设计简介
摘 要
针对大多数企业,具有数量众多和较长使用寿命的普通机床，其加工精度较低、不能批量生产，自动化程度不高，自适应性差，但考虑投资成本，产业的连续性，又不能马上被淘汰。
数控机床作为机电液气一体化的典型产品，能解决机械制造中结构复杂、精密、批量、零件多变的问题，加工质量稳定，生产效率较高。
购买新的数控机床是提高产品质量和效率的重要途径,但是成本高，许多企业在短时间内无法实现，这严重阻碍企业设备更新的步伐。为此把普通机床数控化改造，不失为一条投资少、提升产品质量及生产效率的捷径，提升企业竞争力，在我国成为制造强国的进程中，占有一席之地。本文的主要内容有：
1．对普通车床数控化改造经济性评价详细论证，确定普通车床数控化改造方案；
2．对进给系统的滚珠丝杠型号选择与装配设计，支承方式的设计与轴承型号选择，步进电机选择等进行了详细研究；
3．对常用进口数控装置系统和国产数控装置系统进行仔细比较，根据所改造的性能和精度指标来选配数控装置系统和自动刀架型号，提出选择方法；
4．根据普通车床CA6140电气控制系统和原理图与普通车床数控化改造CJK6140-A的数控系统对比分析，形成普通车床数控化改造完整的电气控制技术图；
5.为保持切削螺纹的功能，仔细研究了在主轴上安装脉冲发生器的选型，脉冲发生器直接与主轴间连接方法，并形成了相应的技术图；
6.拆卸普通机床，甩掉原有进给箱等，对主传动系统的进行大修，滑板贴塑与铲刮调试，对机床相关部件和参数进行测绘、测量；
7.绘出相应的零件图和装备图；
8．给出普通车床数控化改造的安装、调试方法
关键词：普通车床、数控、改造、滚珠丝杠
ABSTRACT
Most enterprises still have large amounts general-purpose machine tools which have longevity of service, low precision, can not adapt to mass production, low automatization and adaptability, but can not be washed out because of its low cost and continuity of enterprise’s production.
As a representative production of mechanical, electronic, hydraulic and pneumatic integration, numerically controlled machines have a stabilization quality and high efficiency, and can solve problems such as complex structure, high precision, mass production, part variety in machining.
Purchasing new numerically controlled machines is an important way to improve production precision and efficiency, but it may not come true to many enterprises because it cost much. Enterprises’ equipment updating steps are counteracted severly. So General lathe's numerically controlled reforming is a quick way that costs less, improve production precision and efficiency, and it can improve enterprises’ competitive power. So it can take its place in our way to a powerful manufacturing country. The main contents are:
1. The economical efficiency of the reform is evaluated in detail and the reforming scheme is maked according to misty optimum’s synthesize adjudicate principle.
2. The ball screw’s type, assembling, supporting, bearing type, and stepping motor of feeding system is designed.
3. The import and domestic NC systems were compared carefully, brought up a choose method and selected the NC system and automatic tool rest according to the function and accuracy index of reforming.
4. The complete electricity control diagram was drawn out according to the result of comparing CA6140’s electricity control system and principle with the reforming CJK6140-A’s NC system.
5. In order to protect the function of cutting a screw ,we carefully studied the impulse regulator and its connection with the principal axis, and draw out a technique diagram.
6. Disassembled the lathe, throw away the old feeding system, repaired the main driving system ,covered plastics on sliding surface, shoveling or scraping and testing, counted or measured the parts of the lathe.
7. Draw out parts diagrams and assemble diagram.
8 .Methods of installing and testing of general purpose lathe’s numerically controlled reforming were put forward.
