管道除塵機(jī)器人結(jié)構(gòu)設(shè)計(jì)【輪式】
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無錫太湖學(xué)院畢畢業(yè)業(yè)設(shè)設(shè)計(jì)計(jì)（論論文文）題目：題目：管道除塵機(jī)器人結(jié)構(gòu)設(shè)計(jì)管道除塵機(jī)器人結(jié)構(gòu)設(shè)計(jì) 信機(jī) 系系 機(jī)械工程及自動(dòng)化 專專 業(yè)業(yè)學(xué) 號： 0923825學(xué)生姓名： 趙金輝 指導(dǎo)教師： 鮑虹蘇（職稱：副教授） （職稱： ）2013 年 5 月 25 日無錫太湖學(xué)院本科畢業(yè)設(shè)計(jì)（論文）無錫太湖學(xué)院本科畢業(yè)設(shè)計(jì)（論文）誠誠 信信 承承 諾諾 書書本人鄭重聲明：所呈交的畢業(yè)設(shè)計(jì)（論文） 管道除塵機(jī)器人結(jié)構(gòu)設(shè)計(jì) 是本人在導(dǎo)師的指導(dǎo)下獨(dú)立進(jìn)行研究所取得的成果，其內(nèi)容除了在畢業(yè)設(shè)計(jì)（論文）中特別加以標(biāo)注引用，表示致謝的內(nèi)容外，本畢業(yè)設(shè)計(jì)（論文）不包含任何其他個(gè)人、集體已發(fā)表或撰寫的成果作品。 班 級： 機(jī)械 97 學(xué) 號： 0923825 作者姓名： 2013 年 5 月 25 日無無錫錫太太湖湖學(xué)學(xué)院院信信 機(jī)機(jī)系系 機(jī)機(jī)械械工工程程及及自自動(dòng)動(dòng)化化 專專業(yè)業(yè)畢畢 業(yè)業(yè) 設(shè)設(shè) 計(jì)計(jì)論論 文文 任任 務(wù)務(wù) 書書一、題目及專題：一、題目及專題：1、題目 管道除塵機(jī)器人結(jié)構(gòu)設(shè)計(jì)的研究 2、專題 二、課題來源及選題依據(jù)二、課題來源及選題依據(jù)1) 該課題為企業(yè)生產(chǎn)實(shí)際，目前，我國燃煤電廠輸灰管道的除垢方法基本上可分為化學(xué)法和物理法。經(jīng)實(shí)踐應(yīng)用，上述方法均存在一定局限性，不能同時(shí)符合環(huán)保及技術(shù)性、經(jīng)濟(jì)性要求，多數(shù)不被電廠接受。目前常用的是化學(xué)清洗法和人工振擊法。但這兩種方法也各有缺點(diǎn)。2) 本課題就是針對這一現(xiàn)狀，對輸灰管道清灰機(jī)器人進(jìn)行初步探討，以期能達(dá)到清潔環(huán)保等功能，完成該課題可對我們大學(xué)期間所學(xué)知識(shí)進(jìn)行一次全面的專業(yè)訓(xùn)練，可以培養(yǎng)我們掌握如何運(yùn)用過去所學(xué)知識(shí)去解決生產(chǎn)中實(shí)際問題的方法，增強(qiáng)從事本專業(yè)實(shí)際工作所必需的基本能力和開發(fā)研究能力，可以提高我們的專業(yè)素質(zhì)，為今后走上工作崗位打下一個(gè)良好的基礎(chǔ)。三、三、本設(shè)計(jì)（論文或其他）應(yīng)達(dá)到的要求：本設(shè)計(jì)（論文或其他）應(yīng)達(dá)到的要求：I1、能正確合理分析產(chǎn)品設(shè)計(jì)的具體要求和產(chǎn)品的功能實(shí)現(xiàn)；2、能合理根據(jù)產(chǎn)品的設(shè)計(jì)要求擬定多種解決方案，并進(jìn)行多方案優(yōu)化分析設(shè)計(jì)； 3、合理選擇和設(shè)計(jì)部件的傳動(dòng)方案，并能進(jìn)行一些必要的設(shè)計(jì)計(jì)算；4、正確選擇零部件中各零件，并能進(jìn)行一定的校核計(jì)算和優(yōu)化設(shè)計(jì)； 5、繪制機(jī)器人行走部件裝配圖；6、設(shè)計(jì)繪制零件工作圖若干；7、編制設(shè)計(jì)計(jì)算說明書 1 份；四、接受任務(wù)學(xué)生：四、接受任務(wù)學(xué)生： 機(jī) 械 97 班班 姓名姓名 趙金輝 五、開始及完成日期：五、開始及完成日期： 自自 2012 年年 11 月月 7 日日 至至 2013 年年 5 月月 25 日日六、設(shè)計(jì)（論文）指導(dǎo)（或顧問）：六、設(shè)計(jì)（論文）指導(dǎo)（或顧問）：指導(dǎo)教師指導(dǎo)教師簽名簽名 簽名簽名 簽名簽名教教研研室室主主任任學(xué)科組組長研究所所長學(xué)科組組長研究所所長簽名簽名II 系主任系主任 簽名簽名2012 年年 11 月月 12 日日摘摘 要要基于利用行星磨頭清洗技術(shù)對管道進(jìn)行清洗的目的，在總結(jié)現(xiàn)有的管道機(jī)器人設(shè)計(jì)方案的基礎(chǔ)上，根據(jù)現(xiàn)場的實(shí)際情況，論文首先對管道清洗機(jī)器人行走部分進(jìn)行方案設(shè)計(jì)，經(jīng)分析比較后確定了新型管道清洗機(jī)器人行走的較佳設(shè)計(jì)方案，并據(jù)此方案對機(jī)器人作了行走部分結(jié)構(gòu)設(shè)計(jì);對機(jī)器人的行走特性進(jìn)行了研究，提出了使機(jī)器人在管道內(nèi)能夠保持穩(wěn)定運(yùn)行的方法.