The installation, adjustment and completion acceptance of CNC machinery are the key steps in the initial management method of machinery and equipment. When the machine tool is shipped, it must first start installation, adjustment, and trial operation, and it can be put into use after the precision engineering acceptance has reached the standard. Most of the CNC machine tools are all dissolved into components, loaded and transported, and then assembled and adjusted again in time.
1. Assembly of CNC machinery Generally, the installation of CNC machinery can be carried out according to the following procedures.
1. After unpacking and reviewing the CNC machinery in time, the equipment maintenance unit should quickly organize the machinery and equipment managers, installation staff, and their salesmen to unpack and check. If it is an imported product, it must also have an import business reception agent China Customs inspection staff, etc. The important contents of the inspection are:
1) the waybill;
2) Review any technical documents such as actual operation, maintenance and use instructions, sample drawing materials, qualification certificates and other technical documents that should be reviewed;
3) According to the terms of the contract, check the total number, specifications and models of accessories, accessories and special tools against the freight bill and their integrity;
4) Check that the server, CNC machine cabinet, workbench, etc. have significant impact damage, deformation, moisture return, rust, etc., and fill in the "Machine Equipment Unpacking Project Acceptance Registration Form" for filing. If the unpacking works acceptance is found to be damaged or neglected, the department or the investor should be contacted immediately. Especially for imported products, you should pay attention to the deadline for settlement of claims.
2. Preparatory work before installation Read and understand the installation equipment level materials carefully, master the basic main standards and assembly regulations of the manufacturer for the machine tool, and do a good job in the preparation work before installation.
3. Component assembly Before the machine tool is assembled, the anti-embroidery architectural coatings on the slide rails and the rolling surfaces and contact areas should be cleaned and tidy, and the components of the machine tool, such as CNC machine tool cabinets, electrical control cabinets, vertical poles, CNC knives, robotic arms, etc. should be assembled. into the whole machine. When assembling, be sure to use the original positioning pins, precise positioning blocks and other precise positioning components to ensure the adjustment accuracy.
4. The connection of the oil pipeline and the bronchus is based on the electrical wiring diagram and the hydraulic machine pipeline diagram in the machine tool instruction manual, and the relevant cables and pipelines are connected according to the identification numbers. When connecting, pay special attention to reliable contact and sealing, otherwise, oil seepage and water seepage during debugging will cause inconvenience to debugging. When connecting oil pipelines and bronchial tubes, it is necessary to avoid dirt from entering the pipelines from the sockets, resulting in abnormality of all hydraulic presses and standard air pressure systems. After the connection of cables and pipes is completed, fix each pipe well and install protective covers to ensure a neat appearance.
5. Connection of CNC system;
1) The connection of external cables is the connection between the value control equipment and the MDI/CRT module, the weak current control box, the actual operation control panel of the machine tool, the driving force line of the servo motor motor and the spindle bearing motor, and the feedback power line, etc. Such connections must meet the requirements of any given connection guidelines. The grounding wire connection generally adopts the radiation type grounding device method, that is, the data signal ground in the CNC machine tool cabinet, the weak current ground, the machine tool ground, etc. are connected to the common grounding address, and the common grounding address is then connected to the ground. The cross-section of the grounding device cable between the CNC machine tool cabinet and the weak current cabinet should be above 5.5mm2. The public connection address should be in better contact with the ground, and the ground wire resistance is generally specified to be lower than 4~7Ω.
2) The connection of the power plug The connection of the input cable of the toroidal transformer of the index control cabinet and the connection of the winding tap of the servo motor transformer. It should be noted that the transformer of overseas machine tool manufacturers has several taps. When connecting, it needs to be connected properly according to the details of the power supply system in my country.
6. Periodic inspection and adjustment before plug-in test run 1) Input the power supply voltage, frequency and determination of neutral and live wire.
