, PP72/48 template 2 blocks
4,611UE drive power supply 1
5,611UE Two-axis closed-loop control unit 2 blocks
6, 611UE single axis power module 2
7, 1FK6 motor 2
8, external 2500P / rotary encoder 1
9, connecting cable and PROFIBUS data bus
10. Scale 2
11. Spindle Servo Drive (M420R) 1
12, hand wheel 1
4.1 SITOP power supply and power feed module
The SITOP power supply provides a stable DC power supply for the PCU module and input/output modules (PP72/48). The servo power feeding module mainly provides power and power supply for the power module and the 611UE module, generates the bus voltage, and simultaneously monitors the status of the power module. According to the total capacity of the selected motor to determine the size of the power feed module power, use the power module I/RF series with a feed device. Whether the servo power feed module can supply power to the 611UE drive module depends on its pulse enable signal (terminals 63 and 9), controller enable signal (terminals 64 and 9), internal contactor enable signal (terminals 48 and 112) ) These enable signals are all controlled through the PLC program. The power-on sequence is the internal contactor enable signal, the pulse enable signal, and the controller enable signal.
4.2 Human-Machine Interface The human-machine interface is mainly used for graphic display, input of numbers and symbols, etc. Including the operation panel (MCP), NC keyboard, LCD display in three parts. According to the characteristics of the machine tool, the same machine control panel as the 802SMCP is selected. The two 50-core flat cable outlets behind the MCP can be connected to the sockets of the PP module via flat cables. The NC keyboard is connected to the PCU's X10 via a dedicated cable provided by SIEMENS. The LCD display integrates with the PCU board.
The communication between the three is such that the PCU interfaces X4 and P72/48 are connected via the PROFIBUS bus, the PCU1 interface X8 and the P72/48 interface X1 are connected to the SITOP power supply, and the SITOP power supply provides constant power for their operation.
4.3 PCU numerical control unit The PCU numerical control unit is the core of the CNC control unit. According to the different storage capacities of the NC and the PLC, this machine tool uses the PCU50 column. PCU CNC unit contains NC CPU and PLC CPU. It is connected through PROFIBUS bus and realizes control of servo power supply module, control of spindle servo drive device and control of feed servo drive device.
4.4 Drive system and servomotor SIMODRIVE 611UE is equipped with a PROFIBUS interface module for speed loop and current loop control. The servo motor adopts 1FK6 series, and the encoder is 1VPP sine wave. The 802D position loop control is done by the PCU. The SIMODRIVE 611UE control modules are double-axis modules that can be used as single-axis modules according to the configuration of the PROFIBUS and can be set on the same module with one superimposed axis (simulated spindle). The analog output interface X441 of the SIMODRIVE 611 UE is used to output the spindle speed reference (±10V), and the digital output interface on the SIMODRIVE 611 UE can be used to simulate the positive and negative enable control of the spindle. The WSG interface X472 is used to connect a spindle encoder (TTL) as speed feedback.
Fifth, software design
The software design of the SINUMERIK 802D is to handle the interface signals between the NCK and the MCP, between the NCK and PLC, between the PLC and the MCP, NC parameter configuration (including various compensations) and PLC alarm texts. NCK, PLC and MCP are mutually independent, each is responsible for a part of functions; Also contact each other, exchange information with each other.
5.1 Communication Cable and PROFIBUS Configuration The personal computer is an essential tool when debugging the 802D CNC system or the 611UE drive. RS-232 communication cable is the only way to connect the two. Therefore, it is very important to ensure the correct connection mode of the communication cable. RS The -232 communication cable is used for PLC programming and 611UE driver connection.
SINUMERIK 802D is a digital control system based on PROFIBUS. The input and output signals are transmitted via PROFIBUS. The position adjustment (speed reference and position feedback signal) is also done via PROFIBUS. Therefore, the configuration of PROFIBUS is very important. In the design process, a digital coordinate axis is used to carry the spindle reference and feedback method to realize the control of the spindle. The carrying axis must be the A channel of the 611UE module. The PROFIBUS address must be either 12 or 10. The PROFIBUS address is 10 since the single-axis module is selected.
5.2 PLC debugging Under normal circumstances, after the connection of various components of the 802D is completed, it is necessary to start debugging the control logic of the PLC. It is essential that you start commissioning the drive after all the safety functions of the PLC have been fully prepared.
5.2.1 PLC Application Creating an 802D PLC application is very simple. This design is configured according to the Siemens 802D standard. The appropriate subroutines can be selected based on the PLC application examples (lathe bed version) and subroutine libraries provided in the system tool tray.
In the use of PLC sample program or subroutine library, you must use the system provided standard lathe and milling machine initialization file (Initial file in the tool box is downloaded to 802D using PCIN software in binary format, file path: Date\Setup\setup_t.ini ).
802D allows up to 64 subroutines, where subroutine 0 to subroutine 31 are reserved for the user, and subroutine 32 to subroutine 63 are occupied by the subroutine library. Users can choose their own programs from subroutine 32 to subroutine 63 according to the actual situation, and modify relevant parameters. The following subroutines are called in the design and modify the input and output section addresses.
