The torsion shaft of heavy armored vehicle is carried out the Controlling System of finish rolling hardening
Technical field
The present invention relates to a kind of knurling machine Controlling System, be specifically related to a kind of Controlling System of the torsion shaft of heavy armored vehicle being carried out finish rolling hardening.
Background technology
The driving conditions of heavy armored vehicle is abominable under the usual conditions, and its transmission needs regular being operated under the large loading condiction with torsion shaft.The torsion shaft of heavy armored vehicle is the important driving parts that vehicle motor is sent to power wheel hub, bearing larger distortion and rolling load in the working process, therefore improve the surperficial matter density of torsion shaft and surface smoothness to improving torsion shaft hardness, reduce torsion shaft and under repeatability, high strength, produce surface crack important effect is arranged.
By roll extrusion polishing and reinforcement processing to torsion shaft, the surface working of particularly torsion shaft axle journal, wheel seat etc. being located has played very large effect to surface quality and the fatigue strength that improves axletree.Although the roll extrusion polishing of axletree and reinforcement processing have a long history, the Ministry of Railways has been widely used in the surface working of axletree, and present employed equipment generally all is engine lathe.This working method exists that labour intensity is large, working (machining) efficiency is low, the workpiece exchange cycle is long, owing to need to carry out manually oil-mist lubrication in the course of processing, also exists the problems such as the feature of environmental protection is poor, the fluid utilization ratio is low, contaminate environment in addition.
Summary of the invention
The purpose of this invention is to provide and a kind of the torsion shaft of heavy armored vehicle is carried out the Controlling System of finish rolling hardening, this Controlling System can realize the full automatic control of machine tooling.
Realize that technical scheme of the present invention is as follows:
A kind of the torsion shaft of heavy armored vehicle is carried out the Controlling System of finish rolling hardening, this system comprises roll extrusion motion control subsystem, milled head hydrostatic control subsystem and measurement and data acquisition process subsystem; Wherein roll extrusion motion control subsystem links to each other with the data acquisition process subsystem with measurement respectively with milled head hydrostatic control subsystem;
The roll extrusion motion control subsystem mainly is comprised of two photoelectric encoders, motion control unit, Z axis servomotor and spindle servo electric machine; Annexation between above-mentioned each parts is: two photoelectric encoders be each positioned on the servomotor and with the servomotor synchronous rotary; Motion control unit links to each other respectively with photoelectric encoder, Z axis servomotor and spindle servo electric machine; Described Z axis servomotor links to each other with platen, and described spindle servo electric machine links to each other with machine tool chief axis;
Photoelectric encoder is for detection of circular frequency and the angle of rotation of coupled servomotor, and detected angle information is transferred to motion control unit;
The angle information that motion control unit transmits according to the photoelectric encoder that links to each other with the Z axis servomotor, control Z axis servomotor drives platen and moves along Z axis, process the tooth root position that the angle information that the photoelectric encoder that links to each other with spindle servo electric machine is transmitted and measurement and data acquisition process subsystem transmit, and generates control signal control spindle servo electric machine and drive the main shaft rotation;
The hydrostatic control subsystem comprises PID control unit, hydraulic power unit, electric flow quantity servo-valve and pressure transmitter; Wherein the hydraulic power unit delivery conduit links to each other with electric flow quantity servo-valve oil-in, pressure transmitter is positioned at the fuel-displaced pipeline of electric flow quantity servo-valve, and the hydro-cylinder of milled head links to each other on the fuel-displaced pipeline of electric flow quantity servo-valve and the lathe, and the PID control unit links to each other with the control end of pressure transmitter with electric flow quantity servo-valve respectively;
The force value that the PID control unit gathers according to pressure transmitter adopts the pid algorithm realization to the control of electric flow quantity servo valve control end;
Measure with data acquisition subsystem and mainly formed by laser displacement sensor, photoelectric coding and data processing module; Wherein laser displacement sensor is installed on the machine slide case and with the lathe slip crate and moves, photoelectric encoder is positioned at lathe headstock and links to each other with main shaft tail by synchronous pulley, and data processing module links to each other with laser displacement sensor and photoelectric coding respectively;
Laser displacement sensor is for detection of the radius R of torsion shaft, and it is transferred to data processing module;
Photoelectric encoder is for detection of the angle of rotation θ of main shaft, and it is transferred to data processing module.
Data processing equipment calculates the angle of rotation θ that receives and the radius R of torsion shaft, obtains the tooth root position of torsion shaft, and is transferred to the roll extrusion motion control subsystem.