(1) Determination of input power supply voltage and frequency In my country, the style of power supply system is AC 380V, three-phase; AC 220V, single-phase; frequency is 50HZ. And some of our country's power supply system style is not the same as in our country. For example, in Japan, the phase voltage of three-phase communication is 220V, the single-phase power is 100V, and the frequency is 60HZ. In order to better meet the different power supply system conditions in different countries in the world, the machinery and equipment at their entrances and exits are generally equipped with toroidal transformers. There are several taps on the transformer for us to choose and apply. There is a 50/60HZ frequency switch on the circuit board. Therefore, before adjusting the imported CNC machinery or CNC system, you must first understand any instructions for use. Before plugging in, you should carefully type in whether the power supply voltage is appropriate, and whether the frequency power switch has been placed in the "50HZ" part.
(2) Determination of power supply voltage variation range Generally, the allowable working voltage variation range of CNC systems is 85%-110% of the rated current, while some western systems have higher requirements. If the range of power supply voltage changes exceeds the requirements of the CNC system, it is necessary to configure the AC adjustable regulated power supply, otherwise it will endanger the accuracy and reliability of the CNC machine tool.
(3) Determination of the power supply voltage, zero line and live line. At this stage, the power supply system switching power supply of the tool movement control module and the spindle bearing control module of the CNC machine tool is mostly selected from the thyristor hydraulic control system. If the neutral line and live line are not correct, connect Switching the power supply is very likely to burn out the key fuse of the tool operation module. There are two ways to check the neutral line and live line: one is to use the phase sequence meter to measure accurately. When the neutral line and live line wiring method is appropriate, the phase sequence meter rotates clockwise, otherwise it is incorrect. At this time, R, S can be adjusted , T in any two can be interchanged. The second is to use a multi-line digital oscilloscope to observe the waveform between the two phases. The two phases are 120° apart in phase difference.
2) Determine whether the output terminal of the DC regulated power supply is short-circuited to ground. If there is a short-circuit fault, be sure to clear it, otherwise the DC adjustable regulated power supply module will be burned.
3) Connect to the switching power supply of the CNC machine tool cabinet, and check the output voltage of each output voltage. Too much fluctuation will endanger the reliability of the system software in operation.
4) Check whether the quality and specifications of each circuit breaker meet the regulations to ensure the safety of machinery and equipment.
5) Determine the connection between the CNC system and the machine tool. Contemporary CNC systems generally have a self-diagnosis function. The CRT interface can indicate the CNC system and the machine tool socket and the internal situation of the CNC system. When a programmable logic controller (PLC) is included, it is generally possible to determine whether the data signal of the socket between the CNC system and the machine tool is appropriate according to the self-diagnosis interface according to the subprogram instructions (including the detailed address table for diagnosis) brought by the manufacturer.
6) Setting of main parameters
The CNC machine tools purchased by the whole machine are randomly attached with a performance parameter (some also attached with a main parameter paper tape or audio tape) when they leave the factory. When adjusting, be sure to carry out a check against the performance parameters, so that the machine has the best performance on the job. Generally, it can be carried out by pressing the "PARAM" (main parameter) key on the MDI/CRT module. If the main parameters are inconsistent, the settings and changes can be carried out according to the methods given in the machine tool maintenance and use instructions. According to the above process, the adjustment of the numerical control system is completed. At this time, the switching power supply of the numerical control system can be disconnected, the driving force line of the motor can be connected, the alarm setting can be repaired, and the plug-in test run can be prepared in advance.
5. Plug-in test run
1) Access to the switching power supply system For large and medium-sized machines and equipment, in order to be better and safer, their own power supply systems should be used. After plugging in and checking that there is no abnormality, manually start each component one after another to check whether the safety device is functioning, whether it can work normally, and whether it can achieve the rated value of the working index value. When starting the hydraulic transmission system, first determine whether the running direction of the hydraulic oil pump motor is appropriate, whether there is steam pressure in the hydraulic oil pipeline after the hydraulic oil pump is in operation, whether all the hydraulic systems are working normally, and whether there is abnormal noise. Whether the interface is leaking, whether the refrigeration equipment of the hydraulic transmission system can work normally, etc. All in all, according to the machine tool instruction material, check the key components of the machine tool roughly, whether the function is normal and complete.