通過對機(jī)器人機(jī)構(gòu)的設(shè)計(jì)和機(jī)器人在直管道內(nèi)運(yùn)動(dòng)情況的思考研究，進(jìn)一步驗(yàn)證了設(shè)計(jì)思想的可行性。最后，研究了管道清洗機(jī)器人行走系統(tǒng)的安全性能，給出了在高壓情況下保證行走系統(tǒng)安全的基本方案，為管道清洗機(jī)器人系統(tǒng)的實(shí)用化提供可靠的依據(jù)。關(guān)鍵詞關(guān)鍵詞: 管道機(jī)器人；安全防護(hù) ；行走IIIAbstract Based on the use of planetary grinding head cleaning technology for the purpose of cleaning pipes, at the conclusion of the existing pipeline robot design based on the actual situation at the scene, the first paper on the pipe cleaning robot to walk part of program design, by analysis and comparison a new pipeline after cleaning robot designed to walk a better program, and accordingly the program made a walk on part of the structure of robot design; characteristics of walking robots have been studied and put forward in the pipeline so that the robot was able to remain stable The method of operation. By the design of the robot body and the robot movement in the straight tube case study of thinking, and further verify the feasibility of the design idea. Finally, the research pipeline cleaning robot running the safety of the system performance, given the high-pressure circumstances to ensure that the basic operating system security program, for pipe cleaning robot system of the utility to provide a reliable basis. Key words: pipe robot; security; walkIV目錄目錄摘 要.IIIABSTRACT.IV緒論.11 概述.21.1 管道清洗機(jī)器人常見問題分析.21.2 除垢機(jī)器人理念.21.3 基本設(shè)計(jì)任務(wù).31.4 畢業(yè)設(shè)計(jì)的目的.32.1 管道射流清洗機(jī)器人的本體設(shè)計(jì).42.1.1 移動(dòng)方式選擇.42.1.2 傳動(dòng)方案的選擇.42.2 管道清洗機(jī)器人變管徑自適應(yīng)性方案設(shè)計(jì).62.3 動(dòng)力系統(tǒng)的設(shè)計(jì)計(jì)算.92.3.1 管道機(jī)器人行駛阻力分析.92.3.2 減速器的選擇.122.4 機(jī)器人的速度和驅(qū)動(dòng)能力校核.132.4.1 運(yùn)動(dòng)速度校核.132.4.2 驅(qū)動(dòng)能力校核.133 鏈輪傳動(dòng)的設(shè)計(jì)計(jì)算.143.1 鏈輪設(shè)計(jì)的初始條件.153.2 鏈輪計(jì)算結(jié)果.153.3 歷史結(jié)果.164 蝸輪蝸桿的設(shè)計(jì)計(jì)算.184.1 蝸輪蝸桿基本參數(shù)設(shè)計(jì).184.1.1 普通蝸桿設(shè)計(jì)輸入?yún)?shù).184.1.2 材料及熱處理.194.1.3 蝸桿蝸輪基本參數(shù).204.1.4 蝸蝸輪精度.214.1.5 強(qiáng)度剛度校核結(jié)果和參數(shù).224.1.6 自然通風(fēng)散熱計(jì)算.224.2 蝸桿軸的結(jié)構(gòu)設(shè)計(jì).234.2.1 軸的強(qiáng)度較核計(jì)算.234.2.2 軸的結(jié)構(gòu)設(shè)計(jì).244.2.3 鍵的校核.255 彈簧的設(shè)計(jì)計(jì)算.25I6 安全性能.26結(jié)論.27參考文獻(xiàn).28致謝.300 緒論緒論1.1 本課題研究的內(nèi)容和意義本課題研究的內(nèi)容和意義用于石油、天然氣乃至民用上下水等管道在傳輸液、氣體過程中，因溫度、壓力不同及介質(zhì)與管道之間的物理化學(xué)作用，常常會(huì)高溫結(jié)焦，生成油垢、水垢，存留沉積物，腐蝕物等，使有效傳輸管徑減少，效率下降，物耗、能耗增加，工藝流程中斷，設(shè)備失效，發(fā)生安全事故。