CN201012430Y - Micro High Speed Inertial Friction Welding Machine - Google Patents
Micro High Speed Inertial Friction Welding Machine Download PDFInfo
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- CN201012430Y CN201012430Y CNU2007200312028U CN200720031202U CN201012430Y CN 201012430 Y CN201012430 Y CN 201012430Y CN U2007200312028 U CNU2007200312028 U CN U2007200312028U CN 200720031202 U CN200720031202 U CN 200720031202U CN 201012430 Y CN201012430 Y CN 201012430Y
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
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Abstract
本实用新型涉及一种微型高速惯性摩擦焊机,其取消了所有中间传动环节,具有转速高、结构紧凑、易于平衡、传动效率高以及重量轻、响应迅速、振动小、噪声低等优点,实现了惯性摩擦焊机的微型化和高速化。本实用新型包括安装在床身上的焊机主轴,工作滑台与推力油缸连接,电主轴通过电磁离合器与焊机主轴以及安装在焊机主轴上的飞轮相连,旋转夹具与焊机主轴连接,移动夹具安装在工作滑台上,电主轴上连有变频器和传感器,变频器和传感器与控制器连接。
The utility model relates to a miniature high-speed inertial friction welding machine, which cancels all intermediate transmission links, has the advantages of high speed, compact structure, easy balance, high transmission efficiency, light weight, quick response, small vibration, low noise, etc., and realizes Miniaturization and high speed of inertial friction welding machine. The utility model includes a welding machine main shaft installed on the bed, a working slide table connected with a thrust oil cylinder, an electric main shaft connected with the main shaft of the welding machine and a flywheel installed on the main shaft of the welding machine through an electromagnetic clutch, a rotary fixture connected with the main shaft of the welding machine, and moving The fixture is installed on the working slide table, the electric spindle is connected with a frequency converter and a sensor, and the frequency converter and the sensor are connected with the controller.
Description
一、技术领域: 1. Technical field:
本实用新型涉及一种焊机,尤其是涉及一种微型高速惯性摩擦焊机。The utility model relates to a welding machine, in particular to a miniature high-speed inertial friction welding machine.
二、背景技术: 2. Background technology:
摩擦焊接技术作为一种先进的固态连接技术(其焊合区为锻造组织),具有优质、高效、节能、低耗、清洁等技术经济特征,通过与材料、计算机、知识与信息处理、光机电一体化、软件、可靠性工程等高新技术的紧密结合,其本身也正在以高新技术的面貌展现在人们面前,并在国防军工等高新技术产业及传统产业技术升级中具有广阔的开发应用与产业化前景。Friction welding technology, as an advanced solid-state connection technology (the welding zone is forged structure), has technical and economic characteristics such as high quality, high efficiency, energy saving, low consumption, and cleanliness. The close combination of high-tech such as integration, software, reliability engineering, etc., itself is also being displayed in front of people with the appearance of high-tech, and has broad development applications and industrial prospects.
随着现代微机械及微细加工技术的发展,摩擦焊机的发展方向之一是实现焊机的微型化与高速化。With the development of modern micro-machinery and micro-processing technology, one of the development directions of friction welding machine is to realize the miniaturization and high-speed of welding machine.
国内摩擦焊机制造业于上世纪70年代开始起步,经过30多年的发展,通用摩擦焊机的研发与生产已形成一定规模,在一定程度上满足了国内低端和部分中端用户的需求,但与国外相比,国内摩擦焊接技术的整体水平和市场竞争力至今仍差距甚大,远不能适应国内市场的迫切需求,迄今为止,国内外在微型高速惯性摩擦焊机技术的开发、应用方面的报道还十分少见。The domestic friction welding machine manufacturing industry started in the 1970s. After more than 30 years of development, the research and development and production of general friction welding machines have formed a certain scale, which meets the needs of domestic low-end and some mid-end users to a certain extent. However, compared with foreign countries, the overall level and market competitiveness of domestic friction welding technology are still far behind, far from being able to meet the urgent needs of the domestic market. Reports are very rare.