Further, pid algorithm of the present invention is: the force value V(K that gathers according to current K sampling instant pressure transmitter), control the oil pressure output(K of electric flow quantity servo-valve oil outlet); Wherein
e(K)=C-V(K);
Wherein, C is the controlling valu of setting according to the required oil pressure of electric flow quantity servo-valve oil outlet, e(K) is the error amount between K sampling instant server-side output valve and the set(ting)value;
Then output increment △ output is:
△ output=Kp * (e (K)-e (K-1))+Ki * e (K)+Kd (e(K-2) * e (K-1)+e (K-2)); Wherein, e (K-1) is the error amount of (K-1) individual sampling instant server-side input, is the error amount of (K-2) individual sampling instant server-side input e(K-2), output(K-1) is (K-1) individual sampling instant control unit work output; Kp=100 is the server-side integral coefficient, and Ki=50 is the server-side scale-up factor, and Kd=700 is the server-side differential coefficient, then work output output(K) be:
output(K)=output(K-1)+△output。
Further, the concrete grammar that the present invention calculates torsion shaft tooth root position is: choose torsion shaft profile of tooth cross section corresponding a group (θ, R), the inferior maximum of R in selected (θ, R) and time minimum are designated as respectively R
MaxAnd R
Min, ascending with pressing θ in selected (θ, R), the successively R that θ is corresponding and R
MaxAnd R
MinRelatively, first is dropped on R
MinThe point of ± 0.3mm scope is designated as S, from S, finds first to drop on R
MinThe point of ± 0.3mm scope also is designated as A, finds first to exceed R
MinThe point of ± 0.3mm scope is designated as B; Then the coordinate of tooth root position is (θ
c, R
c), θ wherein
c=(θ
A+ θ
B)/2, wherein θ
ABe the corresponding angle of A point, θ
BBe the corresponding angle of B point, R
cBe θ
Corresponding distance; Calculate the coordinate (θ of torsion shaft tooth root position
c, R
c).
Further, roll extrusion motion control subsystem of the present invention also comprises Signals Transfer Board, and described Signals Transfer Board is signal input output end mouth on the motion control unit.
Further, roll extrusion motion control subsystem of the present invention also comprises two travel switches that are installed on the lathe base, and two travel switches lay respectively on the positive and negative both direction of machine tool motion; Described travel switch is used for limit control is carried out in the position of lathe, when machine tool motion arrives the travel switch present position, travel switch generates and puts signal in place and be transferred to motion control unit, and motion control unit receives when putting signal in place, then controls the spindle servo electric machine stop motion.
Further, the present invention also comprises the PLC control subsystem, for the lathe working order being detected and showing.
Further, measurement of the present invention and data acquisition subsystem also comprise magneto strictive sensor, described magneto strictive sensor is installed in the hydro-cylinder of hydraulic control system milled head, is used for measuring the physical location of course of processing hydro-cylinder and is transferred to the outside showing.
Further, the present invention also comprises technological data bank, and described technological data bank is used for storage torsion shaft information, and described torsion shaft information comprises lot number, finished size, amount of finish and the processing date of torsion shaft.
Beneficial effect
The first, Controlling System of the present invention comprises roll extrusion motion control subsystem, milled head hydrostatic control subsystem and measurement and data acquisition process subsystem, and then realize processing, measurement, hydraulic efficiency system intelligent control, level of automation is high, and be easy to the expansion of system, realize the intelligent control of torsion shaft, improved the efficient of rolling and processing.
The second, the present invention adopts pid algorithm that the hydraulic pressure of the output of milled head hydrostatic control subsystem is controlled, thereby can realize constant pressure output, has guaranteed the homogeneity to the roll extrusion of torsion shaft each several part, improves the quality of torsion shaft.
Three, seeking the tooth root position with existing artificial rotary torsion axle compares, the present invention adopts accurate algorithm that the tooth root position of torsion shaft is calculated, motion control unit has well improved the efficient of processing according to the rotation of the output control spindle servo electric machine that calculates.
Description of drawings
Fig. 1 is the knurling machine synoptic diagram;
Fig. 2 is the operating panel synoptic diagram;
Fig. 3 is Controlling System synoptic diagram of the present invention;
1-machine tool chief axis 2-processing parts 3-Controlling System 4-laser displacement sensor 5-milled head 6-hydraulic tailstock 7-worktable.