盡管通過添加化學(xué)劑，采用合理的工藝參數(shù)，進(jìn)行水質(zhì)處理措施可以在一定程度上改善這些情況，但要完全避免污垢的產(chǎn)生是不可能的。我國的管道清洗行業(yè)長期以來 80%采用的是化學(xué)方法以及手工清洗和機(jī)械清洗方法，成本高、效率低、污染環(huán)境等，遠(yuǎn)遠(yuǎn)不能滿足現(xiàn)代社會(huì)日益增長的要求。探索和開發(fā)高效的清洗方法成為工業(yè)生產(chǎn)和人民生活的不可或缺的環(huán)節(jié)。利用行星磨頭清洗是一種新的清洗方法。與化學(xué)清洗及手工、機(jī)械清洗相比，具有清洗質(zhì)量好、效率高、適應(yīng)性強(qiáng)、成本低等一系列優(yōu)點(diǎn)，可達(dá)到返舊還新的效果。作為一種清潔、高效、對環(huán)境無污染的清洗技術(shù)，具有可觀的經(jīng)濟(jì)和社會(huì)效益。1.2 國內(nèi)外發(fā)展?fàn)顩r國內(nèi)外發(fā)展?fàn)顩r目前在管道清洗過程中，清洗設(shè)備絕大部分是采用無動(dòng)力纜繩拖拉行走方式來進(jìn)行清洗，無法根據(jù)管道的內(nèi)部情況進(jìn)行清洗參數(shù)的動(dòng)態(tài)調(diào)整，管徑的適應(yīng)能力較差。為了解決這個(gè)問題，著眼于管道行走清洗機(jī)器人的研究開發(fā)，而在國內(nèi)這方面研究尚少。為了較好地解決管道(束)的清洗難題，開發(fā)和研制管道清洗機(jī)器人勢在必行。我們設(shè)計(jì)管道清洗機(jī)器人是把行星磨頭清洗技術(shù)與機(jī)器人技術(shù)結(jié)合起來，進(jìn)行綜合設(shè)計(jì)開發(fā)，因此它的深入研究也將推動(dòng)管道清洗技術(shù)的發(fā)展。1.3 本課題應(yīng)達(dá)到的要求本課題應(yīng)達(dá)到的要求作為高壓水和化學(xué)清洗的有效補(bǔ)充手段，行走式管路清洗方法具有一定的獨(dú)特性：如成本低廉、安全性好、無任何環(huán)境污染、水電消耗非常小。尤其是在化學(xué)清洗和高壓水清洗方法無法應(yīng)用或成本不允許的情況下,利用除垢機(jī)器人清洗能夠發(fā)揮獨(dú)特的作用,并取得良好的效果。我們采用的是壓縮空氣噴洗機(jī)器人。除垢機(jī)器人的首要要解決的問題就是行走問題，怎樣使機(jī)器人在管道中行走是除垢機(jī)器人能否成功完成的重要環(huán)節(jié)之一。目前管內(nèi)機(jī)器人的驅(qū)動(dòng)方式有自驅(qū)動(dòng) (自帶動(dòng)力源)、利用流體推力、通過彈性桿外加推力三種方式。根據(jù)輸灰管道和回水管道內(nèi)的實(shí)際情況，管道除垢機(jī)器人宜采用 自驅(qū)動(dòng)方式。采用雙步進(jìn)電機(jī)驅(qū)動(dòng)，通過諧波減速器將動(dòng)力傳遞給行走裝置。盡管自驅(qū)動(dòng)管內(nèi)機(jī)器人行走可以采用的輪式、腳式爬行式、蠕動(dòng)式，履帶式等多種形式，但因管道內(nèi)有灰、灰垢和其他雜物，環(huán)境惡劣，附著能力差采用履帶式方式比較合適，可以增大行走機(jī)構(gòu)和管道內(nèi)表面的接觸面積，提高行走時(shí)機(jī)器人的附著能力 。 存檔編碼：無無錫錫太太湖湖學(xué)學(xué)院院 2009 屆屆畢畢業(yè)業(yè)作作業(yè)業(yè)周周次次進(jìn)進(jìn)度度計(jì)計(jì)劃劃、檢檢查查落落實(shí)實(shí)表表 系別：信機(jī)系 班級：機(jī)械97 學(xué)生姓名：趙金輝 課題（設(shè)計(jì)）名稱：管道機(jī)器人除塵結(jié)構(gòu)設(shè)計(jì) 開始日期：2012年11月12日周次起止日期工作計(jì)劃、進(jìn)度每周主要完成內(nèi)容存在問題、改進(jìn)方法指導(dǎo)教師意見并簽字備 注1-32012年11月12日-2012年12月 2日老師下達(dá)畢業(yè)設(shè)計(jì)任務(wù)，學(xué)生初步閱讀資料，完成畢業(yè)設(shè)計(jì)開題報(bào)告。按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計(jì)開題報(bào)告書所學(xué)知識(shí)有限，只能完成一些零碎的東西,詢問指導(dǎo)老師4-102012年12月3日-2013年1月20日指導(dǎo)專業(yè)實(shí)訓(xùn)通過實(shí)習(xí)了解熟悉部門的工作情況經(jīng)驗(yàn)的不足，需要時(shí)間的積累和與人的溝通11-122013年1月21日-3月1日指導(dǎo)畢業(yè)實(shí)習(xí)和指導(dǎo)老師的交流完成畢業(yè)實(shí)習(xí)報(bào)告對相關(guān)課題的了解不深，需查閱相關(guān)資料132013年3月4日-3月8日機(jī)器人傳動(dòng)移動(dòng)方式的確定分析產(chǎn)品圖、分析結(jié)構(gòu)，優(yōu)選確定設(shè)計(jì)方案存在問題：缺乏實(shí)際操作經(jīng)驗(yàn)，制定的設(shè)計(jì)方案不合理。