国外,仅有美国MTI公司和德国KUKA公司研发生产微型焊机的报道,MTI公司生产的40型微型高速惯性摩擦焊机采用主轴驱动电机与主轴体同轴安装的结构方案,其主轴转速为45000-60000rpm,飞轮的最大转动惯量为0.00036kg·m2,最大焊接力为2.2KN,管型工件最大焊接面积为45.2mm2;KUKA公司生产的RS05E摩擦焊机的最大焊接力为5.0KN,焊件直径(低碳钢)为φ2-φ8mm。Abroad, there are only reports on the development and production of micro-welding machines by MTI Corporation of the United States and KUKA Corporation of Germany. The 40-type micro-high-speed inertial friction welding machine produced by MTI Corporation adopts a structural scheme in which the spindle drive motor and the spindle body are coaxially installed, and the spindle speed is 45,000 -60000rpm, the maximum moment of inertia of the flywheel is 0.00036kg·m 2 , the maximum welding force is 2.2KN, and the maximum welding area of the tubular workpiece is 45.2mm 2 ; the maximum welding force of the RS05E friction welding machine produced by KUKA is 5.0KN. The diameter of the piece (low carbon steel) is φ2-φ8mm.
三、实用新型内容:3. Contents of the utility model:
本实用新型为了解决上述背景技术中的不足之处,提供一种微型高速惯性摩擦焊机,其取消了所有中间传动环节,具有转速高、结构紧凑、易于平衡、传动效率高以及重量轻、响应迅速、振动小、噪声低等优点,实现了惯性摩擦焊机的微型化和高速化。In order to solve the shortcomings in the above-mentioned background technology, the utility model provides a miniature high-speed inertial friction welding machine, which cancels all intermediate transmission links, and has the advantages of high speed, compact structure, easy balance, high transmission efficiency, light weight, and responsive welding. The advantages of speed, small vibration and low noise have realized the miniaturization and high speed of the inertial friction welding machine.
为实现上述目的,本实用新型采用的技术方案为:In order to achieve the above object, the technical solution adopted by the utility model is:
一种微型高速惯性摩擦焊机,其特殊之处在于:包括安装在床身上的焊机主轴,工作滑台与推力油缸连接,电主轴通过电磁离合器与焊机主轴以及安装在焊机主轴上的飞轮相连,旋转夹具与焊机主轴连接,移动夹具安装在工作滑台上,电主轴上连有变频器和传感器,变频器和传感器与控制器连接。A miniature high-speed inertial friction welding machine, which is special in that: it includes the welding machine main shaft installed on the bed, the working slide is connected to the thrust oil cylinder, the electric main shaft is connected to the welding machine main shaft through the electromagnetic clutch and the welding machine is installed on the main shaft. The flywheel is connected, the rotating fixture is connected with the main shaft of the welding machine, the moving fixture is installed on the working slide table, the frequency converter and the sensor are connected on the electric main shaft, and the frequency converter and the sensor are connected with the controller.
电主轴支撑采用角接触球轴承。The electric spindle is supported by angular contact ball bearings.
旋转夹具和移动夹具采用微型精密弹簧夹头。The rotating and moving fixtures use miniature precision collets.
工作滑台的导轨采用高导向精度的直线导轨。The guide rail of the working slide table adopts the linear guide rail with high guiding precision.
电主轴的轴承和焊机主轴轴承与油雾器连接。The bearing of the electric spindle and the bearing of the welding machine spindle are connected with the lubricator.
电磁离合器包括外套筒,端盖板与外套筒连接构成壳体,壳体内装有励磁线圈,励磁线圈与线圈骨架连接,磁环采用稀土强永磁材料钕铁硼材料制成,胶接于左、右两侧端盖板的环形凸台上,磁环端面上胶合有橡胶垫圈,左侧端盖板中孔设有与电主轴轴体相连的外花键轴,右侧端盖板中孔设有与安装有飞轮的焊机主轴轴体相连的另一外花键轴,外花键轴和另一外花键轴与磁环一侧的内花键套采用花键连接,内花键套、端盖板、外套筒均采用导磁材料制成,外花键轴和另一外花键轴采用非导磁材料制成,励磁线圈通过继电器与直流电源连接,继电器上连有压敏电阻。The electromagnetic clutch includes an outer sleeve, and the end cover plate is connected with the outer sleeve to form a housing. The excitation coil is installed in the housing, and the excitation coil is connected to the coil frame. The magnetic ring is made of rare earth strong permanent magnet material NdFeB material, glued On the annular bosses of the left and right end covers, rubber gaskets are glued on the end faces of the magnetic rings. The middle hole of the left end cover is provided with an external spline shaft connected to the shaft body of the electric spindle. The right end cover The middle hole is provided with another external spline shaft connected with the main shaft body of the welding machine on which the flywheel is installed. The spline sleeve, end cover plate, and outer sleeve are all made of magnetically conductive materials, the outer spline shaft and the other outer spline shaft are made of non-magnetically conductive materials, the exciting coil is connected to the DC power supply through a relay, and the relay is connected to the DC power supply. There are varistors.
