RU2690625C2 - Test bench for intelligent system of adaptive control of cutting process on metal cutting machines with spindle assembly with active magnetic bearings - Google Patents

Abstract

FIELD: test.SUBSTANCE: invention relates to equipment for investigation of cutting process control systems on metal cutting machines, having spindle assembly with active magnetic bearings. Stand consists of three-coordinate metal-cutting machine of accuracy class "C" with CNC system and spindle assembly, which is replaceable and contains electric rotor-spindle arranged vertically in rolling bearings with active magnetic bearings. Test bench also has means for loading rotor-spindle with external load, made in the form of tool mandrel fixed at working end of rotor-spindle with possibility of receiving working dynamic loads from processing tool in process of real mechanical blade treatment of reference specimen of workpiece, and control-measuring structure with sensors. At that, the CNC system, sensors and active magnetic bearings of supports are made with possibility of connection to the analyzed intelligent adaptive control system through the appropriate converters.EFFECT: use of the invention makes it possible to expand the stand's technological capabilities, as well as to increase the reliability and accuracy of the conducted investigations.3 cl, 21 dwg, 1 tbl

Description

The invention relates to the field of electromechanics and can be used in levitational rotary mechanisms on electromagnetic supports. A more specific use is as an experimental stand for researching and testing a sample of an intelligent adaptive control system for the cutting process on metal-cutting machines with a spindle assembly with active AMP magnetic bearings (electrical spindle / motor spindle /).

The main direction of development of metalworking machines with CNC is the modular construction of machine tools (mechatronic complexes) based on single integration platforms with extensive use of mechatronic modular systems and modules that combine information, energy and control functions in a single structural unit. In the electronic (software and hardware) block, a coordinated intelligent selection of parameters of individual subsystems of the numerical control system (NC) is ensured, subordinated to the common task - achieving the required, technologically defined, precision parameters of mechanical blade processing on metal-cutting machines.

To improve the technical level and quality level of machining of machining machines, as the basic components of competitiveness, the following factors come to the fore: reliability, accuracy, productivity, and intelligence.

The reliability of the machine - one of the basic requirements of the consumer, and often serves as the prevailing criterion for assessing quality. Among the mechatronic systems of machine tools (such as: rotary and tilt-swivel tables, turrets, feed drives) electrical spindles (spindles with built-in motor - motor spindles) are the most important components that determine the quality of equipment and precision machining on it. Electric spindles most fully illustrate their specific features of construction, design, basic problems and tasks of mechatronic systems of machine tools.

A modern high-speed or high-torque electrical spindle is a complex rotational mechatronic system with a high level of integration into the design of functional components — intelligent mechatronic modules (built-in engine, spindle supports, engine and bearing cooling, lubrication system, tool clamping mechanism, etc., see fig. 18).

The main advantages of such a mechatronic system of the elecro spindle include:

- direct transformation of energy and information, complete elimination or simplification of kinematic chains and, therefore, high accuracy and improved static and dynamic characteristics;

- compactness of the unified structural scheme of the system and, therefore, improved weight and size parameters;

- the possibility of combining and integrating the electrical spindle into more complex mechatronic systems (angular spindle heads) and complexes (multi-purpose machining centers) allowing for quick reconfiguration (systems for automatic changing of electro-spindles / motor-spindles /);

- the relatively low cost of installation, maintenance and system configuration due to the block-modular design, the unification of software and hardware;

- the ability to perform complex, high-precision, spatially adjustable (i.e., adjustable in a three-coordinate system) rotational motion of the actuator (i.e., the rotor-spindle of the electric spindle), due to the application of methods and means of intelligent and adaptive control of the actuator by means of in the description of the present technical solution of a sample of the intelligent system of adaptive control of the cutting process on metal-cutting machines.

From the current level of technology known stand for the study (testing) of the intelligent system of adaptive control of the magnetic suspension of the rotor-spindle spindle assembly, including the following electromechanical components and structures.

Basic mechatronic structure with a numerical control system (CNC), including a hardware platform with technologically specified software, and a spindle assembly with active magnetic bearings (AMP), which are functionally the front and rear supports of the spindle rotor-spindle assembly. The spindle assembly is structurally formed with the possibility of accommodating its rotor-spindle in the end zones and, accordingly, the location of active magnetic bearings, instrumentation structures in the form of two pairs of contactless sensors of the spatial position of the rotor-spindle rotation axis and, accordingly, the gap in the AMP, which functionally are the means of recording and transmitting data into the aforementioned CNC system by means of analog-digital and digital-analog converters of the studied intellectual systems adaptive control of the rotary spindle of the spindle unit during the cutting process. The design of the spindle assembly provides for the installation of these structures, in planes perpendicular to the axis of rotation of the rotor-spindle of the spindle assembly in pairs, offset by 90 ° from one another in the circumferential direction in each pair.

In addition, the stand also includes a means of dynamically loading the rotor-spindle of the spindle assembly with an external load corresponding to the working load under actual operating conditions of the spindle assembly simulator of typical loads (see S.A. Toguzov, EK Evdokimov, Т.А. Izosimova, the publication “Stand for the study of the automatic control system of the rotor magnetic suspension of a high-energy installation”, materials of the XII All-Russian meeting on the problems of VSPU-2014 control, pp. 4807-4814, Moscow, 2014, UDC 681.52) - a prototype.

The disadvantages of this known technical solution include the impossibility of using it to study the intelligent adaptive control system specifically for the cutting process on metal-cutting machines with a spindle assembly with an AMP (electric spindle) with real ones resulting from the blade processing of the reference part, loads on the spindle rotor-spindle assembly in the mode real time.

This is due to the fact that the dynamic loading of the rotor-fender from the side of the loading device used in the well-known technical solution does not correspond to the dynamic loading conditions of the rotor-fender of the analogous spindle assembly (electric spindle) under the conditions of blade machining on metal-cutting machines with an vertical electric spindle.

The objective of the claimed technical solution is the creation of a scientific and technical reserve in the field of building intelligent systems for adaptive control of the cutting process on metal-cutting machines with an electrical spindle on a real-time basis (that is, with mechanical blade processing on the stand of a real reference workpiece).

More specifically, the following main technical tasks are set:

- development and creation of kinematic, electrical, pneumatic connections and connections in accordance with GOST 2.701-84 experimental bench for testing a sample of the intelligent adaptive control system of the cutting process, ensuring stable and reliable operation of the electrical spindle during testing;

- selection of the necessary layout and design of the main components of the stand for performing applied scientific and technical research;

- development and creation of kinematic, electrical, pneumatic connections and connections in accordance with GOST 2.701-84 experimental model of an intelligent adaptive control process for cutting on machines with a spindle assembly with active magnetic bearings (i.e. with electrical spindle / motor spindle /).

The technical result of the claimed technical solution is to increase the reliability due to the speed (sensitivity) of the adaptive control system and, accordingly, the dynamic accuracy of the spatial positioning of the axis of rotation of the electromagnetic suspension of the rotor-spindle of the spindle assembly (electric spindle), as well as the end result is a tool) as applied to actual cutting conditions.