改進(jìn)方法：多去咨詢老師了解實(shí)際生產(chǎn)過程，重新確立合理的設(shè)計(jì)方案。142013年3月11日-3月15日設(shè)計(jì)方案分析與計(jì)算確定設(shè)計(jì)結(jié)構(gòu)，計(jì)算所需各種尺寸存在問題：結(jié)構(gòu)設(shè)計(jì)不合理，尺寸計(jì)算有誤差，對立式袋裝機(jī)縱封裝置不是很清楚改進(jìn)方法：查閱多種參考資料，改進(jìn)設(shè)計(jì)結(jié)構(gòu)，提高計(jì)算正確率。152013年3月18日-3月22日動(dòng)力系統(tǒng)的設(shè)計(jì)查看相關(guān)資料，對系統(tǒng)粗步了解存在問題：對整理搜集信息方面還是有所欠缺，盲目搜索。改進(jìn)方法：查閱資料時(shí)要分類，多多請教老師162013年3月25日-3月29日減速器的選擇查看資料，選擇合適的減速器存在問題：對機(jī)器人的分析不夠改進(jìn)方法：對機(jī)器人的原理繼續(xù)分析，選擇合理的減速器172013年4月1日-4月5日機(jī)器人速度和驅(qū)動(dòng)能力校核查閱相關(guān)資料，計(jì)算選擇出合理的參數(shù)和相關(guān)的尺寸有些細(xì)節(jié)方面不懂的地方，需向老師請教182013年4月8日-4月12日鏈輪傳動(dòng)的設(shè)計(jì)計(jì)算查閱相關(guān)資料鏈輪傳動(dòng)的計(jì)算有些細(xì)節(jié)方面不懂的地方，需向老師請教192013年4月15日-4月19日渦輪蝸桿的結(jié)構(gòu)設(shè)計(jì)查看相關(guān)資料，并繪出渦輪蝸桿的相關(guān)資料有些細(xì)節(jié)方面不懂的地方，還需向老師請教202013年4月22日-4月26日繪制零件圖，及裝配圖根據(jù)最終確定尺寸繪制CAD零件圖請老師檢查圖紙，修改細(xì)節(jié)問題212013年4月29日-5月3日說明書、摘要、小結(jié)繪制裝置零件圖，不少于6個(gè)存在問題：零件圖的表達(dá)方案不合理，尺寸不符合實(shí)際需要，技術(shù)要求不規(guī)范。改進(jìn)方法：修改零件圖的表達(dá)方案，完善尺寸標(biāo)注和技術(shù)要求。222013年5月6日-5月10日檢查、指導(dǎo)設(shè)計(jì)說明書、摘要和小結(jié)編寫完成設(shè)計(jì)說明書、摘要和小結(jié)存在問題：零件圖的表達(dá)方案不合理，尺寸不符合實(shí)際需要，技術(shù)要求不規(guī)范。改進(jìn)方法：修改零件圖的表達(dá)方案，完善尺寸標(biāo)注和技術(shù)要求。232013年5月13日-5月17日檢查、指導(dǎo)設(shè)計(jì)說明書、摘要和小結(jié)編寫完成設(shè)計(jì)說明書、摘要和小結(jié)存在問題：零件圖的表達(dá)方案不合理，尺寸不符合實(shí)際需要，技術(shù)要求不規(guī)范。改進(jìn)方法：修改零件圖的表達(dá)方案，完善尺寸標(biāo)注和技術(shù)要求。242013年5月20日-5月25日修改論文格式通過老師檢查發(fā)現(xiàn)格式不正確之處回去修改按照學(xué)校給的樣板自習(xí)修改格式 說明：1、“工作計(jì)劃、進(jìn)度”、“指導(dǎo)教師意見并簽字”由指導(dǎo)教師填寫，“每周主要完成內(nèi)容”，“存在問題、改進(jìn)方法”由學(xué)生填寫。2、本表由各系妥善歸檔，保存?zhèn)洳?。周次起止日期工作?jì)劃、進(jìn)度每周主要完成內(nèi)容存在問題、改進(jìn)方法指導(dǎo)教師意見并簽字備 注編號
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目： 管道除塵機(jī)器人行星結(jié)構(gòu)設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化專業(yè)
學(xué) 號： 0923825
學(xué)生姓名： 趙金輝
指導(dǎo)教師： 鮑虹蘇 （職稱：高工）
（職稱： ）
2013年5月25日
目 錄
一、畢業(yè)設(shè)計(jì)（論文）開題報(bào)告
二、畢業(yè)設(shè)計(jì)（論文）外文資料翻譯及原文
三、學(xué)生“畢業(yè)論文（論文）計(jì)劃、進(jìn)度、檢查及落實(shí)表”
四、實(shí)習(xí)鑒定表
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開題報(bào)告
題目： 管道除塵機(jī)器人行星結(jié)構(gòu)設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化 專業(yè)
學(xué) 號： 0923835
學(xué)生姓名： 趙金輝
指導(dǎo)教師： 鮑虹蘇 （職稱：高工 ）
（職稱： ）
2012年11月14日
課題來源
某企業(yè)生產(chǎn)實(shí)際
科學(xué)依據(jù)（包括課題的科學(xué)意義；國內(nèi)外研究概況、水平和發(fā)展趨勢；應(yīng)用前景等）