控制器为可编程控制器,人机界面与可编程控制器连接。The controller is a programmable controller, and the man-machine interface is connected with the programmable controller.
与现有技术相比,本实用新型具有的优点和效果如下:Compared with the prior art, the utility model has the following advantages and effects:
1、本实用新型集成了高速切削加工技术中的电主轴单元技术,实现了焊机主轴——飞轮与其驱动电机的同轴配置和直接驱动,取消了所有中间传动环节,其传动链长度为零(“零传动”),并具有转速高、结构紧凑、易于平衡、传动效率高以及重量轻、响应迅速、振动小、噪声低等优点,从而实现了惯性摩擦焊机的微型化和高速化。1. The utility model integrates the electric spindle unit technology in the high-speed cutting processing technology, realizes the coaxial configuration and direct drive of the welding machine spindle-flywheel and its driving motor, cancels all intermediate transmission links, and its transmission chain length is zero ("Zero transmission"), and has the advantages of high speed, compact structure, easy balance, high transmission efficiency, light weight, quick response, small vibration, low noise, etc., thus realizing the miniaturization and high speed of inertial friction welding machine.
2、本实用新型通过焊机主轴及其轴系转动件结构的优化设计,使其固有的转动惯量的下限值达到3.2×10-5kgm2;同时,在焊机主轴转速高达50000rpm的超高转速条件下,焊机主轴及其轴系转动件的动平衡品质良好。2. The utility model makes the lower limit of the inherent moment of inertia reach 3.2×10 -5 kgm 2 through the optimized design of the structure of the welding machine main shaft and its shaft system rotating parts; Under the condition of high speed, the dynamic balance quality of the main shaft of the welding machine and its rotating parts of the shaft system is good.
3、本实用新型中电磁离合器采用小惯量、推挽式、花键齿结构,能保证电磁离合器在高达数万转的超高转速下频繁、快速和可靠的离合和传递较大的摩擦峰值扭矩,具有结构紧凑、外形尺寸小、转动惯量小、响应速度快等优点,并实现了电磁离合器的小型化。3. The electromagnetic clutch in this utility model adopts a small inertia, push-pull type, and spline tooth structure, which can ensure frequent, fast and reliable clutching and transmission of relatively large frictional peak torque of the electromagnetic clutch at an ultra-high speed of up to tens of thousands of revolutions , has the advantages of compact structure, small size, small moment of inertia, fast response, etc., and realizes the miniaturization of the electromagnetic clutch.
4、本实用新型所能焊接的工件尺寸的下限可细至Φ1.5mm(棒材)。4. The lower limit of the workpiece size that can be welded by the utility model can be as small as Φ1.5mm (bar).
四、附图说明: 4. Description of drawings:
图1为本实用新型的结构示意图;Fig. 1 is the structural representation of the utility model;
图2为本实用新型中电主轴的结构示意图;Fig. 2 is the structural representation of electric spindle in the utility model;
图3为本实用新型中电主轴的电气连接图;Fig. 3 is the electrical connection diagram of the electric spindle in the utility model;
图4为本实用新型中电磁离合器分离时的结构示意图;Fig. 4 is the schematic diagram of the structure when the electromagnetic clutch is separated in the utility model;
图5为本实用新型中电磁离合器接合时的结构示意图;Fig. 5 is a structural schematic diagram when the electromagnetic clutch is engaged in the utility model;
图6为本实用新型中电磁离合器励磁线圈的电源接线图;Fig. 6 is the power wiring diagram of the magnetic clutch excitation coil in the utility model;
图7为本实用新型中液压系统原理图;Fig. 7 is a schematic diagram of the hydraulic system in the utility model;
图8为本实用新型中计算机测控系统的接线图;Fig. 8 is the wiring diagram of computer measurement and control system in the utility model;
图9为计算机测控系统中控制器的接线图;Fig. 9 is the wiring diagram of the controller in the computer measurement and control system;
图10为计算机控制流程图。Figure 10 is a computer control flow chart.