Embodiment
As shown in Figure 1, knurling machine comprises that mainly several parts such as machine tool chief axis 1, Controlling System 3, hydraulic tailstock 6, worktable 7 form.Need to be installed on the main shaft 1 by the torsion shaft 2 of roll extrusion, the operator operates at operating panel as shown in Figure 2.
As shown in Figure 3, the present invention carries out the Controlling System of finish rolling hardening to the torsion shaft of heavy armored vehicle, and this system comprises roll extrusion motion control subsystem, milled head hydrostatic control subsystem and measurement and data acquisition process subsystem; Wherein roll extrusion motion control subsystem links to each other with the data acquisition process subsystem with measurement respectively with milled head hydrostatic control subsystem.
The roll extrusion motion control subsystem mainly is comprised of two photoelectric encoders, motion control unit, Z axis servomotor and spindle servo electric machine; Annexation between above-mentioned each parts is: two photoelectric encoders be each positioned on the servomotor and with the servomotor synchronous rotary; Motion control unit links to each other respectively with photoelectric encoder, Z axis servomotor and spindle servo electric machine; Described Z axis servomotor links to each other with platen, and described spindle servo electric machine links to each other with machine tool chief axis.
Photoelectric encoder is for detection of circular frequency and the angle of rotation of coupled servomotor, and detected angle information is transferred to motion control unit; The angle information that motion control unit transmits according to the photoelectric encoder that links to each other with the Z axis servomotor, control Z axis servomotor drives platen and moves along Z axis, process the tooth root position that the angle information that the photoelectric encoder that links to each other with spindle servo electric machine is transmitted and measurement and data acquisition process subsystem transmit, and generates control signal control spindle servo electric machine and drive the main shaft rotation.
Roll extrusion motion control subsystem of the present invention is the core of the motion control of knurling machine, finishes the driving to platen horizontal direction (namely along Z-direction), and control main shaft (namely around the C axle) rotatablely moves realization Z, the interpolation of C two-axle interlocking.
The hydrostatic control subsystem comprises PID control unit, hydraulic power unit, electric flow quantity servo-valve and pressure transmitter; Wherein the hydraulic power unit delivery conduit links to each other with electric flow quantity servo-valve oil-in, pressure transmitter is positioned at the fuel-displaced pipeline of electric flow quantity servo-valve, and the hydro-cylinder of milled head links to each other on the fuel-displaced pipeline of electric flow quantity servo-valve and the lathe, and the hydro-cylinder of milled head links to each other on the fuel-displaced pipeline of electric flow quantity servo-valve and the lathe, and the PID control unit links to each other with the control end of pressure transmitter with electric flow quantity servo-valve respectively; The force value that the PID control unit gathers according to pressure transmitter adopts the pid algorithm realization to the control of electric flow quantity servo valve control end; Provide hydraulic efficiency oil to realize roll extrusion by the fuel-displaced pipeline of electric flow quantity servo-valve to the hydro-cylinder of milled head on the lathe.
Measure with data acquisition subsystem and mainly formed by laser displacement sensor, photoelectric coding and data processing module; Wherein laser displacement sensor is installed on the machine slide case and with the lathe slip crate and moves, photoelectric encoder is positioned at lathe headstock and links to each other with main shaft tail by synchronous pulley, and data processing module links to each other with laser displacement sensor and photoelectric coding respectively; Laser displacement sensor is for detection of the radius of torsion shaft, and it is transferred to data processing module; Photoelectric encoder is for detection of the angle of rotation of main shaft, and it is transferred to data processing module; Data processing equipment calculates the angle of rotation θ that receives and the radius R of torsion shaft, obtains the tooth root position of torsion shaft, and is transferred to the roll extrusion motion control subsystem.
Reason owing to the transmission rotation, there is certain error between the angle of rotation of spindle servo electric machine and main shaft, the high precision photoelectric encoder that setting of the present invention links to each other with main shaft, be arranged at the photoelectric encoder that spindle motor links to each other, by the angle of rotation that two encoders gather respectively, accurately control the rotation of spindle motor.