目前，我國燃煤電廠輸灰管道的除垢方法基本上可分為化學(xué)法和物理法。經(jīng)實(shí)踐應(yīng)用，上述方法均存在一定局限性，不能同時(shí)符合環(huán)保及技術(shù)性、經(jīng)濟(jì)性要求，多數(shù)不被電廠接受。目前常用的是化學(xué)清洗法和人工振擊法。但這兩種方法也各有缺點(diǎn)。
本課題就是針對這一現(xiàn)狀，對輸灰管道清灰機(jī)器人進(jìn)行初步探討，以期能達(dá)到清潔環(huán)保等功能，完成該課題可對我們大學(xué)期間所學(xué)知識(shí)進(jìn)行一次全面的專業(yè)訓(xùn)練，可以培養(yǎng)我們掌握如何運(yùn)用過去所學(xué)知識(shí)去解決生產(chǎn)中實(shí)際問題的方法，增強(qiáng)從事本專業(yè)實(shí)際工作所必需的基本能力和開發(fā)研究能力，可以提高我們的專業(yè)素質(zhì)，為今后走上工作崗位打下一個(gè)良好的基礎(chǔ)。
研究內(nèi)容
除垢機(jī)器人的首先要解決的問題就是行走問題，怎樣使機(jī)器人在管道中行走是除垢機(jī)器人能否成功完成的重要環(huán)節(jié)之一。
管道除垢機(jī)器人宜采用自驅(qū)動(dòng)方式。并采用履帶式方式比較合適，可以增大行走機(jī)構(gòu)和管道內(nèi)表面的接觸面積，提高行走時(shí)機(jī)器人的附著能力 。
本課題就是針對這一結(jié)構(gòu)進(jìn)行初步的設(shè)計(jì)。
擬采取的研究方法、技術(shù)路線、實(shí)驗(yàn)方案及可行性分析
在畢業(yè)實(shí)習(xí)調(diào)研以及查閱有關(guān)資料的基礎(chǔ)上，擬定清洗機(jī)器人行走部件結(jié)構(gòu)設(shè)計(jì)的最初方案，通過與指導(dǎo)老師協(xié)商討論方案的可行性，并確定最終設(shè)計(jì)方案，并完成相關(guān)的設(shè)計(jì)計(jì)算及相應(yīng)的設(shè)計(jì)圖紙。
研究計(jì)劃及預(yù)期成果
通過現(xiàn)場調(diào)研、模擬、建模、實(shí)驗(yàn)和機(jī)器調(diào)試，根據(jù)最初擬定的清洗機(jī)器人行走部件結(jié)構(gòu)設(shè)計(jì)的方案，設(shè)計(jì)出具有一定清灰功能的清洗機(jī)器人，合理確定清灰機(jī)器人的驅(qū)動(dòng)方式及行走形式，并選用最佳的設(shè)計(jì)方案，達(dá)到清灰功能。
特色或創(chuàng)新之處
適用于煤電廠管道清灰的優(yōu)化設(shè)計(jì)，力求在清潔環(huán)保的前提下最大限度的減少企業(yè)成本，并降低工人的勞動(dòng)強(qiáng)度和生產(chǎn)成本。
已具備的條件和尚需解決的問題
針對實(shí)際煤電企業(yè)管道清灰存在的問題，綜合所學(xué)的機(jī)械理論設(shè)計(jì)、方法及工藝裝備，探索和開發(fā)高效的清洗方法，將行星磨頭清洗技術(shù)與機(jī)器人技術(shù)結(jié)合起來，進(jìn)行綜合設(shè)計(jì)開發(fā)管道清洗機(jī)器人，進(jìn)而提升學(xué)生開發(fā)和創(chuàng)新機(jī)械產(chǎn)品的能力。
指導(dǎo)教師意見
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見
教研室主任簽名：
年 月 日
系意見
主管領(lǐng)導(dǎo)簽名：
年 月 日
Numerical control technology and equipping development trend and countermeasure
Numerical control technology is the technology controlled to mechanical movement and working course with digital information, integrated products of electro mechanics that the numerical control equipment is the new technology represented by numerical control technology forms to the manufacture industry of the tradition and infiltration of the new developing manufacturing industry, namely the so-called digitization is equipped, its technological range covers a lot of fields: (1)Mechanical manufacturing technology; (2)Information processing , processing , transmission technology; (3)Automatic control technology; (4)Servo drive technology; (5)Technology of the sensor ; (6)Software engineering ,etc..