The technical result is achieved by the fact that in the test bench for (testing) an intelligent system of adaptive control of the cutting process on metal-cutting machine tools with a spindle assembly with an AMP, including:

- a basic mechatronic structure with a numerical control system (CNC), including a hardware platform with technologically specified software, and a spindle assembly with active magnetic bearings, which are functionally the front and rear supports of its rotor-spindle;

- spindle assembly, structurally formed with the possibility of placing in the end zones of its rotor-spindle and, respectively, areas of the location of active magnetic bearings, control and measuring structures in the form of two pairs of contactless sensors of spatial position of the rotor-spindle axis and, accordingly, the gap in the active magnetic bearings which, i.e. these structures are installed in planes perpendicular to the axis of rotation of the rotor-spindle of the spindle assembly in pairs, offset from each other by 90 ° in the circumferential direction in each pair, and functionally are the means of recording and transmitting data into the above-mentioned CNC system using analog digital and analogue converters of the studied intellectual adaptive cutting process control systems;

- as well as a means of loading the rotor-spindle of the spindle assembly by an external load corresponding to the working load in actual operating conditions of the spindle assembly, according to the invention:

At the working end of the rotor-spindle, an instrumental mandrel is fixed, which is functionally a means of dynamically loading the rotor-spindle of the spindle assembly with the mentioned external load due to its perception of the actual working dynamic loads from the tool during the actual mechanical blade processing of the reference sample of the workpiece in real time testing the above-mentioned intellectual adaptive cutting process control systems;

- the case assembly unit of the spindle assembly is equipped with means for placing in the area of the working end of the tool holder, as well as, in the area of the rear end of the rotor-spindle, two pairs of additional non-contact sensors, functionally being the means of recording and monitoring the spatial position of the end of the tool holder, and hence the spatial the positions of the tool itself, and the rear end of the rotor-spindle, respectively, are commutatively connected through the corresponding transformative structures tivity intelligent adaptive control system with software and hardware platform of said CNC system;

- the mentioned means are structurally designed to provide installation of said sensors in each pair in a plane perpendicular to the axis of rotation of the rotor-spindle of the spindle assembly with an offset of 90 ° relative to one another in the circumferential direction;

- the front support of the spindle assembly is made in the form of a radial-resistant active magnetic bearing; The basic mechatronic structure is structurally organized on the basis of a three-coordinate metal cutting machine of particularly high accuracy, i.e., accuracy class C, with a CNC system and a vertical arrangement of the rotor-spindle axis of the spindle assembly;

- the above-mentioned machine includes auxiliary functional systems controlled by the CNC system, as well as the following main structural units:

- a bed with flat and V-shaped guides, the surfaces of which are equipped with a textolite coating, and also have means of protection against contamination in the form of a tape structure with means of adjusting the belt tension;

- mounted on the guides of the bed, the slide of the slide table with the CNC-controlled precision drive of their movement, while the upper slide guides intended for mounting the table also equipped with the CNC-controlled precision drive of its movement are made structurally identical to the above-described bed guide and are also equipped with the same a means of protection against pollution in the form of a tape structure with a means of adjusting the tension of the tape, which, i.e., the tape structure, is constructive ostranno organized with the possibility of adjusting the tightness of pressing the guide table table-sled to counter-guides with textolite sled coating, due to the coverage mentioned by the tape rollers mounted in the sled table-sled;

- a vertical stand with front and rear guides and a spindle head mounted on the front rails of the rack with a CNC-controlled precision drive for its movement, structurally including a speed box and a spindle unit placed in the structural structure of the means for installing the spindle unit in the spindle head, the headstock is equipped with balancing weights installed with the possibility of working movement along the rear rails of the stand by means of adjustable no flexible couplings, the ends of which are fixed to the body and headstock, respectively, on the balance weights, and rear rack rails are equipped with means of protection against pollution in the form of a telescopic plate structure;

- in addition, the structure of the means for mounting the spindle assembly in the spindle headstock is structurally formed with the possibility of mounting on the spindle headstock both a spindle assembly in the form of a typical mechanical spindle assembly and a spindle assembly of mechatronic type, made in the form of an electrical spindle with active magnetic bearings, equipped with the above mentioned controls - measuring structures based on the respective sensors of the spatial position of the axis of rotation of its rotor-spindle.

Optimally, the aforementioned precision drives for displacing the main structural units would be made in the form of a drive screw - rolling gear transmission and equipped with electric motors, mainly servomotors.

It is advisable that the mentioned mutually movable basic structural units would be equipped with: means for automatically turning off their precision drives in extreme positions; means of automatic emergency shutdown of these drives; automatic means to ensure access to the reference point - that is, to the zero point of reference of the movement of the corresponding node; means for counting the movement of the corresponding nodes, made in the form of linear transducers, commutatively connected with the CNC system.

The spindle unit can be made, for example, in the form of an electrical spindle of the model “IBAG 200 MA 40 K”

As a rule, the aforementioned auxiliary functional systems of the stand should be made in the form:

- the hydraulic system, which is functionally a means of pressing the tool in the spindle, switching the speed ranges of the main drive of the stand, lubricating the gearbox and supplying oil to the centralized system of periodic lubrication;

- centralized lubrication systems, functionally being a means of periodic centralized lubrication: on the rack - bearings of the spindle moving the headstock; on the frame - bearings of the lead screw for moving the sled of the sled-table; on the headstock - spindle nuts move the headstock along the guides and reverse slats; on the sled of the sled table - bearings of the lead screw for moving the table, nuts for the running screw for moving the sled, guides the pairs of the sled-bed; on the table - the lead screw for moving the table, guides the table-sled;

- pneumatic equipment system, functionally being a means of cooling the spindle assembly;

The hydraulic system, in reasonable performance, should be made in the form of a constructive and technologically interconnected:

- hydraulic stations (for example, type CB-M5A-40-H-1.1-3-6.3), including: pump, filter, accumulator, pressure switch, hydraulic unit with modular equipment;

- hydraulic equipment installed on the stand;

- executive bodies in the form of a hydraulic cylinder for switching speeds and a hydraulic cylinder for pressing the tool.

The system of centralized lubrication, as a rule, includes: distributor; pressure reducing valve; the central feeder, which includes a node with a rod-indicator, functionally being a means of controlling the work of said feeder visually and automatically; microswitch; secondary feeders, which are located on the sled, on the table, on the rack and on the spindle headstock.

The system of pneumatic equipment, as a rule, includes: a compressor with a receiver, an air drying and cooling station, as well as an air preparation panel and pneumatic distributors.

Conducted by the applicant's analysis of the level of technology, including a search for patent and scientific and technical sources of information and the identification of information about the analogues of the claimed technical solution, did not find analogues characterized by signs and relationships between them, identical or equivalent to all the essential features of the claimed technical solution. The prototype chosen from the identified analogues (as the closest analogue in terms of the totality of features) made it possible to identify in the claimed object a set of essential (with respect to the technical result perceived by the applicant) distinctive features set forth in the formula.

Therefore, the claimed technical solution meets the condition of patentability "novelty" under the current legislation.

The invention is illustrated by the following graphic materials:

FIG. 1 - a general view of the stand (front view);

FIG. 2 - a general view of the stand (side view / right / in Fig. 1);

FIG. 3 - a general view of the stand (top view on Fig. 1);

FIG. 4 - kinematic scheme of the stand;

FIG. 5 - bed (front view);

FIG. 6 - bed (top view on Fig. 5);

FIG. 7 - skid table (frontal view, partial cut);

FIG. 8 - table-sled (section aa in Fig. 7);

FIG. 9 - stand (front view);

FIG. 10 - stand (section BB in Fig. 9);

FIG. 11 - headstock (front view);

FIG. 12 - headstock (side view / left / according to Fig. 11);

FIG. 13 - gearbox of spindle head (side view, longitudinal section);

FIG. 14 is a sectional view BB of FIG. 13;

FIG. 15 - knot (spindle, standard mechanical, longitudinal section);

FIG. 16 is a block diagram of an intelligent adaptive process control system for cutting machines with a spindle assembly with active magnetic bearings (AMP);

FIG. 17 is a control circuit of a typical active magnetic bearing (AMP);

FIG. 18 is a block diagram of an electrical spindle system (main subsystems of a range of typical electrical spindles of main motion drives);

FIG. 19 is a photograph of a typical electrical spindle design (with partial longitudinal notch, axonometry);

FIG. 20 is a block diagram of a high-speed spindle system (spindle assembly) made by Ibag on active magnetic bearings (AMP);

FIG. 21 is a longitudinal section of the general appearance of the electrical spindle with the AMP of the IBAG HF 200 MA 40 K model;

Systems, units, assemblies, mechanisms and other structural elements of the declared experimental test bench in graphic materials are indicated by the following positions:

General view of the stand (Fig. 1 - Fig. 3):

1 - bed;

2 - table-sled;

3 - stand;

4 - grandma (spindle);

5 - gearbox (spindle head 4);

6 - hydraulic cylinder (switching speeds in the box 5 speeds);

7 - hydraulic cylinder (pressing tool);

8 - a casing (protection of the hydraulic cylinder 7 for pressing the tool);

9 - bracket (for balancing load-counterweight);

10 - coolant station;

11 - transmission (drive screw-nut drive drive 12);

12 - drive (movement of the table 21);

13 - fencing (protective working area of the table-sled 2);

14 - node (spindle, standard mechanical);

15 - box (for the tool);

16 - table (universal);

17 - hydraulic station;

18 - electrical cabinet;

19 - CNC system (with control panel).