图中,1-电主轴,2-电磁离合器,3-焊机主轴,4-飞轮,5-旋转夹具,6-旋转侧工件,7-移动侧工件,8-移动夹具,9-推力油缸,10-床身,11-直线导轨,12-工作滑台,13-转子轴,14-前防尘罩,15-前螺母,16-前小盖,17-前轴承,18-前外隔垫,19-前内隔垫,20-前外套,21-前轴承座,22-定子,23-壳体和水套,24-后轴承,25-后内隔垫,26-后外隔垫,27-滚珠保持架,28-后轴承座,29-后螺母,30-调整垫,31-弹簧座和弹簧,32-后盖,33-进水嘴,34-进油嘴,35-接线座,36-出油嘴,37-进水嘴,38-顶丝,39-出水嘴,40-进油嘴,41-出油嘴,42-进水嘴,43-油雾发生器,44-压力继电器,45-变频器,46-外花键轴,47-磁环,48-内花键套,49-外套筒,50-励磁线圈,51-线圈骨架,52-橡胶垫圈,53-端盖板,54-外花键轴,55-继电器,56-继电器,57-励磁线圈,58-压敏电阻,59-油箱,60-吸油滤油器,61-液压泵,62-电动机,63-线隙式滤油器,64-压力表,65-压力表,66-压力表,67-基板,68-减压阀,69-流量控制阀,70-电磁换向阀,71-减压阀,72-流量控制阀,73-电磁换向阀,74-电磁溢流阀,75-单向阀,76-三位四通电磁换向阀,77-冷却器,78-推力油缸,79-软管总成,80-软管总成,81-压力继电器,82-照明灯,83-液压启动灯,84-液压停止灯,85-离合器,86-离合器,87-液压泵电机,88-主轴变频器,89-电主轴,90-焊接开始按钮,91-焊接停止按钮,92-急停按钮,93-滑台原位行程开关,94-滑台快进行程开关,95-滑台远端限位,96-焊件接触压力开关,97-水压开关,98-水雾气压开关,99-油雾器液位,100-油雾器液位,101-变频预设速度到达,102-液压泵起动,103-液压泵停止,104-位移传感器,105-速度设定。106-液压建立,107-滑台快进,108-滑台工进,109-顶锻,110-滑台快进,111-离合器合,112-液压油泵电机,113-焊接开始指示,114-焊接停止指示。In the figure, 1-electric spindle, 2-electromagnetic clutch, 3-welding machine spindle, 4-flywheel, 5-rotating fixture, 6-rotating side workpiece, 7-moving side workpiece, 8-moving fixture, 9-thrust cylinder, 10-bed, 11-linear guide, 12-working slide, 13-rotor shaft, 14-front dust cover, 15-front nut, 16-front small cover, 17-front bearing, 18-front outer septum , 19-front inner septum, 20-front outer jacket, 21-front bearing seat, 22-stator, 23-housing and water jacket, 24-rear bearing, 25-rear inner septum, 26-rear outer septum, 27-ball cage, 28-rear bearing housing, 29-rear nut, 30-adjusting pad, 31-spring seat and spring, 32-back cover, 33-water inlet, 34-oil inlet, 35-wire seat, 36-oil outlet, 37-water inlet, 38-top wire, 39-water outlet, 40-oil inlet, 41-oil outlet, 42-water inlet, 43-oil mist generator, 44-pressure relay, 45 -Inverter, 46-external spline shaft, 47-magnetic ring, 48-inner spline sleeve, 49-outer sleeve, 50-excitation coil, 51-coil bobbin, 52-rubber washer, 53-end cover plate, 54-external spline shaft, 55-relay, 56-relay, 57-excitation coil, 58-varistor, 59-oil tank, 60-suction oil filter, 61-hydraulic pump, 62-motor, 63-line gap Type oil filter, 64-pressure gauge, 65-pressure gauge, 66-pressure gauge, 67-base plate, 68-pressure reducing valve, 69-flow control valve, 70-electromagnetic reversing valve, 71-pressure reducing valve, 72 -flow control valve, 73-electromagnetic reversing valve, 74-electromagnetic overflow valve, 75-one-way valve, 76-three-position four-way electromagnetic reversing valve, 77-cooler, 78-thrust cylinder, 79-hose Assembly, 80-hose assembly, 81-pressure relay, 82-light, 83-hydraulic start light, 84-hydraulic stop light, 85-clutch, 86-clutch, 87-hydraulic pump motor, 88-spindle frequency conversion Device, 89-electric spindle, 90-welding start button, 91-welding stop button, 92-emergency stop button, 93-sliding table original position travel switch, 94-sliding table fast travel switch, 95-sliding table remote limit Position, 96-weldment contact pressure switch, 97-water pressure switch, 98-water mist air pressure switch, 99-lubricator liquid level, 100-lubricator liquid level, 101-frequency conversion preset speed arrival, 102-hydraulic pressure Pump start, 103-hydraulic pump stop, 104-displacement sensor, 105-speed setting. 106-Hydraulic setting, 107-Sliding table fast forward, 108-Sliding table working forward, 109-Upsetting, 110-Sliding table fast forwarding, 111-Clutch close, 112-Hydraulic oil pump motor, 113-Welding start instruction, 114- Welding stop indication.