Key words: General purpose lathe、 Numerical control(NC)、Reform、Ball screw
目录
1.绪论…‥…………………………………………………‥………1
1.1课题背景…………………………………………………………1
1.2机床改造的内容及意义‥………………………………………1
1.3 机床的经济型数控化改造主要解决的问题……………………2
2.设计要求‥…………………………………‥……………………3
2.1 CA6140车床的介绍……………………‥……………………3
2.2 总体方案设计要求……………………………………………4
2.3 设计参数………………………………………………‥……5
2.4 其它要求………………………………………………………8
3.进给伺服系统机械部分设计与计算…………………………………9
3.1进给系统机械结构改造设计………… ………………………9
3.2进给伺服系统机械部分的计算与选型…… …………………9
3.2.1确定系统的脉冲当量………………………………………10
3.2.2纵向滚珠丝杠螺母副的型号选择与校核步骤……………10
3.2.3横向滚珠丝杠螺母副的型号选择与校核步骤……………13
3.2.4齿轮有关计算………………………………………………14
3.2.4（1）纵向齿轮及转矩的有关计算…………………………14
3.2.4 (2)横向齿轮及转矩的有关计算…………………………18
4. 步进电动机的计算与选型……………………………………… 21
4.1步进电动机选用的基本原则…………………………………21
4.2步进电动机的选择……………………………………………22
5.主轴交流伺服电机…………………………………………………23
5.1主轴的变速范围………………………………………………23
5.2初选主轴电机的型号…………………………………………23
5.3主轴电机的校核………………………………………………23
6.刀架部分的改造……………………………………………………24
7.微机控制系统硬件电路设计…………………………………… 26
7.1控制系统的功能要求………………………………………… 26
7.2硬件电路的组成………………………………………………26
7.3设计说明………………………………………………………26
8.车床改造的结构特点……………………………………………30
8.1.滚珠丝杆………………………………………………………30
8.2导轨副…………………………………………………………30
8.3安装电动卡盘…………………………………………………30
8.4脉冲发生器……………………………………………………30
9．安装调整中应注意的问题……………………………………… 31
9.1滚珠丝杠螺母副的选择…………… ……………………… 31
9.2滚珠丝杠螺母副的调整………… ………………………… 31
9.3联轴器的安装……………………………………………… 31
9.4主轴脉冲发生器的安装………… …………………………31
9.5电动刀架的安装…………………… ………………………31
总结……………………………………………………………………32
参考文献………………………………………………………………33
针对大多数企业,具有数量众多和较长使用寿命的普通机床，其加工精度较低、不能批量生产，自动化程度不高，自适应性差，但考虑投资成本，产业的连续性，又不能马上被淘汰。
数控机床作为机电液气一体化的典型产品，能解决机械制造中结构复杂、精密、批量、零件多变的问题，加工质量稳定，生产效率较高。
购买新的数控机床是提高产品质量和效率的重要途径,但是成本高，许多企业在短时间内无法实现，这严重阻碍企业设备更新的步伐。为此把普通机床数控化改造，不失为一条投资少、提升产品质量及生产效率的捷径，提升企业竞争力，在我国成为制造强国的进程中，占有一席之地。本文的主要内容有：
1．对普通车床数控化改造经济性评价详细论证，确定普通车床数控化改造方案；
2．对进给系统的滚珠丝杠型号选择与装配设计，支承方式的设计与轴承型号选择，步进电机选择等进行了详细研究；
3．对常用进口数控装置系统和国产数控装置系统进行仔细比较，根据所改造的性能和精度指标来选配数控装置系统和自动刀架型号，提出选择方法；
4．根据普通车床CA6140电气控制系统和原理图与普通车床数控化改造CJK6140-A的数控系统对比分析，形成普通车床数控化改造完整的电气控制技术图；
5.为保持切削螺纹的功能，仔细研究了在主轴上安装脉冲发生器的选型，脉冲发生器直接与主轴间连接方法，并形成了相应的技术图；
6.拆卸普通机床，甩掉原有进给箱等，对主传动系统的进行大修，滑板贴塑与铲刮调试，对机床相关部件和参数进行测绘、测量；
7.绘出相应的零件图和装备图；
8．给出普通车床数控化改造的安装、调试方法
关键词：普通车床、数控、改造、滚珠丝杠
ABSTRACT
Most enterprises still have large amounts general-purpose machine tools which have longevity of service, low precision, can not adapt to mass production, low automatization and adaptability, but can not be washed out because of its low cost and continuity of enterprise’s production.