20 - sled (table-sled 2);

21 - table (table-sled 2).

Kinematic scheme of the stand (Fig. 4):

22 - drive (movement of the slide 20);

23 - drive (movement of the spindle head 4);

24 - drive (rotation gears 29-33 boxes 5 speeds);

25 - motor (drive movement of the slide 20);

26 - motor (drive movement of the table 21);

27 - electric motor (drive movement of the headstock 4 spindle);

28 - electric motor (drive 24 boxes 5 speeds);

29, 30, 31, 32, 33 - wheels (gear boxes 5 speeds);

34 - couplings (no backlash for connecting the drives 12, 22, 23, 24 with the corresponding electric motors).

Stand bed (Fig. 5 and Fig. 6):

35 - tape (protection belt guides of the bed 1);

36 - screws (for rigid fastening of one end of the tape 2 to protect the belt guides of the bed 1);

37 - bar (for fastening the tape 2 with screws 11);

38 - screw (tension for the second end of the tape 2 to protect the belt guides of the bed 1);

39 - surface (bed 1);

40 - surface (bed 1);

41, 42 - supports (base 1 adjustable vibration damping);

43 - head (reading linear transducer, mounted on the base 1);

44 microswitches (extreme positions of movement of a sled 20 of a table-sled 2);

45 - microswitch (output of the slide of the table-slide 2 to the reference point / i.e., to the zero point of reference of the movement of this organ).

46 - microswitches (emergency stop sled table-sled 2);

47 - window (for the drain of used lubricant in the bed tray 1);

48 - cover (for the transport opening of the stand);

Table-sled stand (Fig. 7 and Fig. 8).

49 - tape (tape protection of the guide sled 20 of the table-sled 2;

50 - sensor (reference movement of the table 21 in the form of a linear transducer).

Stand 3 stand (Fig. 9 and Fig. 10):

51 - flaps (lamellar / flap / protection guides sliding racks);

52 - strips (guides for flaps 51);

53 - electric motor (high torque to drive 23 move spindle head 4);

54 - brackets (units for counterweight ropes 55);

55 - counterweight;

56 - screws (adjusting the length of the counterweight cables 55);

57 - microswitch (to disable the movement of the spindle head 4 in the extreme upper and lower positions);

58 - microswitch (emergency shutdown of the movement of the spindle head 4);

59 - microswitch (to ensure the output of the spindle head 4 to the reference / zero / point);

60 - ruler (sensor / in the form of a linear transducer / reference of the movements of the spindle head 4);

Headstock 4 stands (Fig. 11 and Fig. 12):

61 - head (displacement sensor / in the form of a linear converter / headstock 4);

62 - clamp (tool);

63 - blocks (for cables of balancing load);

64 - remote control (headstock control 4);

65 - cam (turn off the corresponding movements of the spindle head 4);

66 - microswitch (signal about the clamped tool);

67 - microswitch (signal about the pressed tool);

68 — cam (for microswitches 66 and 67, connected to the cylinder of the tool clamping hydraulic cylinder);

69 - coupling (for connecting the spindle device 14 with the gearbox 5 speeds);

70 - support (for installation of the engine 28).

Box 5 stand speeds (Fig. 13 and Fig. 14):

71 - hydraulic cylinder (hydraulic systems for switching the speed ranges of the gearbox 5 speeds);

72 - rod (hydraulic cylinder 71);

73 - ball (spring-loaded ball lock position of the rod 72);

74, 75, 76 - microswitches (signals to the CNC system that the spindle speed range was switched);

77 - hole (to drain the grease).

Typical design of the mechanical spindle assembly 14 of the stand (Fig. 15).

78 - sleeve (standard spindle assembly);

79 - spindle (standard spindle assembly);

80, 81 - roller bearings (precision radial double row);

82 - ball bearing (radial-thrust two-row);

83 and 84 - nuts (for the implementation of the tension of the bearings);

85 and 86 - terminals (for locking the nuts 83 and 84);

87 - spring (cup);

88 - pusher;

89 - collet;

90 - sleeve (crimping collet petals 89, locking the fungus 91);

91 - fungus (tool holder);

92 - protrusion (locking);

The block diagram of the investigated intellectual system of adaptive control of the cutting process (Fig. 16):

93 - sensors (front, the spatial position of the rotor-spindle 100, contactless, for example, optical, to monitor and measure the deviation of the axis of rotation of the rotor-spindle 100 / and, accordingly, the radial clearance in the AMP 97 / front radial-thrust / from the technologically specified spatial position in the process of cutting / machining of the reference blank in real time /, in an amount of two pieces, spatially located in a plane perpendicular to the axis of rotation of the spindle of the spindle assembly with an offset one flax other in the circumferential direction of 90 ° / the second sensor in Fig. 16 is conventionally not shown, due to the two-dimensional image of the scheme /);

94 - sensors (rear, rotor-spindle positions 100, and, accordingly, radial clearance in AMP 98 / rear /, contactless, for example, optical, for monitoring and measuring the deviation of the axis of rotation of the rotor-spindle 100 from the technologically specified spatial position during cutting / machining the reference blank in real time /, in the amount of two pieces, spatially located in a plane perpendicular to the axis of rotation of the spindle of the spindle assembly with displacement of one relative to the other in the circumferential direction by 90 ° / the second sensor in Fig. 16 is conventionally not shown, due to the two-dimensional image of the scheme /);

95 - sensors (contactless, for example, optical, to control the rotational speed and the spatial position of the rear end of the rotor-spindle 100, i.e., the deviation of its end from the technologically predetermined spatial position in the process of cutting / machining the reference workpiece in real time /, in the amount of two pieces, spatially located in a plane perpendicular to the axis of rotation of the spindle of the spindle assembly with an offset of 90 ° relative to each other in the circumferential direction / the second sensor in Fig. 16 is conditionally not coupled, scheme due to the two-dimensional /) image;

96 - sensors (contactless, for example, optical, for monitoring the spatial position of the front end of the tool holder, i.e., measuring the spatial deviation of the axis of rotation of the end of the tool holder (due to bending and vibrations) from its technologically specified spatial position during cutting / machining reference blank in real time /, in the amount of two pieces, spatially located in a plane perpendicular to the axis of rotation of the spindle of the spindle assembly with one offset . In relative each other in the circumferential direction by 90 ° / second sensor in FIG 16 is not shown, circuits /) due to the two-dimensional image;

97 - bearing (active magnetic / AMP /, front, angular contact);

98 - bearing (active magnetic / AMP /, rear, radial);

99 - electric motor (asynchronous);

100 - rotor-spindle (spindle assembly in the form of an electrical spindle);

101 - converter (analog-digital, / ADC /);

102 - converter (digital-analog / D / A);

103 - amplifier (power over current);

104 - controller (digital control of the intelligent system of adaptive control of the cutting process);

105 - converter (analog-digital, / ADC /);

106 - controller (digital control of the electric motor 99);

107 — subsystem (measuring and recording the spatial position of the end of the tool holder);