五、具体实施方式: 5. Specific implementation methods:
本实用新型主要由主机机械系统、液压系统、传感与传感器系统、计算机测控系统组成,各分系统的构造特征如下:The utility model is mainly composed of a main machine mechanical system, a hydraulic system, a sensing and sensor system, and a computer measurement and control system. The structural features of each subsystem are as follows:
1、主机机械系统:1. Host mechanical system:
参见图1,主机机械系统的主要配置见图1,它主要由高速电主轴1、电磁离合器2、焊机主轴3、飞轮4、旋转夹具5、移动夹具8、推力油缸9,以及床身10、箱体、支架等支撑件(大件)组成。其中:电主轴1(内藏电机式主轴)是焊机机械系统的动力源,它通过电磁离合器2与焊机主轴3和安装其上的飞轮4相连,其支撑选用7204C(C级精度,两个)及7203C(C级精度,一个)型角接触球轴承;飞轮4的作用是主要靠其释放的转动动能提供给焊接工件所需的能量(主要转换为摩擦加热功率),以使电主轴1内藏电机功率大为减小;旋转夹具5和移动夹具8均采用微型精密弹簧夹头,旋转夹具5与焊机主轴3相连,移动夹具8安装在工作滑台12上,工作滑台12进给由推力油缸9驱动,其导轨选用高导向精度的直线导轨11;在结构设计时,还综合考虑了各支撑件(大件)的自身刚度、局部刚度和接触刚度。See Figure 1, the main configuration of the host mechanical system is shown in Figure 1, which mainly consists of a high-speed electric spindle 1, an
本实用新型焊机主轴或飞轮的转速可高达50000rpm,由于微细工件施焊时所需之焊接能量甚小,故在设计焊机机械传动系统时,必须最大限度地减小焊机主轴及其轴系传动件(不包括飞轮)的固有转动惯量,以使焊机所能焊接的工件尺寸的下限尽可能降低。经计算,焊机主轴轴系转动件的固有转动惯量为3.2×10-5kgm2,其最大输出功率为0.058KW。为满足焊接不同材质及尺寸工件的要求,飞轮转动惯量分级为三级,即3.7×10-3kgm2、1.56×10-3kgm2、4.83×10-4kgm2。The rotation speed of the main shaft or flywheel of the welding machine of the utility model can be as high as 50000rpm. Since the welding energy required for the welding of fine workpieces is very small, when designing the mechanical transmission system of the welding machine, the main shaft and its shaft of the welding machine must be minimized. The inherent moment of inertia of the transmission parts (excluding the flywheel) is used to reduce the lower limit of the workpiece size that can be welded by the welding machine as much as possible. After calculation, the inherent moment of inertia of the rotating parts of the main shaft of the welding machine is 3.2×10 -5 kgm 2 , and its maximum output power is 0.058KW. In order to meet the requirements for welding workpieces of different materials and sizes, the moment of inertia of the flywheel is classified into three levels, namely 3.7×10 -3 kgm 2 , 1.56×10 -3 kgm 2 , and 4.83×10 -4 kgm 2 .
参见图2和图3,高速电主轴单元的功能是驱动焊机主轴及安装在主轴上的飞轮等轴系转动件,其结构见图2。电主轴最大转速为60000rpm,输出功率为2.0KW;前轴承17和后轴承24分别选用B7003C/P4×1和B7002C/P4×1型角接触球轴承,前者极限转速为60000rpm,后者极限转速为75000rpm;电主轴采用油雾润滑,兼有润滑和冷却双重作用,其方法是以压缩空气为动力,通过油雾发生器43将油液雾化并混入空气流中,然后输送到需要润滑的部位。当电主轴高速旋转时,油雾可在轴承沟道内形成弹性润滑油膜。油雾润滑属持续润滑,油雾经过油路源源不断进入轴承,油、气混合装置的油路及气路连接图见图3。Referring to Fig. 2 and Fig. 3, the function of the high-speed electric spindle unit is to drive the shaft system rotating parts such as the welding machine main shaft and the flywheel installed on the main shaft, and its structure is shown in Fig. 2 . The maximum speed of the electric spindle is 60000rpm, and the output power is 2.0KW; the
高速电主轴选用丹麦Danfuss公司生产的VCT2840型变频调速器(1000Hz)进行无级调速。该变频调速器具有U1/f1=Const比例控制调速、网络电压补偿、电机转速PID调节、电机加速启动与刹车快停控制等转速控制功能,以及过流、过压、过热、缺相等保护功能,故其安全可靠性较高。The high-speed electric spindle adopts the VCT2840 frequency conversion speed controller (1000Hz) produced by Danfuss Company of Denmark for stepless speed regulation. The frequency conversion speed controller has speed control functions such as U 1 /f 1 =Const proportional control speed regulation, network voltage compensation, motor speed PID adjustment, motor acceleration start and brake quick stop control, as well as overcurrent, overvoltage, overheating, lack of Equal protection function, so its safety and reliability are high.