5.2.2 PLC User Alarms PLC alarms are one of the most effective diagnostic tools. For example, if an operation is prohibited by the PLC logic, or an output condition is satisfied, the operator or maintenance personnel can immediately know the operation error or the reason of the hardware failure if the corresponding newsletter is activated.
Six, drive debugging
Only after all the safety functions have been validated, such as the PLC controlled emergency stop, hardware limit, and the enabling of the power feeding module, the driver can be debugged. The driver's debugging and optimization are accomplished with the help of the tool software SIMOSOMU provided on the tool tray. Starting the SIMOSOMU software is sufficient. The first parameter configuration is the selection of the motor and the PROFIBUS address. After the power feeding module enable terminal is fully closed, the coordinate axis is moved to a neutral position, and then the SIMO OMU software enters the PC control status (position open loop), and the parameters of the speed loop and the current loop can be optimized.
Seven, NC debugging
7.1 Loading Initial Files Under the manufacturer's password, the initial file (Setup_T.ini) is downloaded via the communication software PCIN in the tool box.
7.2 General Machine Data (MD10000?—MD18999)
The general machine data is mainly used for the definition of the machine coordinate axis, the setting and monitoring of PLC running time, and the setting of user data custom parameters.
MD10000[0]=X //Machine axis name X axis
MD10000[1]=Z // machine axis Z axis
MD10000[2]=SP //machine axis name SP axis
MD11240 =6 //Configuration of PROFIBUS Fieldbus
7.3 Machine data for basic channel (MD20000-MD28999)
The basic channel type machine data is mainly used for channel setting, geometry axis setting and selection, and G function selection.
MD20000=C61160 //Channel name
MD20050[1]=5 //Set the geometric axis number used for the machine to 5
MD20050[2]=2 //Set the geometry axis number for the machine to 2
MD20080[0]=X //Set the name of the axis for programming this machine in the channel
MD20080[1]=Z //Set the name of the axis for programming this machine in the channel
MD20080[2]=SP //Set the axis name for programming the machine in the channel
7.4 Shaft Machine Data (MD30000-MD38999)
Axis machine tool data is the machine tool coordinates of each channel axis speed size, direction and positioning, CNC machine tool protection, error compensation and other parameter settings.
MD30110[0 AX1]=5 //define speed given port axis number 5
MD30220[0 AX1]=5 //define feedback port axis number 5
MD30130[0 AX1]=1 //Control given output type is 1 Set value output is valid
MD30240[0 AX1]=1 //Encoder Feedback Type 1 X-axis encoder is the original signal generator, high resolution
MD31000[0 AX1]=1 //Direct measurement system X-axis scale
MD32000[AX1]=3000mm/min // Maximum axis speed of X axis
MD32010[AX1]=15000mm/min //The X axis moves fast
MD32020[AX1]=1000mm/min // X axis jogging speed
MD32020[AX1]=1000mm/min // Initial value of X-axis velocity
MD32110[AX1]= -1 // Direction of X-axis motion
MD32200[AX1]=2.3 // X axis servo gain factor
MD32600[AX1]=2000 rev/min // Servo gain factor of X axis
MD32700[AX1]=1 //X axis interpolation compensation
MD34020[AX1]=1000 mm/min // The speed of X-axis detection reference point switch
MD34060[AX1]=200 mm // Maximum distance of X-axis detection reference point switch
MD34070[AX1]=200mm/min //positioning speed of X axis returning to reference point
MD34100[AX1]=1111.471mm // The X-axis reference point (relative to the machine coordinate system)
MD36100[AX1]=0 mm // X-axis first software limit switch negative
MD36110[AX1]=1176 mm // The positive direction of the X-axis first software limit switch
MD36110[AX1]=10 // The X-axis lead screw pitch error compensation points
Eight, analog spindle debugging
For analog spindles, the 611UE's analog reference interface and TTL encoder interface can be used as speed feedback ports.
This is a method using a digital spindle to carry the spindle reference and feedback. The spindle's enable signal can be output from the 611UE's digital output Q0.X to the spindle drive.
Feed 611UE is a dual-axis module, PROFIBUS address (12), and the spindle simulates the A channel of a given 611UE. Since the simulation of the A channel is generated by an 8-bit D/A converter, the minimum analog equivalent given is 78MV. So you cannot use analog spindle positioning control.
Carrying axis X1-611UE (machine axis 1) Spindle SP1 (CT) Full digital DC drive terminal 75A (Spindle speed reference signal ±10V) Speed ​​reference signal (±10V)
Terminal 15 (Signal Ground) Signal Ground Terminal Q0.A (Digital Output) Drive Forward Enable Terminal Q1.A (Digital Output) Drive Reverse Enable Interface Signal (Encoder Interface) Spindle TTL Encoder 5V
NC-machine parameter
MD13060[4 ]=0 // Message type of bus address 10
MD30110[0,AX3]=5 //The logical axis number carrying the axis
MD30220 [0,AX3]=5 //The logical axis number carrying the axis
MD30120 [0,AX3]=5 //Encoder module number
MD30230 [0,AX3]=5 //Encoder signal port number
MD31020 [0, AX3] = 2500 // TTL encoder pulse number
MD32250 [0] = 100 // Rated output value 100%
MD32260 [0, AX3] = 9000 // Rated output speed
Driver 611UE data
P890 encoder feedback port setting = 4
P922 PROFIBUS packet type = 104
Store and then power it back on
P922 PROFIBUS packet type=0
P915[8]PZD-Setpoint assignment PB=50103
P915[9]PZD-Setpoint assignment PB=50107
Store and then power on again. Set analog output 75.A/15 to "Signal DAU1 form PROFIBUS PPO"
Set analog output Q0.A and Q1.A to "Controll via Profibus"
Go to this editor. The edited alarm text can be sent to the corresponding directory using PCIN.