108 - system (numerical control / CNC / test bench);

109 - converter (analog-digital, / ADC /)

The typical design of the spindle assembly in the form of an electric spindle / motorspindle / - FIG. nineteen:

110 - device (tool clamping);

111 - bearings (hybrid ceramic);

112 - flange;

113 - brushes (antistatic);

114 - tool (hydraulic unclenching tool);

115 - gauges (spindle / rotor position monitoring);

116 - sensor (control position of the piston);

117 - drainage

118 means (automatic compensation of axial expansion of the spindle shaft / spindle /);

119 - sensors (temperature measurement of hybrid ceramic bearings 111);

120 - recorder (data);

121 - sensor (rotor vibrations of the electrical spindle);

122 - configuration (installation of bearings for optimally high axial stiffness);

123 — means (for providing hydraulic preload);

124 - encoder (for vector control and spatial orientation of the rotor / spindle / electric spindle / spindle assembly);

125 - device (supply of coolant / coolant / through the center of the spindle / rotor of the electric spindle /);

126 - elongation (spindle / rotor of the electrospindle /);

The design of the test bench (research) of the intelligent system of adaptive control of the cutting process on metal-cutting machines includes the following main and auxiliary structural and technological mechanisms, components and systems (see Fig. 1-Fig. 16).

The basic mechatronic structure with system 19 (Fig. 3) or 108 (Fig. 16) of numerical control (CNC), including a hardware platform with technologically specified software, and spindle assembly 14 with active magnetic bearings (AMP) 97 and 98, functionally being the front and rear supports of the rotor-spindle 100 of the spindle assembly, and also with the tool mandrel attached to the working end of the rotor-spindle 100. Spindle unit 14 is structurally formed with the possibility of placing in the end zones of its rotor-spindle 100 and, respectively, areas of the location of the AMP 97 and 98, measuring and measuring structures in the form of two pairs of contactless sensors 93 and 94 of the spatial position of the axis of the rotor-spindle 100 and , the gap in AMP 93 and 94. The mentioned structures are installed in planes perpendicular to the axis of rotation of the rotor-spindle 100 of the spindle assembly 14 pairs, offset by 90 ° from each other in the circumferential direction in each pair and function They are logging and transmitting data into said system 19 (Fig. 3) or 108 (Fig. 16) CNC by means of analog-digital and digital-analog converters 101, 105, 109 and 102, respectively, of the intelligent adaptive cutting process control system under study.

The stand also includes a means of loading the rotor-spindle 100 of the spindle assembly 14 with an external load corresponding to the working load under actual operating conditions of the spindle assembly 14 in the form of an electric spindle with a rotor-spindle 100 mounted on supports with AMP 97 and 98.

The means of loading the rotor-spindle 100 of the spindle assembly 14 (in the form of an electro-spindle) the said external load is functionally an instrumental mandrel attached to the working end of the rotor-spindle 100, due to its perception of the actual working dynamic loads from the tool during the actual mechanical blade processing of the reference sample of the workpiece Real-time testing of the above-mentioned intelligent adaptive cutting process control system.

The body assembly unit of the spindle assembly 14 in the form of an electric spindle is also equipped with means for placing in the area of the working end of the tool holder installed in it, as well as, in the area of the rear end of the rotor-spindle 100, two pairs of additional proximity sensors 96 and 95, respectively. The said means are structurally arranged to provide installation of the said sensors 96 and 95, in each pair, in a plane perpendicular to the axis of rotation of the rotor-spindle 100 of the spindle assembly 14 with an offset of 90 ° from one another in the circumferential direction. The sensors 96 and 95 functionally are the means of recording and monitoring the spatial position of the end of the tool holder, and hence the spatial position of the tool itself, and the rear end of the rotor-spindle 100, respectively, commutatively connected through the appropriate transformative structures of the studied intelligent adaptive control system with the hardware-software platform the aforementioned system 19 (Fig. 3) or 108 (Fig. 16) CNC.

The front support spindle node 14 is made in the form of a radial-resistant AMP 97.

The basic mechatronic structure is structurally organized on the basis of a three-coordinate metal-cutting machine of especially high accuracy (i.e., accuracy class C) with system 19 (Fig. 3) or 108 (Fig. 16) CNC and vertical arrangement of the rotor-spindle axis 100 of the spindle assembly 14 .

The mentioned machine includes managed by the system 19 (Fig. 3) or 108 (Fig. 16) CNC auxiliary functional systems, as well as the following main structural units:

- frame 1 with flat and V-shaped guides, the surfaces of which are equipped with a textolite coating, and also have means of protection against contamination in the form of a tape structure with means of adjusting the tension of the tape 35;

- mounted on the guides of the bed 1 of the slide 20 of the table-slide 2 with a precision-driven drive 22 controlled by the CNC, moving them, while the upper guides of the slide 20 (intended for installing the table 21, also equipped with a controlled system 19 / Fig. 3 / or 108 / Fig 16 / CNC precision drive of its movement) are made constructively identical to the above-described bed 1 guides and are also equipped with a similar means of protection against contamination in the form of a tape structure with a means of adjusting the belt tension; this tape structure is structurally organized with the possibility of adjusting the tightness of pressing the guide table 21 of the sled table 2 to counter-guides with a textolite coated sled 20, due to the coverage of the rollers mounted in the sled 20 of the sled table 2;

- a vertical stand 3 with front and rear guides and a spindle head 4 mounted on the front guides of the rack 3 with the system 19 (Fig. 3) or 108 (Fig. 16) controlled by the CNC, with a precision drive 23 of its movement, structurally including a box of 5 speeds and spindle assembly 14 housed in the structural structure of the means for mounting the spindle assembly 14 in the spindle head 4; the headstock 4 is equipped with balancing weights — a counterweight 55, installed with the possibility of working movement along the rear rails of the rack 3 by means of flexible links that are adjustable along the length, the ends of which are fixed to the body of the headstock 4 and, accordingly, on balancing weights (counterweight 55), and rear guide racks 3 are equipped with a means of protection from contamination in the form of a plate telescopic structure;

- in addition, the structure of the means for mounting the spindle assembly 14 in the headstock 4 is structurally formed with the possibility of installing on the spindle headstock 4 both the spindle assembly 14 in the form of a typical mechanical spindle assembly (FIG. 15) and a spindle assembly of mechatronic type, made in the form electric spindle with AMP (Fig. 16, Fig. 18 - Fig. 21), equipped with the above-mentioned control and measuring structures based on the respective sensors 93, 94, 95, 96 of the spatial position of the axis of rotation of its rotor-spindle 100.

Optimally, the aforementioned precision drives for moving the main structural components of the stand would be made in the form of a drive screw - rolling gear transmission and would be equipped with electric motors, mainly servo motors.

It is advisable that the mentioned mutually movable basic structural units would be equipped with: means for automatically turning off their precision drives in extreme positions; means of automatic emergency shutdown of these drives; automatic means to ensure access to the reference point - that is, to the zero point of reference of the movement of the corresponding node; means for counting the movement of the corresponding nodes, made in the form of linear transducers, commutatively connected with the CNC system.

The spindle unit can be made, for example, in the form of an electrical spindle of the “IBAG 200 MA 40K” model.

As a rule, the aforementioned auxiliary functional systems of the stand should be made in the form:

- the hydraulic system, which is functionally a means of pressing the tool in the spindle, switching the speed ranges of the main drive of the stand, lubricating the gearbox and supplying oil to the centralized system of periodic lubrication;

- centralized lubrication systems, functionally being a means of periodic centralized lubrication: on the rack - bearings of the spindle moving the headstock; on the frame - bearings of the lead screw for moving the sled of the sled-table; on the headstock - spindle nuts move the headstock along the guides and reverse slats; on the sled of the sled table - bearings of the lead screw for moving the table, nuts for the running screw for moving the sled, guides the pairs of the sled-bed; on the table - the lead screw for moving the table, guides the table-sled;

- pneumatic equipment system, functionally being a means of cooling the spindle assembly;

The hydraulic system, in reasonable performance, should be made in the form of a constructive and technologically interconnected:

- hydraulic stations (for example, type CB-M5A-40-H-1.1-3-6.3), including: pump, filter, accumulator, pressure switch, hydraulic unit with modular equipment;

- hydraulic equipment installed on the stand;

- executive bodies in the form of a hydraulic cylinder for switching speeds and a hydraulic cylinder for pressing the tool.