As a representative production of mechanical, electronic, hydraulic and pneumatic integration, numerically controlled machines have a stabilization quality and high efficiency, and can solve problems such as complex structure, high precision, mass production, part variety in machining.
Purchasing new numerically controlled machines is an important way to improve production precision and efficiency, but it may not come true to many enterprises because it cost much. Enterprises’ equipment updating steps are counteracted severly. So General lathe's numerically controlled reforming is a quick way that costs less, improve production precision and efficiency, and it can improve enterprises’ competitive power. So it can take its place in our way to a powerful manufacturing country. The main contents are:
1. The economical efficiency of the reform is evaluated in detail and the reforming scheme is maked according to misty optimum’s synthesize adjudicate principle.
2. The ball screw’s type, assembling, supporting, bearing type, and stepping motor of feeding system is designed.
3. The import and domestic NC systems were compared carefully, brought up a choose method and selected the NC system and automatic tool rest according to the function and accuracy index of reforming.
4. The complete electricity control diagram was drawn out according to the result of comparing CA6140’s electricity control system and principle with the reforming CJK6140-A’s NC system.
5. In order to protect the function of cutting a screw ,we carefully studied the impulse regulator and its connection with the principal axis, and draw out a technique diagram.
6. Disassembled the lathe, throw away the old feeding system, repaired the main driving system ,covered plastics on sliding surface, shoveling or scraping and testing, counted or measured the parts of the lathe.
7. Draw out parts diagrams and assemble diagram.
8 .Methods of installing and testing of general purpose lathe’s numerically controlled reforming were put forward.
Key words: General purpose lathe、 Numerical control(NC)、Reform、Ball screw
目录
1.绪论…‥…………………………………………………‥………1
1.1课题背景…………………………………………………………1
1.2机床改造的内容及意义‥………………………………………1
1.3 机床的经济型数控化改造主要解决的问题……………………2
2.设计要求‥…………………………………‥……………………3
2.1 CA6140车床的介绍……………………‥……………………3
2.2 总体方案设计要求……………………………………………4
2.3 设计参数………………………………………………‥……5
2.4 其它要求………………………………………………………8
3.进给伺服系统机械部分设计与计算…………………………………9
3.1进给系统机械结构改造设计………… ………………………9
3.2进给伺服系统机械部分的计算与选型…… …………………9
3.2.1确定系统的脉冲当量………………………………………10
3.2.2纵向滚珠丝杠螺母副的型号选择与校核步骤……………10
3.2.3横向滚珠丝杠螺母副的型号选择与校核步骤……………13
3.2.4齿轮有关计算………………………………………………14
3.2.4（1）纵向齿轮及转矩的有关计算…………………………14
3.2.4 (2)横向齿轮及转矩的有关计算…………………………18
4. 步进电动机的计算与选型……………………………………… 21
4.1步进电动机选用的基本原则…………………………………21
4.2步进电动机的选择……………………………………………22
5.主轴交流伺服电机…………………………………………………23
5.1主轴的变速范围………………………………………………23
5.2初选主轴电机的型号…………………………………………23
5.3主轴电机的校核………………………………………………23
6.刀架部分的改造……………………………………………………24
7.微机控制系统硬件电路设计…………………………………… 26
7.1控制系统的功能要求………………………………………… 26
7.2硬件电路的组成………………………………………………26
7.3设计说明………………………………………………………26
8.车床改造的结构特点……………………………………………30
8.1.滚珠丝杆………………………………………………………30
8.2导轨副…………………………………………………………30
8.3安装电动卡盘…………………………………………………30
8.4脉冲发生器……………………………………………………30
9．安装调整中应注意的问题……………………………………… 31
9.1滚珠丝杠螺母副的选择…………… ……………………… 31
9.2滚珠丝杠螺母副的调整………… ………………………… 31
9.3联轴器的安装……………………………………………… 31
9.4主轴脉冲发生器的安装………… …………………………31
9.5电动刀架的安装…………………… ………………………31
总结……………………………………………………………………32
参考文献………………………………………………………………33