参见图4和图5,电磁离合器采用小惯量、推挽式、花键齿结构,以花键齿机械嵌合副作为接合元件。参见图4,包括外套筒49,端盖板53与外套筒49连接构成壳体,壳体内装有励磁线圈50,励磁线圈50密绕于线圈骨架51上,左侧端盖板53中孔设有与电主轴轴体相连的外花键轴46,右侧端盖板53中孔设有与安装有飞轮的焊机主轴轴体相连的外花键轴54,外花键轴46和外花键轴54与磁环47一侧的内花键套48采用花键连接。根据磁路设计的要求,磁环47采用稀土强永磁材料钕铁硼材料制成,并将其胶接于左、右两侧端盖板53的环形凸台上,为防止内花键套48与磁环47吸合时产生冲击,在磁环47端面上胶合了一定厚度的橡胶垫圈52;内花键套48、端盖板53、外套筒49均采用导磁材料电工纯铁DT4A制成,外花键轴采用非导磁材料1Cr18Ni9Ti不锈钢制成。电磁离合器的励磁线圈50在其线圈骨架51上密绕而成,铜线有效线径为0.55mm,绕线层数为31层,每层匝数为61匝,励磁电流为1.03A。计算结果表明,电磁离合器产生的最大吸力或斥力为4.5kg,传递的最大扭矩为0.045kgm。Referring to Figure 4 and Figure 5, the electromagnetic clutch adopts a small inertia, push-pull type, spline tooth structure, and the spline tooth mechanical fitting pair is used as the engaging element. Referring to Fig. 4 , it includes the
参见图6,电磁离合器的励磁线圈57由直流电源(24VDC)供电,励磁线圈57通过继电器55和继电器56与直流电源连接,继电器上连有压敏电阻58,励磁电流的方向由图中继电器55或继电器56控制,压敏电阻58的作用是用来保护继电器触头,防止在频繁通断电路时触头间产生电弧而损坏触头。Referring to Fig. 6, the excitation coil 57 of electromagnetic clutch is powered by DC power supply (24VDC), and excitation coil 57 is connected with DC power supply by
参见图4,当电磁离合器处于分离状态时,内花键套48仅与外花键轴46嵌合;参见图5,当继电器得电时,励磁线圈50中通过正向励磁电流,内花键套48在左侧磁环产生的斥力和右侧磁环产生的吸力的共同作用下,加速沿轴向向右移动,其花键齿处于同时与外花键轴46、外花键轴54嵌合的状态,即电主轴1轴体与焊机主轴3接合,电磁离合器处于接合状态;反之,当继电器55得电(继电器56失电)时,励磁线圈50中通过反向励磁电流,内花键套48在右侧磁环产生的斥力和左侧磁环产生的吸力的共同作用下,加速沿轴向向左移动,其花键齿与外花键轴46嵌合,而与外花键轴54脱离,即焊机主轴3与其动力源分离,电磁离合器处于分离状态,只要通过焊机计算机测控系统交替地改变励磁线圈中励磁电流的方向,即可交替地控制电磁离合器的接合或分离。Referring to Fig. 4, when the electromagnetic clutch is in a disengaged state, the
实际工作时,焊机主轴3及安装在它上面的飞轮4通过电磁离合器2中的外花键轴46、内花键套48、外花键轴54与电主轴1相连。惯性摩擦焊接时,待焊工件的旋转端夹持于旋转夹具5中,而其移动端夹持于工作滑台12上的移动夹具8中,飞轮4首先被加速到预先设定的转速(电磁离合器处于接合状态),以转动动能的形式储存焊接所需的能量,随后焊机主轴3通过电磁离合器2与电主轴1脱离(电磁离合器2处于分离状态),飞轮4进入惯性运转;当移动夹具8夹持的工件移动端在推力油缸9施加的轴向力的作用下,向旋转侧工件6靠拢、接触、并压紧后,处于惯性运转的飞轮因受摩擦扭矩的阻尼作用,其转速逐渐降低,储存在飞轮中的转动动能通过被焊工件表面间的高速摩擦,逐渐将其大部分能量转化为热能,并快速加热摩擦表面及其近区金属,直至飞轮能量耗尽而停止转动并保压一段时间后,焊接过程结束。During actual work, the welder
2、液压控制系统:2. Hydraulic control system:
参见图7,液压控制系统主要由液压泵61、推力油缸78以及液压控制阀组等组成,其功能是对工件施加焊接力,并实现工作滑台的快进、工进、顶锻、快退等工作程序的自动变换。液压控制系统的原理图见图7。Referring to Figure 7, the hydraulic control system is mainly composed of a hydraulic pump 61, a
液压控制系统的工作原理简述如下:The working principle of the hydraulic control system is briefly described as follows:
系统建压与调压:启动液压泵61的控制按钮,电磁铁1DT得电,系统建压。系统压力通过电磁溢流阀74调节,当供油压力表64指示为5.0MPa时,表示系统压力正常。System pressure building and pressure regulation: start the control button of the hydraulic pump 61, the electromagnet 1DT is energized, and the system pressure is built. The system pressure is regulated by the electromagnetic overflow valve 74, and when the oil
滑台快进油路:启动快进控制按钮,电磁铁1DT、2DT同时得电,压力油经电磁换向阀76进入推力油缸78右腔;同时,推力油缸78左腔的压力油经单向阀75流回油箱(卸荷),工作滑台向左快进。Slide table fast-forward oil circuit: Start the fast-forward control button, electromagnets 1DT and 2DT are energized at the same time, and the pressure oil enters the right chamber of the
滑台工进油路:当工作滑台移动至行程开关预先调定的位置时,电磁铁2DT失电,3DT得电,压力油经减压阀71、流量控制阀72、电磁换向阀73流入推力油缸右腔,转入工进状态;工进速度通过流量控制阀72调节,焊接压力通过减压阀71调节,其值由压力表7显示。Sliding table worker oil inlet circuit: When the working sliding table moves to the preset position of the travel switch, the electromagnet 2DT is de-energized, 3DT is energized, and the pressure oil passes through the
顶锻油路:当压力油达到压力继电器81预先调定的工作压力时,压力继电器动作,3DT失电,4DT得电,转入快速顶锻状态;顶锻速度通过流量控制阀69调节,顶锻压力通过减压阀68调节,其值由压力表66显示。Upsetting oil circuit: When the pressure oil reaches the pre-set working pressure of the
滑台快退油路:当顶锻保压延时一定时间后,电磁铁4DT失电,5DT得电,工作滑台快速后退、复位,并进入下一个工作循环。Sliding table quick return oil circuit: After a certain period of delay in upsetting pressure holding, electromagnet 4DT is de-energized, 5DT is energized, and the working slide table quickly retreats, resets, and enters the next working cycle.
为了保证液压控制系统工作的可靠性,供油过滤器选用高纳污能力(β≥200)、高过滤精度(10μ)的过滤器。In order to ensure the reliability of the hydraulic control system, the oil supply filter uses a filter with high dirt-holding capacity (β≥200) and high filtration precision (10μ).
液压控制系统的主要技术参数是:额定压力,50bar;工作压力调节范围,35~50bar;系统额定流量,12L/min;油箱有效容积,100L;工作介质,VG32或VG46高抗磨液压油;电动机功率,1.5KW;电压,380VAC;频率,50Hz。The main technical parameters of the hydraulic control system are: rated pressure, 50bar; working pressure adjustment range, 35-50bar; system rated flow, 12L/min; oil tank effective volume, 100L; working medium, VG32 or VG46 high anti-wear hydraulic oil; motor Power, 1.5KW; Voltage, 380VAC; Frequency, 50Hz.