The system of centralized lubrication, as a rule, includes: distributor; pressure reducing valve; the central feeder, which includes a node with a rod-indicator, functionally being a means of controlling the work of said feeder visually and automatically; microswitch; secondary feeders, which are located on the sled, on the table, on the rack and on the spindle headstock.

The system of pneumatic equipment, as a rule, includes: a compressor with a receiver, an air drying and cooling station, as well as an air preparation panel and pneumatic distributors.

The bench is installed on the foundation on four adjustable vibration-suppressing supports 41, 42 that provides the necessary dynamic characteristics in accordance with the technical conditions.

A more detailed description of the main components of the stand is given below.

The basic structure of the stand includes: bed 1; table-sled 2 (with a movable sled 20 and table 21); rack 3 vertical; headstock 4 spindle; a box of 5 speeds (spindle head 4); 6 shift cylinder (gearbox 5 speeds); spindle assembly 14 (in particular, standard mechanical); hydraulic cylinder 7 pressing tool spindle node 14; casing 8 protection cylinder 7 pressing tool; bracket 9 for balancing weight-counterweight 55; station 10 coolant; transfer 11 running screw-drive nut drive 12; drive 12 to move the table 21 of the sled table 2; fencing 13 of the working area of the sled table 2; 15 - box 15 for the tool; table 16 universal; hydraulic station 17; electrical cabinet 18; 19 CNC system with control panel.

The basic structure of the stand is equipped with a domestic CNC system FlexNC, which allows you to control the parameters of the blade processing process and organize adaptive control in accordance with the specified technological characteristics.

The construction of the bed 1 is shown in the graphic materials in FIG. 5 and FIG. 6.

The bed 1 is made in the form of a box-shaped element with internal stiffening ribs. In the upper part of the frame 1, there is a V-shaped and flat horizontal sliding guides for the sled 20 of the sled table 2. The working surfaces of the V-shaped and flat form of the horizontal sliding guides of the sled 20 of the sled table 2 are equipped with a fluoroplastic coating (for example, glued strips from fluoroplastic), which ensures the smooth movement of the sled 20 of the table-sled 2 along the guides of the bed 1.

The guide frame 1 is protected from dirt and shavings tape protection in the form of a tape 35.

On the frame 1, from one of its ends, the tape 35 tape protection is fixed rigidly with screws 36 through the bar 37, the other end of the tape 35 is tensioned with an adjusting tension screw 38. The tape 35 bends around the rollers mounted in the sled 20 of the table-sled 2. Chips from the table 21 table-sled 2 falls on the surface 39 and 40 of the frame 1, where it is removed manually (brush). The oil leaks from the rack pillars 3, the lead screw supports, the slide rails 20 and the table 21 of the slide table 2 are poured through window 47 in frame 1 and are collected in a tray.

Between the guides of the frame 1, the actuator 22 is mounted for moving the slide 20 of the table-slide 2. The actuator 22 consists of a pair of rolling screw-nut, connected by a backlash-free coupling with a high-torque electric motor mod. AIR M100L4Y2.

This ensures the entire range of feeds considered mutually movable nodes without the use of gearboxes. The lead screw is installed in two bearings on rolling bearings.

To count the movement of the slide of the table-slide 2, a sensor in the form of a linear transducer is used. The sensor ruler is fixed on the sled 20 of the sled table 2, the read head 43 is mounted on the bed 1. The coordinate of the actual position of the movable organ (sled 20) is displayed on the screen of the CNC unit 19 of the basic structure (stand).

To disable the movement of the slide of the table-2 slide 2 in extreme positions, 2 microswitches are installed: microswitches 44 - to disable the movement of the slide 20 in their extreme positions; microswitches 46 - for emergency shutdown of the drive 22 move the slide 20 of the table-slide 2.

The microswitch 45 provides the output of the slide 20 to the reference point (i.e., to the zero point of reference of the movement of this stand body).

In the case of the frame 1 there are two through holes for transporting the stand. The holes are covered with lids 48.

The design of the sled table 2 is shown in the graphic materials in FIG. 7 and FIG. 8.

Table 21 of the table-sled 2 has a rectangular shape, on the working surface of the table 21 T-shaped grooves are cut to secure the workpiece. Table 21 is mounted on a sled 20 of a sled table 2.

The drive 12 of the movement of the table 21 is similar to the drive movement of the slide 20 of the table-slide 2 (see in the previous section, "the description of the design of the frame").

The table 21 moves along the guides of the sled 20 of the sled table 2. The sliding guides used in the stand enable the table 21 and the sled 20 of the sled table 2 to move smoothly without jerks.

The slide guides of the table 21 are equipped with tape protection in the form of a tape 49 against ingress of dirt and shavings. The principle of protection of the guide table 21 is the same as that of the guide sled 20 of the table-sled 2 and described in the previous section "description of the bed construction". Tape 49 tape protection guide table 21 has another purpose - it functionally is also a means of pressing the surface of the guide table 21 to the surface of the guide sled 20. The tension of the tape 49 through the adjusting screws presses the table 21 to the sled 20 of the sled table.

To turn off the movement of the table 21 in extreme positions and transfer it to the reference point (i.e., to the zero point of reference of the movement of this stand body), microswitches (conventionally not indicated in the graphic materials).

The principle of operation of microswitches is similar to the operation of microswitches described in the previous section, "description of the bed construction".

To count the movement of the table 21 is used, the sensor 50 in the form of a linear transducer. The ruler of the sensor 50 is fixed on the table 21, the read head - on the sled 20 of the table-sled 2.

The structure of the rack 3 is shown in the graphic materials in FIG. 9 and FIG. ten.

The rack 3 is a box-shaped casting with vertical V-shaped and flat sliding guides to move the headstock 4. A lamellar (shield) telescopic protection is provided to prevent dirt from entering the sliding guides. The protection flaps 51 slide along the grooves of the strips 52. A high-torque 53 DAT100-4.0-1500-U2 engine is installed in the upper part of the rack. It is kinematically connected by means of a coupling to the drive screw of the movement 23 of the spindle head 4 movement. drive screw 23 is mounted on the headstock 4.

In addition, there are two brackets 54 with blocks for sliding the cables, to which the counterweight 55 is hung, designed to balance the headstock 4.

The counterweight 55 moves inside the rack 3. To obtain an equal length of both cables, there are adjustment screws 56. The movement of the headstock 4 in the extreme positions is turned off by microswitches 57, 58, 59.

Microswitches 57 - are designed to disable the movement of the headstock 4 in the extreme upper and lower positions. Microswitches 58 - designed for emergency shutdown of the movement of the spindle head 4. Microswitches 59 - provide the output of the spindle head 4 to the reference (zero) point.

To count the movements of the spindle head 4, a linear transducer is used, the ruler 60 of which is fixed on the rack 3.

The design of the headstock 4 is shown in the graphic materials in FIG. 11 and FIG. 12.

Headstock 4 is moved in the vertical direction along the guides of the rack 3 by means of an actuator 23 structurally arranged in the form of a transmission running screw-rolling nut. The lead screw is mounted in supports mounted on a stand 3, the rolling nut is fixed on the body of the headstock 4. The movement of the headstock 4 is measured by a sensor in the form of a linear transducer, the head of which is fixed on the legs 3, and the head 61 is mounted on the headstock 4.