Development trend of a numerical control technology
The application of numerical control technology has not only brought the revolutionary change to manufacturing industry of the tradition, make the manufacturing industry become the industrialized symbol , and with the constant development of numerical control technology and enlargement of the application, the development of some important trades (IT , automobile , light industry , medical treatment ,etc. ) to the national economy and the people's livelihood of his plays a more and more important role, because the digitization that these trades needed to equip has already been the main trend of modern development. Numerical control technology in the world at present and equipping the development trend to see, there is the following several respect [1- ] in its main research focus .
1.A high-speed , high finish machining technology and new trend equipped
The efficiency , quality are sub-manufacturing technology. High-speed , high finish machining technology can raise the efficiency greatly , improve the quality and grade of the products, shorten production cycle and improve the market competitive power. Japan carries the technological research association first to classify it as one of the 5 great modern manufacturing technologies for this, learn (CIRP ) to confirm it as the centre in the 21st century and study one of the directions in international production engineering.
In the field of car industry, produce one second when beat such as production of 300,000 / vehicle per year, and many variety process it is car that equip key problem that must be solved one of; In the fields of aviation and aerospace industry, spare parts of its processing are mostly the thin wall and thin muscle, rigidity is very bad, the material is aluminium or aluminium alloy, only in a situation that cut the speed and cut strength very small high, could process these muscles , walls . Adopt large-scale whole aluminium alloy method that blank " pay empty " make the wing recently, such large-scale parts as the fuselage ,etc. come to substitute a lot of parts to assemble through numerous rivet , screw and other connection way, make the intensity , rigidity and dependability of the component improved. All these, to processing and equiping the demand which has proposed high-speed , high precise and high flexibility.
According to EMO2001 exhibition situation, high-speed machining center is it give speed can reach 80m/min is even high , air transport competent speed can up to 100m/min to be about to enter. A lot of automobile factories in the world at present, including Shanghai General Motors Corporation of our country, have already adopted and substituted and made the lathe up with the production line part that the high-speed machining center makes up . HyperMach lathe of U.S.A. CINCINNATI Company enters to nearly biggest 60m/min of speed, it is 100m/min to be fast, the acceleration reaches 2g, the rotational speed of the main shaft has already reached 60 000r/min. Processing a thin wall of plane parts, spend 30min only, and same part general at a high speed milling machine process and take 3h, the ordinary milling machine is being processed to need 8h; The speed and acceleration of main shaft of dual main shaft lathes of Germany DMG Company are up to 12* separately! 000r/mm and 1g.
In machining accuracy, the past 10 years, ordinary progression accuse of machining accuracy of lathe bring 5|ìm up to from 10|ìm already, accurate grades of machining center from 3- 5|ìm, rise to 1- 1.5|ìm, and ultraprecision machining accuracy is it enter nanometer grade to begin already (0.01|ìm).
In dependability, MTBF value of the foreign numerical control device has already reached above 6 000h, MTBF value of the servo system reaches above 30000h, demonstrate very high dependability .
In order to realize high-speed , high finish machining, if the part of function related to it is electric main shaft , straight line electrical machinery get fast development, the application is expanded further.
1.2 Link and process and compound to process the fast development of the lathe in 5 axes
Adopt 5 axles to link the processing of the three-dimensional curved surface part, can cut with the best geometry form of the cutter , not only highly polished, but also efficiency improves by a large margin . It is generally acknowledged , the efficiency of an 5 axle gear beds can equal 2 3 axle gear beds , is it wait for to use the cubic nitrogen boron the milling cutter of ultra hard material is milled and pared at a high speed while quenching the hard steel part, 5 axles link and process 3 constant axles to link and process and give play to higher benefit. Because such reasons as complicated that 5 axles link the numerical control system , host computer structure that but go over, it is several times higher that its price links the numerical control lathe than 3 axles , in addition the technological degree of difficulty of programming is relatively great, have restricted the development of 5 axle gear beds.