3、计算机测控系统:3. Computer measurement and control system:
参见图8和图9,计算机测控系统主要由人机界面、可编程控制器(PLC)、变频器88、传感器及低压电器等组成,其中:PLC是系统的控制中心,系统的顺序控制、互锁保护及各部分的功能协调均由它来完成;人机界面是人机对话的窗口,用于焊机操作、参数设置与在线修改以及焊机运行状态显示等;变频器用于焊机主轴的驱动及其转速的调速;传感器用于焊机主轴转速、工件轴向缩短量和油雾发生器液位的实时检测以及工作滑台行程的限位;低压电器包括空开、继电器、接触器等。图10所示为本实用新型的计算机控制流程图。Referring to Fig. 8 and Fig. 9, the computer measurement and control system is mainly composed of man-machine interface, programmable logic controller (PLC),
本实用新型PLC控制器选用日本三菱公司产品,配置的主要器件包括:FXIN-24MR-001型主机;FX2N-2AD型A/D模块(12位模拟量输入,1~5V);F930GOT-BWD-C型触摸显示器及FX-50DU-CABO型触摸显示屏电缆等。飞轮转速由变频器实时检测,工件轴向变形量选用WDYC-10L型差动变压器式位移传感器(12VDC供电,0~5VDC输出,量程10mm)实时检测。The PLC controller of this utility model selects the products of Mitsubishi Corporation of Japan, and the main components of the configuration include: FX IN -24MR-001 type host; FX 2N -2AD type A/D module (12-bit analog input, 1 ~ 5V); F930GOT- BWD-C type touch display and FX-50DU-CABO type touch display cable, etc. The flywheel speed is detected by the frequency converter in real time, and the axial deformation of the workpiece is detected by the WDYC-10L differential transformer displacement sensor (12VDC power supply, 0-5VDC output, range 10mm) for real-time detection.
实际工作时,计算机测控系统上电后,人机界面进行自检,自检完成后进入“操作画面”;操作面板上设置有多个功能按钮,主要包括:手动/自动操作方式转换、液压泵启/停、液压建立/取消、滑台快进/工进/快退、离合器接合/分离、顶锻,以及焊机主轴旋转/停转等;为实施程序控制和电气互锁保护,还配置了用于表征工件已处于接触状态的压力继电器、滑台限位行程开关,以及用于工况监测的水压继电器、气压继电器、油雾器液位监测传感器等。In actual work, after the computer measurement and control system is powered on, the man-machine interface performs a self-inspection, and enters the "operation screen" after the self-inspection is completed; there are multiple function buttons on the operation panel, mainly including: manual/automatic operation mode conversion, hydraulic pump Start/stop, hydraulic pressure establishment/cancellation, slide table fast forward/work forward/fast reverse, clutch engagement/disengagement, upsetting, and welding machine spindle rotation/stop, etc.; for the implementation of program control and electrical interlock protection, it is also configured The pressure relay, slide limit travel switch used to indicate that the workpiece is in contact, and the water pressure relay, air pressure relay, lubricator liquid level monitoring sensor, etc. used for working condition monitoring.
当人机界面上“手动/自动”按钮转换到手动方式时,可实现液压泵启/停、液压建立/取消、滑台快进/工进/快退、离合器接合/分离、焊机主轴停止、顶锻等操作;当转换到自动方式时,整个系统转换为自动操作,其控制流程见图10。When the "manual/automatic" button on the human-machine interface is switched to the manual mode, the hydraulic pump can be started/stopped, the hydraulic pressure is established/cancelled, the slide table is fast forwarded/worked/reversed, the clutch is engaged/disengaged, and the welding machine spindle is stopped. , Upsetting and other operations; when switching to automatic mode, the whole system is converted to automatic operation, and its control flow is shown in Figure 10.
焊机主轴转速、滑台工进时间、顶锻保压时间等参数均可在线设置与修改。Parameters such as the rotating speed of the welding machine spindle, the working time of the sliding table, and the pressure holding time of the upsetting can be set and modified online.
本实用新型微型高速惯性摩擦焊机的主要性能参数如下:The main performance parameters of the utility model miniature high-speed inertial friction welding machine are as follows:
①主轴转速:10000-50000rpm(可调);①Spindle speed: 10000-50000rpm (adjustable);
②主轴最小转动惯量:3.2×10-5kgm2;②Minimum moment of inertia of main shaft: 3.2×10 -5 kgm 2 ;
③最大焊接力:5.0KN;③Maximum welding force: 5.0KN;
④焊件直径范围(棒材):φ1.5-φ5.0mm;④Weldment diameter range (bar): φ1.5-φ5.0mm;
⑤焊件长度:旋转端,20-30mm;移动端,20-50mm;⑤Weldment length: rotating end, 20-30mm; moving end, 20-50mm;
⑥焊机动态精度:主轴径向跳动量≤0.015mm,轴向窜动量≤0.020mm;⑥Dynamic accuracy of welding machine: the radial runout of the main shaft is ≤0.015mm, and the axial movement is ≤0.020mm;
⑦旋转夹具径向跳动量:≤0.035mm;⑦Radial runout of rotating fixture: ≤0.035mm;
⑧移动夹具轴线与主轴轴线同轴度偏差:≤0.05mm。⑧Concentricity deviation between the moving fixture axis and the spindle axis: ≤0.05mm.
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