The spindle headstock 4 includes the following main components: the spindle device 14, the tool clamp 62, the gearbox 5 speeds. The blocks 63 move the cables on which the counterweight 55 of the spindle head 4 hangs. The balance control 64 is located on the front side of the spindle head 4.

To disable the movement of the spindle head 4 in the extreme positions on the body of the spindle head 4 fixed cam 65.

Microswitches 57, 58 and 59 are installed on the rack 3 (see Fig. 9).

The shutdown of the headstock 4 in the extreme positions is switched off by microswitches 57, 58, 59 (see Fig. 9).

Microswitches 57 - are designed to disable the movement of the headstock 4 in the extreme upper and lower positions. Microswitches 58 - designed for emergency shutdown of the movement of the spindle head 4. Microswitches 59 - provide the output of the spindle head 4 to the reference (zero) point.

Microswitches 66 and 67 are designed to signal the pressed or clamped instrument.

If the cam 68 connected to the cylinder of the tool clamping cylinder presses the microswitch 66 - the tool is clamped, if the cam 68 presses the microswitch 67 - the tool is released.

The spindle assembly 14 is connected to the 5-speed box by the flexible backlash-free coupling 69.

The main drive (spindle rotation) is driven from a high-torque electric motor 28 of model DAT100-4.0-1500-U2, mounted on support 70.

The design of the speed box 5 is shown in the graphic materials in FIG. 13 and FIG. 14.

Box 5 speeds provides two ranges of numbers of revolutions of the output shaft connected directly to the spindle of the spindle node 14. Switching from range to range is carried out from the hydraulic system using a hydraulic cylinder 71.

By applying pressure to the lower or upper part of the hydraulic cylinder 71, we obtain three positions of the rod 72. These positions are fixed by a spring-loaded ball 73 of the ball retainer.

The upper range of numbers of revolutions of the spindle 79 is achieved by the introduction into gearing of the gear wheel 30 with the gear wheel 31.

The speed range 6.3 ... 800 is achieved by introducing into gearing the gear 32 with the gear wheel 33. With the average position of the gear wheel 30, when it is disengaged from the gear wheel 31 and not entered into engagement with the gear wheel 33, the rotation is transmitted to the spindle 79 no. Within each range, the change in speed is infinitely variable from a DC drive.

The upper, lower ranges of spindle speeds 79 and the middle position (zero) are fixed by microswitches 74, 75, 76. Microswitches 74, 75, 76 give a signal to the CNC system 19 that the spindle speeds 79 are switched.

Lubrication of gears and bearings of the box 5 speeds is carried out centrally by irrigation from the lubrication system. Oil is drained from the speed box 5 through hole 77 into the cavity of the body of the headstock 4, from where it is discharged into the hydraulic station. Spindle speed 79 is set on the CNC control panel. The CNC system 19 gives a signal to turn on the hydraulics and oil is fed under pressure into the corresponding cavity of the hydraulic cylinder 71.

The design of a typical mechanical spindle assembly 14 is shown in graphic materials in FIG. 15.

Mechanical spindle node 14 is installed in the housing of the headstock 4 and is attached to it with screws.

The mechanical spindle assembly 14 consists of a fixed sleeve 78 and a spindle 79. Precision radial double-row roller bearings 80 and 81 are used as supports for the spindle 79, and axial-force radial double-row ball bearing 82 with a contact angle of 60 ° is used to perceive axial forces. The bearings are tensioned with the help of nuts 83 and 84. The nuts are fixed against spontaneous unscrewing by clamps 85 and 86. The bearings are lubricated with grease. To prevent accidental ingress of liquid lubricant from the 5-speed gearbox into the spindle device 14 bearings, labyrinth and rubber seals are provided.

The device healed tool is mounted inside the spindle 79. The tool is clamped by cup springs 87.

When clamping, the cup springs 87 transmit an axial force through the pusher 88 of the collet 89, the petals of which enter the sleeve 90 and compress and lock the fungus 91 screwed into the tool holder. The conical seating surface of the tool holder is tightened to the mating conical surface of the spindle 79. The clamping force of the tool is P = 7000 N. To prevent the tool from turning in the spindle 79, during the machining of the part, there are two locking protrusions 92 on the spindle end 79.

Auxiliary systems

Stand hydraulic system performs the following functions:

- spin tool in the spindle;

- switching the speed ranges of the main drive of the stand;

- grease gear box;

- oil supply to the system of centralized periodic lubrication.

Stand hydraulic system consists of:

- hydro;

- hydraulic equipment installed on the stand;

- executive bodies: hydraulic cylinders for switching speeds, hydraulic cylinders for pressing the tool.

Hydraulic station CB-M5A-40-H-1.1-3-6.3 is used in the hydraulic system of the stand.

The main components of the hydraulic station: pump, filter, accumulator, pressure switch, hydraulic unit with modular equipment.

The hydraulic system works on oil IGP-20 TU38 101798-79.

Oil is supplied to the hydraulic system from a pump with a capacity of 3 l / min, through a filter. Pressure is regulated by a safety valve and controlled by a pressure gauge when the toggle switch is turned on. After measuring the pressure switch toggle off.

The power supply of the hydraulic system and the centralized lubrication system is carried out from the battery, which starts charging when the pump and the hydraulic distributor electromagnet are turned on.

Description of the lubrication system.

The system is designed for periodic centralized lubrication:

- on the rack 3 - the bearings of the spindle movement of the spindle head 4;

- on the base 1 - bearings of the lead screw for moving the slide 20;

- on the spindle headstock 4 - the nuts of the spindle screw for moving the headstock 4, on the guides and reverse slats;

- on the sled-bearings of the chassis movement of the table, the nut of the chassis screw of movement of the sled, guides of the sled-bed;

- on the table - the lead screw of the displacement of the table, guides the table-sled.

The lubrication system is powered by the hydraulic system of the machine. The control unit of the lubrication system includes a distributor, a reducing valve, a central feeder, complete with a node with a rod indicator, which allows to control its operation visually and automatically, a microswitch, secondary feeders located on the slide, on the table, on the rack, on the spindle grandmother.

The system works as follows: using the CNC system 19, the solenoid valve is activated. Oil from the pump begins to flow to the central feeder, sections of which supply lubricant to the secondary feeders, and from them to the lubricated points. After counting the required number of strokes of the central feeder indicator, i.e. the number of pulses, the electromagnet is turned off and the oil supply stops.

After the required time interval, the CNC re-activates the electromagnet and lubricates again. If the stock indicator makes an insufficient or excessive number of strokes, a lubrication failure is indicated on the machine control panel.

The pneumatic equipment of the stand is designed to cool the spindle 79 of the stand.

The pneumatic equipment of the stand consists of a compressor with a receiver, a dehumidification and air cooling station, as well as an air preparation panel and pneumatic distributors.

To test an experimental model of an intelligent adaptive process control system on a metal-cutting machine with an electrical spindle, in addition to installing a mechanical spindle assembly 14 on the stand, it is possible to install a mechatronic spindle assembly (electrical spindle / motor spindle /), mainly the IBAG HF 200 MA 40 K model ( see Fig. 20 and Fig. 21).

In addition, the constructive formation of the structure of the means for installing the spindle assembly 14 in the spindle headstock 4 can be installed on the spindle headstock 4 as a spindle assembly 14 in the form of a typical mechanical spindle assembly (Fig. 15), as well as a spindle assembly of mechatronic type, made in the form of an electrical spindle with the AMP (Fig. 16, Fig. 18 - Fig. 21), equipped with the above-mentioned control and measuring structures based on the respective sensors 93, 94, 95, 96 of the spatial position of the axis of rotation of its rotor-spindle 100, allows To create a comparative analysis of the processing parameters of real identical reference blanks using one or another spindle assembly 14.