At present because of electric appearance of main shaft, is it realize 5 axle complex main shaft hair structure processed to link greatly simplify to make, it makes degree of difficulty and reducing by a large margin of the cost, the price disparity of the numerical control system shrinks . So promoted 5 axle gear beds of head 無效 of complex main shaft and compound to process the development of the lathe (process the lathe including 5 ).
At EMO2001 exhibition, new Japanese 5 of worker machine process lathe adopt complex main shaft hair, can realize the processing of 4 vertical planes and processing of the wanton angle , make 5 times process and 5 axles are processed and can be realized on the same lathe, can also realize the inclined plane and pour the processing of the hole of awls . Germany DMG Company exhibits the DMUVoution series machining center, but put and insert and put processing and 5 axles 5 times to link and process in once, can be controlled by CNC system or CAD/CAM is controlled directly or indirectly.
1.3 Become the main trend of systematic development of contemporary numerical control intelligently , openly , networkedlily
The numerical control equipment in the 21st century will be sure the intelligent system, the intelligent content includes all respects in the numerical control system: It is intelligent in order to pursue the efficiency of processing and process quality, control such as the self-adaptation of the processing course, the craft parameter is produced automatically; Join the convenient one in order to improve the performance of urging and use intelligently, if feedforward control , adaptive operation , electrical machinery of parameter , discern load select models , since exactly makes etc. automatically automatically; The ones that simplified programming , simplified operating aspect are intelligent, for instance intelligent automatic programming , intelligent man-machine interface ,etc.; There are content of intelligence diagnose , intelligent monitoring , diagnosis convenient to be systematic and maintaining ,etc..
Produce the existing problem for the industrialization of solving the traditional numerical control system sealing and numerical control application software. A lot of countries carry on research to the open numerical control system at present, such as NGC of U.S.A. (The Next Generation Work-Station/Machine Control), OSACA of European Community (Open System Architecture for Control within Automation Systems), OSEC (Open System Environment for Controller ) of Japan, ONC (Open Numerical Control System ) of China ,etc.. The numerical control system melts to become the future way of the numerical control system open. The so-called open numerical control system is the development of the numerical control system can be on unified operation platform, face the lathe producer and end user, through changing, increasing or cutting out the structure target(numerical control function), form the seriation, and can use users specially conveniently and the technical know-how is integrated in the control system, realize the open numerical control system of different variety , different grade fast, form leading brand products with distinct distinction. System structure norm of the open numerical control system at present, communication norm , disposing norm , operation platform , numerical control systematic function storehouse and numerical control systematic function software developing 包含ument ,etc. are the core of present research.
The networked numerical control equipment is a new light spot of the fair of the internationally famous lathe in the past two years. Meeting production line , manufacture system , demand for the information integration of manufacturing company networkedly greatly of numerical control equipment, realize new manufacture mode such as quick make , fictitious enterprise , basic Entrance that the whole world make too. Some domestic and international famous numerical control lathes and systematic manufacturing companies of numerical control have all introduced relevant new concepts and proto無效s of a machine in the past two years, if in EMO2001 exhibition, " CyberProduction Center " that the company exhibits of mountain rugged campstool gram in Japan (Mazak ) (intellectual central production control unit, abbreviated as CPC); The lathe company of Japanese big Wei (Okuma ) exhibits " IT plaza " (the information technology square , is abbreviated as IT square ); Open Manufacturing Environment that the company exhibits of German Siemens (Siemens ) (open the manufacturing environment, abbreviated as OME),etc., have reflected numerical control machine tooling to the development trend of networked direction.
2 pairs of basic estimations of technology and industry development of numerical control of our country
The technology of numerical control of our country started in 1958, the development course in the past 50 years can roughly be divided into 3 stages: The first stage is from 1958 to 1979, namely closed developing stage. In this stages, because technology of foreign countries blockade and basic restriction of terms of our country, the development of numerical control technology is comparatively slow. During " Sixth Five-Year Plan Period " , " the Seventh Five-Year Plan Period " of the country in second stage and earlier stage in " the Eighth Five-Year Plan Period ", namely introduce technology, digest and assimilate, the stage of establishing the system of production domesticization arisesing tentatively. At this stage , because of reform and opening-up and national attention , and study the improvement of the development environment and international environment, research , development and all making considerable progress in production domesticization of the products of the technology of numerical control of our country. The third stage is and during the " Ninth Five-Year Plan Period " on the later stage in " the Eighth Five-Year Plan Period " of the country, namely implement the research of industrialization, enter market competition stage. At this stage , made substantive progress in industrialization of the domestic numerical control equipment of our country. In latter stage for " the Ninth Five-Year Plan ", the domestic occupation rate of market of the domestic numerical control lathe is up to 50%, it is up to 10% too to mix the domestic numerical control system (popular ).
Make a general survey of the development course in the past 50 years of technology of numerical control of our country, especially through tackling key problems of 4 Five-Year Plans, all in all has made following achievements.
a.Have establish the foundation of the technical development of numerical control, has mastered modern numerical control technology basically. Our country has already, the numerical control host computer , basic technology of special plane and fittings grasped and driven from the numerical control system and servoly basically now, among them most technology have already possessed and commercialized the foundation developed , some technology has already, industrialization commercialized.