2) When connecting to the switching power supply, you should be prepared to tap the direction-changing button at the same time, so that you can prepare to disconnect the switching power supply in advance anytime and anywhere. If the feedback data signal of the rotor of the servo motor is wrongly connected or disconnected, the machine tool will "collide with the car". At this time, the switching power supply must be disconnected immediately to check whether the wiring is appropriate.
2. Adjustment of machine tool accuracy and function
1) Use the anchor screws and spacers to finely adjust the level of the machine bed. After aligning the level, move the uprights, slides and consoles on the machine to observe the level change of the machine within the full travel arrangement of each coordinate. And correspondingly adjust the geometrical precision of the machine tool to make it within the range of dimensional tolerance. When adjusting, the key is to adjust the shims, and if necessary, the inserts and torque rollers on the slide rail can be slightly changed.
2) Adjust the relative position of the mechanical arm, spindle bearing and CNC tool. Use the manual method to carry out the exchange of CNC blade positions layer by layer, and check whether the positions such as grasping the knife, applying the knife, and drawing the knife are accurate and appropriate. During the adjustment, the calibration inspection is used to carry out the inspection. When there is a deviation, the stroke arrangement of the robot arm can be adjusted or the rubber support of the robot arm or the CNC knife part can be moved. 3) The machine tool with APC interchangeable console should move the console to the exchange position, adjust the relative position of the tray edge and the table top of the interchangeable cabinet, so that the posture of the console is stable, reliable and appropriate when the console is fully exchanged. . Then, use 70%~80% of the allowable load on the cabinet table during the work, carry out several automatic exchange positions, and tighten the relevant screws after being properly and accurately.
4) Carefully check whether the preset values of the main parameters in the CNC system and PLC equipment meet the required data information in any material, and then experiment with key practical operation functions, safety precautions, and common command execution conditions. For example, whether various motion modes (manual, starting, fully automatic methods, etc.), spindle bearing shift commands, and various speed ratio commands are appropriate and accurate.
3. Test run of machine tool
After the CNC machine tool is installed and adjusted, it should carry out a long period of self-starting training under a certain load or full load. The national industry standard GB9061-88 requires: the time for self-starting and tempering, the machining center will run continuously for 16h, and the CNC machining center will run continuously for 32h. During the self-starting period, all common failures other than those caused by incorrect operation shall not occur. If the common fault resolution time exceeds the required time, it should be adjusted and run again. Fourth, the engineering acceptance of the machine tool For the newly purchased CNC machinery, it is necessary to carry out installation, adjustment and engineering acceptance of the CNC machine tool equipment and its matching tool, spindle bearing servo motor drive module. Generally, it can be carried out according to the following process.
1. Inspection of machine tool performance and functions of CNC machining tools
1) Inspection of machine tool performance The key performance of the machine tool includes the performance of the spindle bearing system software, the software performance of the tooling system, the software of the automatic tool changing system, electrical devices, safety devices, lubricating equipment, vapor-liquid equipment and various auxiliary equipment. Different types of machine tools have different inspection items. The performance inspection of CNC machine tools is basically the same as that of general machine tools. It is mainly based on "hearing and seeing" and trial operation to check whether there are any abnormal conditions and noises in the operation, termination and operation of various fitness exercise components and auxiliary equipment. Whether the refrigeration system and its fans are working normally.
2) Inspection of CNC machine tool function The function of CNC system varies with the type of machine tool it is equipped with. The inspection and acceptance of CNC machine tool function should be carried out in accordance with the instructions for use of the CNC system configured by the machine tool and the requirements of the order contract. Manual method or program flow method to verify the key functions that the machine should have. The specific contents of CNC machine tool function inspection are as follows:
(1) Exercise command function Check the accuracy of the rapid movement command and the parallel line tool radius compensation and arc tool radius compensation commands.