Nine, pitch error compensation and backlash compensation
During the processing of the workpiece by the machine tool, errors may occur during the transmission of the measurement system and the force and the wear of the machine tool itself. The deviation of the contour of the machined workpiece from the ideal geometrical curve leads to a decrease in the quality of the machined workpiece. Especially when processing large workpieces, the loss of machining accuracy due to temperature and mechanical forces is even more severe. Therefore, before the machine leaves the factory, a certain amount of error compensation is required. Pitch error compensation and backlash compensation are the two most common compensation methods.
9.1 Pitch error compensation 9.1.1 Pitch error compensation The activation of the pitch error compensation is performed on the coordinate axis. The following relevant machine parameters must be set to activate the error compensation:
(1) MD 38000 axis maximum error compensation points According to the characteristics of the machine tool X-axis pitch error parameter compensation points is 50, which is MD 38000 [0 AX1] =10; Z-axis pitch error compensation points is 20, that is, MD 38000 [0 AX2] =20. After the parameters are set, the system automatically generates the compensation file for the corresponding axis. The compensation file is stored in the directory /NC-ACTIVE-DATA/Meas-System-err-comp.
(2) MD32700 pitch error compensation enable
MD32700=0 The pitch compensation does not take effect and modification of the compensation file is allowed.
MD32700 = 1 The pitch compensation is effective and it is not allowed to modify the compensation file.
When the parameters are set, after entering the compensation file into the system, it will not take effect until the axis returns to the reference point.
9.1.2 Editing the pitch compensation file (1) Transfer the compensation file generated by the system, edit and input the compensation value on the PC, and then transfer the compensation file to the system.
(2) Change the compensation file format to a machining program, edit the compensation value of the program, and run the machining program to write the compensation value to the system.
9.1.3 Editing the pitch compensation operation procedure (1) Modify the MD 38000 parameter: It is determined according to the maximum number of compensation points.
(2) Copy the compensation file to the hard disk or computer using hard disk data backup or PCIN software data backup. Edit the backup file and enter the compensation value (see the compensation value).
(3) Set MD32700 = 0 to transfer the modified compensation file to the system through data recovery or once as a part program.
(4) Set MD32700=1 and the new compensation value will take effect after axis reference.
9.2 Backlash compensation Due to mechanical wear during machine operation, the pitch compensation cannot meet the machining accuracy requirements. Especially if the error of the machine tool during reverse operation is too large, the designer should consider the compensation of the response gap. Its machine parameter number is MD32450, and the compensation data in this design is BACKLASH[1]=0.01.
Ten, data backup
It is very important to back up the data after the system is commissioned. The SINUMERIK 802D provides a variety of data backup methods. System data can be backed up inside the system, data can be backed up to a PC card, and data can also be transferred to a computer hard disk.
Data internal backups can be easily implemented via the "Data Storage" soft menu key. The SINUMERIK 802D is equipped with 16MB of flash memory and 16MB of static memory. All valid data is stored in the static memory. After the capacitor's energy is exhausted, the data in the static memory will be lost. Internal data backup stores all valid data in flash memory. In this way, when the data of the static memory is lost, the system detects that the static memory has been powered down when the self-check can be booted, and the system will automatically copy the data stored in the flash memory to the static memory.
The external backup of data is backed up to the PC's hard disk or floppy disk via serial communication (RS232). The communication port C0M1 or COM2 of the computer is linked with 802D through the communication software WINPCIN.
XI. Conclusion
At present, the transformation, installation and commissioning of the machine tool, electrical system and system have been completed, and the sample processing has fully achieved the desired results. After the transformation, the machine tool has been put into normal use. From the point of view of use and operation status, compared with the original machine tool after the transformation, the function has been greatly enhanced and the degree of automation has been improved. The powerful CNC system broadens the range of machined parts. Better guarantee the quality of parts processing. At the same time a high degree of automation has also greatly reduced the labor intensity of the operating workers, but put forward higher requirements for the overall quality of operating workers. From the point of view of the reliability of the machine tool, the tight structure is reasonable, and the display, various switches and indicator layouts are more suitable for the use of the operator. At the same time, a hand-held operating unit has been added so that the operator can select a more suitable operating position under different conditions. After the transformation of the machine has increased maintainability, the CNC system can monitor the movement of the control components and failures, and timely display on the display, while the use of PLC control, the entire machine control system circuit is greatly simplified, all of these Machine fault detection and maintenance are more convenient and faster.
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