In order to guarantee the homogeneity to the roll extrusion of torsion shaft each several part, improve the quality of torsion shaft, the present invention has designed pid algorithm and has realized control to output hydraulic pressure, pid algorithm of the present invention is: the force value V(K that gathers according to current K sampling instant pressure transmitter), control the oil pressure output(K of electric flow quantity servo-valve oil outlet); Wherein
e(K)=C-V(K);
Wherein, C is the controlling valu of setting according to the required oil pressure of electric flow quantity servo-valve oil outlet, e(K) is the error amount between K sampling instant server-side output valve and the set(ting)value;
Then output increment △ output is:
△output=Kp×(e(K)-e(K-1))+Ki×e(K)+Kd(e(K-2)×e(K-1)+e(K-2));
Wherein, e (K-1) is the error amount of (K-1) individual sampling instant server-side input, is the error amount of (K-2) individual sampling instant server-side input e(K-2), output(K-1) is (K-1) individual sampling instant control unit work output; Kp=100 is the server-side integral coefficient, and Ki=50 is the server-side scale-up factor, and Kd=700 is the server-side differential coefficient, then work output output(K) be:
output(K)=output(K-1)+△output。
In order to obtain accurately the tooth root position of torsion shaft, realize that automatization ground processes tooth root, the present invention designs a cover and uses algorithm calculating torsion shaft tooth root position to be specially: choose one group of (θ corresponding to torsion shaft profile of tooth cross section, R), time maximum and inferior minimum of R in selected (θ, R) is designated as respectively R
MaxAnd R
Min, ascending with pressing θ in selected (θ, R), the successively R that θ is corresponding and R
MaxAnd R
MinRelatively, first is dropped on R
MinThe point of ± 0.3mm scope is designated as S, from S, finds first to drop on R
MinThe point of ± 0.3mm scope also is designated as A, finds first to exceed R
MinThe point of ± 0.3mm scope is designated as B; Then the coordinate of tooth root position is (θ
c, R
c), θ wherein
c=(θ
A+ θ
B)/2, wherein θ
ABe the corresponding angle of A point, θ
BBe the corresponding angle of B point, R
cBe θ
cCorresponding distance; Calculate the coordinate (θ of torsion shaft tooth root position
c, R
c).
In order to prevent that outside forceful electric power signal from burning motion control unit; the present invention also be provided with on the roll extrusion motion control subsystem Signals Transfer Board as motion control unit on the signal input output end mouth; play the bi-directional effect of signal, also possess photoelectricity insulation blocking effect simultaneously.
In order to prevent that rotatablely moving of lathe from surpassing its limit, the present invention also is provided with travel switch and is used for limit control is carried out in the position of lathe on the roll extrusion motion control subsystem, when machine tool motion arrived the travel switch present position, travel switch generated and puts signal in place and be transferred to motion control unit.
Because it is unusual that lathe may occur in the process of work, therefore the working order of lathe need to be told in real time outside staff, so the present invention designed the PLC control subsystem, be used for the lathe working order is detected and shows.The PLC Controlling System mainly is comprised of CPU, storer, switching value input/output module and analog input/output module; CPU is used for the input/output signal of lathe is carried out logical operation, finishes the internal clocking of PLC Controlling System, counting, arithmetical operation, data processing and transmission, communication and various application instruction explanation functions etc.Employed data need to read from storage in the CPU computation process, and the result after the data analysis processing is stored in the storer too, and storer and CPU are two-way data transmission relations.Storer be used for that switch amount input/output module and analog input/output module transmit numerary signal store, the data after CPU is calculated send switching value input/output module and analog input/output module to.The switching value input/output module is used for the high-low level status signal of lathe is gathered, and the status signal that gathers is changed in the digital form write store; Status signal in the switching value input/output module read memory, and convert thereof into lathe can recognition mode output; Analog input/output module is used for gathering the continually varying analog signals that the lathe working process produces, and converts thereof in the digital form write store; Data after being processed by CPU in analog input/output module memory read, and convert thereof into simulating signal for the electric system of lathe.
Can see in real time the force value of milled head output for the staff, the present invention is provided with magneto strictive sensor in the hydro-cylinder of hydraulic control system milled head, this magneto strictive sensor be used for to be measured the physical location of course of processing hydro-cylinder, location variation is gone out by the RS485 protocol transmission and shows.
Simultaneously, the present invention has also designed technological data bank, and it uses the programming of ACCESS form, has part lot number, part finished size, finished size, amount of finish, processing date and time information.Can be uploaded to remote server by ICP/IP protocol after machining analyzes and preserves at every turn.
In sum, more than be preferred embodiment of the present invention only, be not for limiting protection scope of the present invention.Within the spirit and principles in the present invention all, any modification of doing, be equal to replacement, improvement etc., all should be included within protection scope of the present invention.