The intelligent system of adaptive control of the cutting process on metal-cutting machines with a spindle assembly with active magnetic bearings, investigated by means of a patented test bench, includes the following functional and technological structures (Fig. 16):

- basic spatially adjustable electromechanical structure in the form of a spindle unit, the rotor-spindle 100 of which is installed on supports with active magnetic bearings - AMP 97 and 98 with the ability to control its spatial position through the registration, control and regulation contours through numerical control system 108 - CNC, structurally organized as a hardware platform, equipped with technologically specified software and commutatively interacting with the mentioned circuit E adaptive control system;

- placed in the zone of the rotor-spindle 100 of the spindle assembly, and, accordingly, in the zone of location of its active magnetic bearings 97 and 98, a two-channel measuring and measuring structure in the form of two pairs of contactless sensors 93 and 94, which is functionally a registration circuit whose channels are functionally organized with the possibility of (through the analog-digital converter 101 and the digital controller 104 of the adaptive system control) feedback commutative communication with the CNC system 108, with the digital the adaptive system control controller 104 is commutatively connected via a digital-to-analog converter 102 and a power amplifier 103 with electric windings of active magnetic bearings 97 and 98, and each pair of said proximity sensors 93 and 94 is installed in a plane perpendicular to the axis of rotation of the spindle rotor 100, offset one relative to another at 90 ° in the circumferential direction;

- as well as a means of dynamic loading of the rotor-spindle 100 of the spindle assembly by an external load corresponding to the working load under actual operating conditions of the spindle assembly.

The spindle unit is structurally formed as an electro-spindle with an instrumental mandrel fixed on the working end of its rotor-spindle 100, and spatially organized with the vertical axis of its rotor-spindle 100, moreover, the radial-thrust AMP 97 is used as the lower support of the latter.

The means of dynamic loading of the rotor-spindle 100 of the spindle assembly by the external dynamic load is functionally a tool holder fixed at the working end of the spindle assembly, due to its perception of the actual working dynamic loads from the tool during machining (i.e., during cutting) of the reference sample billet in real time.

The mentioned measuring structure is equipped with two additional, placed in the area of the working end of the tool holder, contactless sensors 96 installed in a plane perpendicular to the axis of rotation of the rotor-spindle 100 of the spindle assembly offset from one another by 90 ° in the circumferential direction, and functionally means registration and control of the spatial position of the working end of the tool holder, and, accordingly, the spatial position of the tool itself a. This tool is commutatively connected via its own analog-to-digital converter 109 with the subsystem 107 of measuring the position of the end of the tool holder, which, i.e., subsystem 107, is commutatively connected with the hardware and software platform of the above-mentioned CNC system 108.

In addition, the system is equipped with an electric motor 99 digital controller 106. This controller 106 is commutatively connected (via its own analog-digital converter 105, with the means of recording the rotational speed and angular position of the rotor-spindle 100 of the spindle assembly, made in the form of two proximity sensors 95, installed in the zone the rear end of the rotor-spindle 100 in a plane perpendicular to the axis of rotation of the rotor-spindle, offset from one another by 90 ° in the circumferential direction. The controller 106 is connected by a reversible commutative interaction with the hardware and software platform of the CNC system 108 and the control electric winding of the electric motor 99.

The control and regulation circuits of this intelligent system, as a rule, provide for the use of embedded hardware based on programmable logic integrated circuits (FPGAs), which are functionally a means of implementing technologically defined control algorithms with high speed in hard real-time mode.

The principles of the functioning of the main structural units and systems of the patented stand are widely known from the current level of technology, since they are typical, therefore the Applicant considers it inappropriate to disclose them in detail in the framework of this application.

The operation of the intelligent system of adaptive control of the cutting process on metal-cutting machines with an electrical spindle is carried out in accordance with the principal block diagram shown in FIG. 16 graphic materials.

To control the electromagnetic bearings 97 and 98, a digital controller 104 is used to control an adaptive system with active feedback. Initially, the paired optical sensors 93, 94 of the position of the rotor-spindle 100 measure its deviation from the axis of rotation. Through the A / D converter 101, the signal from the sensors is transmitted to the digital controller 104 for controlling the adaptive system, which calculates the control signal necessary to return the rotor-spindle 100 to the normal position. The control signal passes through a digital-to-analog converter - D / A converter 102 and a power amplifier 103, where a control current is formed. The control current is fed to the windings of electromagnets AMP 97 and 98, which create the electromagnetic field necessary to return and hold the rotor-spindle 100 in a technologically specified position. This system, as a rule, works with a frequency of the order of kilohertz, which allows stabilizing the rotor-spindle 100 during rotation, as well as adjusting the rigidity and damping properties of the rotor-spindle.

The CNC system 108 of the stand through the controller 106 controls the rotation of the electric motor 99. Information about the rotational speed and the angular position of the rotor-spindle 100 comes from a pair of sensors 95 through the ADC 105 back to the controller 106 and then to the CNC system 108 of the stand. In the event of a fault, the adaptive system gives an error signal by inhibiting the rotation of the rotor-spindle 100.

To monitor the deviation and vibrations at the working end of the rotor-spindle 100 (more precisely, at the end of the tool holder fixed in it) from the axis of rotation, paired sensors 96 are provided during the cutting process. Through the ADC 109, the signal from the sensors enters the end position measuring subsystem 107 and further in the system 108 CNC stand.

The creation of a scientific and technical basis focused on the development of intelligent adaptive control systems with a complete electrical spindle on active magnetic bearings allows us to start creating and producing a new class of competitive processing complexes and machines for high-performance blade and abrasive machining of modern and advanced structural materials, including for micro- and nano-processing of structural nanostructured materials.

A process with the development of defects in time can be monitored using primary transducers of one or another physical quantity, for example, wear - using displacement sensors, instability - using acceleration sensors (accelerometers), increased friction - using temperature sensors, etc. The introduction of sensor elements into the design of the reference node transforms it into a purely mechatronic module consisting of the mechanical part (bearing parts), electrical (sensors, control microcontrollers) and software (adaptive control software for the signal system).

In the claimed invention, the layout solution of the stand was selected, ensuring reliable operation of the intelligent adaptive system. The stand uses modern components and components of domestic and imported.

The purpose of the implementation of scientific research is the creation of a scientific and technical foundation focused on the development of intelligent adaptive control systems with a complete electrical spindle on electromagnetic bearings, which allows to start the creation and production of a new class of competitive processing complexes and machines for high-performance cutting and abrasive machining of modern and advanced structural materials, including for micro- and nano-processing of structural nanostructured materials.

The results of scientific and practical research will be used in conducting research on the electrical spindle on electromagnetic bearings on a patented experimental test bench with the participation of a foreign partner (Fraunhofer IWU, Germany) in the framework of joint scientific and technical cooperation.

The scientific and technical background created as a result of the invention of the invention contributes to the improvement of the scientific and technical potential of the domestic machine-tool industry and to the strengthening of Russia's competitive position in the global community of manufacturers and researchers of machine tool products.

The main field of application of the AMP is currently high-speed mechanical engineering, from small turbomolecular pumps to turbine generators and compressors with a capacity of tens of MW. The advantage of AMP for this area is the ability to control vibrations, damping elastic vibrations, as well as obtaining well-defined dynamic characteristics. Other important features that have been confirmed by practical research are the ability to provide monitoring and diagnostics, low maintenance costs, and low energy consumption. Thanks to the high-performance power electronics for high-power high-speed mechanical engineering, the use of the AMP is promising and justified. Also, research is currently being conducted on the possibility of using the AMP in aircraft electrical machines as traction engines or generators of electrical energy for all electric aircraft.

The development of modern engineering industry places high demands on the machining accuracy, productivity, reliability of metalworking equipment and the level of its automation. Studies assessing the influence of various factors on the accuracy of processing have established that a spindle assembly (CI) determines it to 80%. The output characteristics of the SHU mainly depend on the type of supports used in them, since the latter provide the necessary rapidity, accuracy of spindle rotation, load capacity and durability of the SHU. In modern high-speed SHU (dxn over 1 million mm / min) use rolling bearings, hydrostatic, gas and magnetic. High-speed SHU on rolling bearings are characterized by thermal deformations, instability of the trajectory of the spindle, associated with a change in the angle of rotation of the separator with a set of rolling elements and the error in the manufacture of rings, as well as limited service life.