.Have formed the industrial base of numerical control tentatively. In tackling key problems the foundation that the achievement and some technology commercialize , set up the systematic factories of numerical control with production capacity in batches such as numerical control in Central China , numerical control of the spaceflight etc.. Electrical machinery plant of Lanzhou, such factory and the first machine tool plant of Beijing , the first machine tool plant of Jinan ,etc. several numerical control host computer factories of a batch of servo systems and servo electrical machineries as the numerical control in Central China,etc.. These factories have formed the numerical control industrial base of our country basically.
Have set up a numerical control research, development , managerial talent's basic team .
Though has made considerable progress in research and development and industrialization of numerical control technology, but we will realize soberly, the research and development of the technology of advanced numerical control of our country, especially there is greater disparity in current situation and current demand of our country of engineering level in industrialization. Though very fast from watching the development of our country vertically, have disparity horizontally more than (compare foreign countries with ) not merely engineering level, there is disparity too in development speed in some aspects, namely the engineering level disparity between some high-grade , precision and advanced numerical control equipment has the tendency to expand . Watch from world , estimate roughly as follows about the engineering level of numerical control of our country and industrialization level.
On the engineering level, in probably backward 10- 1 years with the advanced level in foreign countries, it is bigger in high-quality precision and sophisticated technology.
On the industrialization level, the occupation rate of market is low, the variety coverage rate is little, have not formed the large-scale production yet; The specialized level of production of function part and ability of forming a complete set are relatively low; Appearance quality is relatively poor; Dependability is not high, the commercialized degree is insufficient; One's own brand effect that the domestic numerical control system has not been set up yet, users have insufficient confidence.
On the ability of sustainable development, research and development of numerical control technology , project ability are relatively weak to the competition; It is not strong that the technological application of numerical control expands dynamics; Research , formulation that relevant standards are normal lag behind.
It is analysed that the main reason for having above-mentioned disparity has the following several respect.
Realize the respect. Know to industry's process arduousness , complexity and long-term characteristic of domestic numerical control insufficiently; It is difficult to underestimate to add strangling , system ,etc. to the unstandard , foreign blockade of the market; It is not enough to analyse to the technological application level and ability of numerical control of our country.
System. Pay close attention to numerical control industrialization many in the issue , consider numerical control industrialization little in the issue synthetically in terms of the systematic one , industry chain in terms of technology; Have not set up related system , perfect training , service network of intact high quality ,etc. and supported the system.
Mechanism. It causes the brain drain, restraining technology and technological route from innovating again , products innovation that the bad machine is made, and has restricted the effective implementation of planning , has often planned the ideal , implement the difficulty.
Technology. The autonomous innovation in technology of enterprises is indifferent, the project of key technology is indifferent. The standard of the lathe lags behind, the level is relatively low, it is not enough for new standard of the numerical control system to study.
數(shù)控技術(shù)和裝備發(fā)展趨勢及對策
數(shù)控技術(shù)是用數(shù)字信息對機(jī)械運(yùn)動(dòng)和工作過程進(jìn)行控制的技術(shù)，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(jī)電一體化產(chǎn)品，即所謂的數(shù)字化裝備，其技術(shù)范圍覆蓋很多領(lǐng)域：(1)機(jī)械制造技術(shù)；(2)信息處理、加工、傳輸技術(shù)；(3)自動(dòng)控制技術(shù)；(4)伺服驅(qū)動(dòng)技術(shù)；(5)傳感器技術(shù)；(6)軟件技術(shù)等。
1 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(kuò)大，他對國計(jì)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，因?yàn)檫@些行業(yè)所需裝備的數(shù)字化已是現(xiàn)代發(fā)展的大趨勢。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(diǎn)有以下幾個(gè)方面［1～4］。
1．1 高速、高精加工技術(shù)及裝備的新趨勢
效率、質(zhì)量是先進(jìn)制造技術(shù)的主體。高速、高精加工技術(shù)可極大地提高效率，提高產(chǎn)品的質(zhì)量和檔次，縮短生產(chǎn)周期和提高市場競爭能力。為此日本先端技術(shù)研究會(huì)將其列為5大現(xiàn)代制造技術(shù)之一，國際生產(chǎn)工程學(xué)會(huì)（CIRP）將其確定為21世紀(jì)的中心研究方向之一。
在轎車工業(yè)領(lǐng)域，年產(chǎn)30萬輛的生產(chǎn)節(jié)拍是40秒/輛，而且多品種加工是轎車裝備必須解決的重點(diǎn)問題之一；在航空和宇航工業(yè)領(lǐng)域，其加工的零部件多為薄壁和薄筋，剛度很差，材料為鋁或鋁合金，只有在高切削速度和切削力很小的情況下，才能對這些筋、壁進(jìn)行加工。近來采用大型整體鋁合金坯料
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