(2) Prepare the command function in advance to check plane coordinate selection, plan selection, stop, compensation for the length of the CNC blade, compensation for the half length of the CNC blade, compensation for the deviation of the tooth pitch, compensation for the gap in the opposite direction, mirror system function, automatic acceleration and deceleration, fixed The accuracy of commands such as dynamic circulation system and customer macro programs.
(3) Actual operation functions Check the accuracy of functions such as returning to the starting point, single assembler program, assembler program skip reading, adjustment of spindle bearing and pass multiples, pass maintenance, emergency termination, spindle bearing and coolant start and stop. (4) CRT display function Check the accuracy of functions such as part display, program flow display, menu bar display and editing changes. The best way to test the function of CNC machine tools is to compile a test program process by yourself, so that the machine tool can continue to self-start for 16h or 32h under full load.
The test procedure process may include the following points:
The test procedure process includes the following points:
(1) The rotation of the main shaft bearing shall include forward rotation, overturning and stop operation of five or more speeds within the minimum, middle and maximum speed ratios of the tolerance.
(2) The fitness movement of each coordinate should include the minimum, middle and maximum spindle speed and rapid movement of the tolerance. The movement range of the knife should be close to the full stroke arrangement, and the rapid movement distance should be 1/2 of the full stroke arrangement of each coordinate. within. (3) Some functions and codes commonly used in general automatic production and processing should be used
(4) The automatic tool changer should exchange at least about one-third of the tool numbers in the CNC tool, and all need to install a collet with a net weight above the medium level to carry out specific exchange
(5) The unique functions that must be used, such as the precise measurement function, APC exchange and customer macro programs, etc., continue to operate with the test machine program process, check the stability and stability of various fitness movements and postures of the machine tool, and pay attention to the Common faults are not allowed within the required time period, otherwise, the time evaluation should be required from the beginning after the maintenance, and it is not allowed to divide the total to the required operation time.
2. Engineering acceptance of machine tool accuracy
The acceptance of the machine tool accuracy project is carried out after the machine tool is installed and adjusted. The inspection content specifically includes geometric figure accuracy, precise positioning accuracy and drilling accuracy.
1) Inspection of machine tool geometry accuracy The geometry accuracy of CNC machine tools is a comprehensive reflection of the important parts of the machine tool and the deviation of the three-dimensional geometry after assembly. At this stage, the common test tools used in China to test the geometrical accuracy of machine tools include high-precision level, high-precision scribing platform, square, square, collimator, micrometer, micrometer, high-precision inspection rod, etc. The accuracy of the test tool must be one level higher than the accuracy of the geometry being measured. The accurate measurement method of the accuracy of each geometric figure can be measured according to JB2674-82 "Detailed Rules for Precision Inspection of Drilling Machine Tools for Metal Materials", JB4369-86 "Accuracy of Horizontal Lathes of CNC Machine Tools", and JB/T8771.1-7-1998 "CNC Machining" It can also be carried out in accordance with the new items of geometrical accuracy inspection during machine tool production. The inspection of the accuracy of the geometric figures of the machine tool must be carried out at one time after the fine adjustment of the machine tool, and one inspection at a time is not allowed. Due to the geometrical precision there are some new items that are interconnected and affect each other. At the same time, one needs to be mindful of the bias introduced by test tools and measurement methods.
2) Inspection of the precise positioning accuracy of the machine tool The precise positioning accuracy of the CNC machine tool refers to the accuracy of the parts reached by the ordinates of the machine tool under the control of the CNC machine tool equipment. The key inspection points for the precise positioning accuracy of CNC machine tools are as follows:
(1) Precise positioning accuracy of uniform linear motion The precise positioning accuracy of uniform linear motion is generally accurately measured under the full load standard.
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