The application of electromagnetic bearings with an adaptive control system is promising. The action of an electromagnetic field is based on the principle of electromagnetic stabilization of the position of a ferromagnetic body installed with a gap between diametrically located electromagnets, each of which attracts the body to itself. Obviously, if you do not adjust the current in the windings of electromagnets, then the position of the body will not be stable even if the attracting forces are equal.

The current is regulated by an electronic tracking system, the displacement sensors of which control the deviation of the body from the equilibrium position. The signal from the sensors is amplified, detected and fed to a power amplifier that supplies current to the windings of the electromagnets. When the gap between the body and the electromagnet decreases, the induction in the gap decreases and vice versa. Under the action of the resultant force, the body returns to its original position, to ensure stable body balance, a signal proportional to the velocity of the body is additionally introduced into the tracking system, and to increase the static rigidity of the support, a signal proportional to the integral of the displacement.

FIG. 18 schematically shows the main subsystems of the gamma of electrical spindles of main motion drives.

The composition of subsystems of an optional level may vary and differ slightly due to the characteristics of individual subsystems, operating conditions and customer requirements.

Electrical spindles include two types of subsystems:

- embedded subsystems in one structural unit (the electrical spindle itself);

- service and auxiliary subsystems, which are installed in close proximity to the electrical spindle.

An active magnetic bearing is a classic mechatronic object (Fig. 17), which has practically no basic drawbacks inherent in rolling and sliding bearings. In such a bearing, the centering of the rotor and the transfer of the load to the housing is due to the active magnetic field, the intensity of which is regulated by the control system depending on the rotor movements recorded by the displacement sensors. Such increased performance and safety characteristics affect the cost, in comparison with standard rolling bearings and relatively simple designs of hydrostatic bearings, due to the high demands on accuracy and speed of the elements of the instrumentation system. The high cost, large radial dimensions, the complexity of installation causes the use of active magnetic bearings only in the most critical nodes of machine tools - spindle bearings. Based on the advantages of active magnetic bearings, it is justified that they are used instead of traditional bearing assemblies in the machine tool industry, where their use is most effective.

Increasing the rotational speed through the use of active magnetic bearings significantly improves the performance of the equipment and improves the cleanliness of processing.

A promising is the possibility of combined tool movement together with a tool holder and, accordingly, a rotor-spindle when using adaptively controlled spindle assemblies with a rotor-spindle on the AMP supports (for example, during micromachining when drilling, micro-oscillation when grinding, drilling holes of non-circular shape and t .), which significantly increases the technological capabilities of the equipment. Scope of application - high-performance precision metalworking machines.

Scope of application - high-performance precision metalworking machines.

Based on the analysis of publications in the field of AMP and control systems, we can draw the following conclusions:

Publications in the field of magnetic suspension of rotating rotors in the overwhelming majority relate to rotary machines, where the working loads are torque.

The data of theoretical and experimental studies of electrical spindles with AMP for machine tools, the distinguishing feature of which are the loads on three axes of coordinates, are practically absent.

A few studies relate to small-size electrical spindles (0.4-0.6 kW), which have a relatively narrow scope. From the above it follows that in order to expand the fields of application of AMP in metal-cutting machines in order to widely introduce high-speed blade and abrasive processing of materials, it is necessary to conduct further theoretical and experimental studies of electrical spindles with AMP aimed at expanding their technological capabilities and improving energy efficiency

The above information shows that the following set of conditions is fulfilled when using the claimed technical solution:

- an object embodying the claimed technical solution for its industrial implementation, is intended for use in rotor mechanisms on electromagnetic bearings, and more specifically, as an experimental stand for testing a sample of an intelligent system of adaptive control of the cutting process on machine tools with a spindle assembly with active magnetic bearings (electrical spindle);

- for the declared object, as it is described in the independent clause of the formula below, it is confirmed that it can be implemented using the means and methods described in the application or known from the prior art on the priority date;

- an object embodying the claimed technical solution in its implementation, is able to achieve the technical result perceived by the applicant: improving the reliability due to the speed (sensitivity) of the adaptive control system and, accordingly, the dynamic accuracy of spatial positioning of the axis of rotation of the electromagnetic rotor suspension of the spindle assembly (electric spindle), also the end part of the tool holder (i.e., ultimately, the tool) as applied to real technological their cutting conditions.

Therefore, the claimed technical solution meets the condition of patentability "industrial applicability" under the current law.

Claims (7)

1. Stand for the study of intelligent adaptive control of the cutting process on a cutting machine with a spindle assembly with active magnetic bearings, consisting of basic mechatronic structure, which is made in the form of a three-coordinate metal cutting machine of accuracy class "C", which includes a CNC system with an architecture made on the basis of programmable logic integrated circuits with the ability to implement specified control algorithms of the intelligent system of adaptive control of the cutting process and with the ability to change drive settings machine, and the CNC system contains a hardware platform with the specified software, a bed with a flat and V-shaped guide MI, whose surfaces are equipped with a textolite coating with the ability to reduce the coefficient of static friction, mounted on the bed guides to move in the horizontal plane the sled with the upper guides, on which it is placed to move in the horizontal plane in the direction perpendicular to the direction of movement of the sled, table for fixing CNC-controlled workpieces, precision drives for moving the aforementioned slide and table, are made in the form of their servomotors and gears “spindle screw - rolling nut”, a vertical stand with guides, on which a spindle head with a precision-controlled drive of the spindle head, containing an electric servo motor, a spindle screw and gear box, controlled by the CNC system, is mounted; at the same time, the headstock is equipped with balancing weights to compensate for its weight, and a spindle assembly installed in the headstock, made replaceable and containing an electric rotor-spindle l located vertically in the rolling bearings with active magnetic bearings placed in the end zones of the rotor-spindle, and the front support of the spindle assembly is made in the form of a radial-resistant active magnetic bearing, the loading means of the above-mentioned rotor-spindle by an external load, made in the form of an instrumental mandrel fixed to the working end of the rotor-spindle with the possibility of it accepting the working dynamic loads from the processing tool in the process of a real mechanical blade processing of a reference sample of the workpiece, and an instrumentation structure containing two pairs of contactless spatial position sensors of said rotor-spindle, which are installed in areas where active magnetic bearings are located in pairs in planes perpendicular to the axis of rotation of the rotor-spindle, offset from one another by 90 ° in the circumferential direction each pair, two additional contactless spatial position sensors of the rear end of the rotor-spindle and its rotational speed, which are installed in the area of the rear end of the rotor-sh Indeli in the plane perpendicular to the axis of rotation of the rotor-spindle offset by 90 ° relative to each other in the circumferential direction, and two additional non-contact spatial position sensors of the end of the instrumental mandrel installed in the zone of the said end in the plane perpendicular to the axis of rotation of the rotor-spindle with an offset of one relative to another at 90 ° in the circumferential direction, however, the aforementioned CNC system, sensors, and active magnetic bearings of the supports are capable of being connected through appropriate digital-analog and analog-to-digital converters to the intelligent adaptive control system under study. 2. Stand under item 1, characterized in that the spindle assembly is made in the form of an electro-spindle assembly of the model "IBAG 200 MA 40 K". 3. The stand according to claim 1, characterized in that said three-coordinate cutting machine further comprises a pneumatic equipment system for cooling the spindle assembly and a hydraulic system connected with means for fixing the tool holder in the rotor-spindle and with a system of centralized lubrication of the elements of the said drives, said guides of a bed and a sled are supplied with means of protection against pollution, executed in the form of tape structure with means of adjustment of its tension.

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