PLC-based centerless grinder automatic feeding system
In the modern production process, Die Casting is a very common form of production. Common die castings include Aluminum Alloy Die Casting and zinc alloy die casting.
Die Casting: (Pressure casting) involves the rapid pressing of a liquid or semi-liquid alloy under high pressure into a mold cavity and solidification under pressure to obtain a casting:
1. Inject metal
The mold cavity is closed first, and the molten metal is injected into the mold inlet gate through the injection hole on the pressure chamber.
2. Die casting
The injection plunger advances and the molten metal is pressed into the mold cavity.
3. Remove the casting
After the casting is solidified, the core-pulling mechanism extracts the cores on both sides of the cavity at the same time, the mold is separated from the mold before and after, and the ejector ejects the casting.
Widely used in aerospace, automotive, communication, electronics, instruments, medical...large application industry and [Excellent quality, high efficiency, energy saving, environment protection" required industry.
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just use as technology sample
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position.
The control device is the core of the whole system automation. Using the popular PLC control technology at home and abroad, the entire feed processing process can be controlled in real time.
Third, the centerless grinder automatic feeding system software and hardware design 1, programmable controller selection Grinder automatic feeding system is a single machine control small automation system, requires PLC with multiple input points and output point characteristics, high control accuracy, reliable work, programming It has good flexibility and strong anti-interference ability, and can adapt to the vibration environment of industrial sites. Based on the above considerations, the FXON-60MR programmable controller manufactured by Mitsubishi Corporation of Japan is selected, which is a new product of the FXON series, which is a miniature programmable controller that condenses many functions in an ultra-small cabinet, and the company's F1/F2. Compared with the series, the installation area is only 41% of the former, and the volume is only 37%. The controller has convenient functions such as analog potentiometer and RUN/STOP switch. It can be freely selected and connected by the expansion unit expansion module and the basic unit. Convenient, the control system is as shown.
The input point of the PLC control system block diagram system is the button on the electric control board, the limit switch quantity signal at each actuator, and the output of the system is the electromagnetic reversing valve coil and the indication alarm lamp for controlling each execution cylinder. The input signal of the PLC is the switch quantity, which can be directly connected with the input terminal of the PLC. The solenoid valve is directly connected to the PLC output terminal and can be driven by the 24VDC power supply carried on the PLC.
2, automatic feeding system loop design The automatic feeding system mainly has two basic feeding circuits and one is the feeding circuit. The other is the feed loop. The main task of the feeding circuit is to take the workpiece from the chute and change the position and direction of the workpiece by the robot. Finally, the workpiece is placed into the V-shaped grate of the loader according to the specified posture. The specific working process is as follows: the initial state of the feeding circuit is S2. When the transfer start M8041 is ON, and the workpiece switch X035 in the slide is detected to be ON, the robot is released. After the robot is released for 500ms, a workpiece is sent to the loader. In the robot, the workpiece switch X034 is turned ON, the timer is timed, and the robot is clamped after 500 ms. After the robot clamps for 500ms, the robot is on the right. The right line to the limit switch X016 is ON, the manipulator rotates, and when it is rotated to the limit end, the limit switch X020 is ON, and the robot is locked.
There is no workpiece in the V-groove of the loader, the loader is at the back end, the pusher is at the back end, and the loader and the pusher are not advanced, the manipulator is lowered. When the robot is lowered to the limit end, the limit switch X022 is ON, and the robot releases the workpiece. When the timing is released for 500ms, the robot is raised. When it reaches the rising limit. The limit switch X023 is ON, the manipulator is turned back to the original position, the limit switch X021 is ON, and the manipulator is left.
From the left line to the limit end, the switch XO17 is ON, the feeding circuit returns to the initial state S2, and the feeding circuit completes one cycle.
The main task of the feeding circuit is to feed the workpiece in the V-groove of the loader into the gap between the two grinding wheels of the centerless grinding machine for grinding. The working process of the feeding circuit is: the initial state of the feeding circuit is s3, when the transfer command M8041 is ON, when there is a workpiece in the V-shaped groove of the loader, the loader advances and advances to the limit end, and the limit switch X024 is ON, the pusher advances and the workpiece is sent to the grinding position. After the timer is 100ms, the loader and the pusher are retracted. Back to the limit end, the limit switches X025 and X027 are ON, and the abrasive device advances. Advance to the limit end, the limit switch X033 is ON, and the timing is determined by D8030. After the grinding time is up, the abrasive device retreats and retreats to the limit end. The limit X031 is ON and the output device advances. Advance to the limit end, the limit switch X033 is ON. After the time is 500ms, the output device retreats and retreats to the limit end. The limit switch X032 is ON, and the feeding circuit returns to the initial state 83 to complete a cycle.
3. Preparation of the sequence control flow function diagram According to the working characteristics of the automatic feed system, a sequence control flow chart is prepared, as shown. At the beginning of the system, it is first judged whether it is manual or automatic. If it is manual, it will be transferred to the manual program. At this time, each time the button on the control panel is connected, the feeding system will perform a corresponding action. If it is automatic, the automatic start button on the control panel will be pressed. After that, the system automatically completes the feeding action of the workpiece.
According to the function diagram of the feeding system and the input and output terminal table of the PLC, we use the FX series basic programming command and sequence control function command. We have programmed the ladder diagram of the automatic feeding system. In addition to the input relay (X) and output relay (in the ladder diagram) In addition to Y), a large number of auxiliary relays (M), status elements (S), timers (T), conditional jumps CJ (P), and the like are also used. The entire ladder diagram is roughly divided into three basic modules: input module, logic operation module, and output module. The input module completes the manual automatic state selection, and the switching signal acquisition input logic operation module completes the logical relationship between the input signal and the state. The output module completes the logic operation and controls the external actuator through the output relay.
The system uses the vibrating hopper and the slide to separate the workpiece and the directional automatic feeding system. The sequential control flow chart arrangement fully considers that the tappet does not allow large impact and friction. The use of a robot to feed the workpiece allows the entire feed system to be compact and positionally accurate. With the programmable controller as the central control unit, it has the advantages of high reliability, stable operation and strong anti-interference.
The centerless grinder automatic feeding system is a relatively complicated mechatronics equipment with high degree of automation, which greatly improves the efficiency of the centerless grinding machine and completely changes the manual feeding speed and low efficiency. At present, from the results of the operation, the system can invest about 30,000 yuan at a time, which can improve the production efficiency of single machine several times and reduce the cost by nearly 50%. It is a low-cost centerless grinder technical transformation project suitable for national conditions. Great promotion and application value. The system uses a stalk part as the processing object for the feeding system. For other parts with similar shape and size, due to the flexibility of PLC development, the PLC parameters are adjusted and Japan is US$402 million, Malaysia is US$407 million, and the Netherlands and Thailand each have US$0.4 billion. Wait. In 2002, it exported a total of 1.05 billion gold cutting machine tools and 398 million forming machine tools, totaling 1.44 billion US dollars, second only to Switzerland's 1.48 billion US dollars. When the world economy was sluggish, Taiwan exported 1.44 billion machine tools in 2002, an increase of 5.5% from 1.36 billion in 2001. It should be said that its competitiveness is strong.
In order to explain the competitiveness of Taiwanese machine tools in the world market, this paper analyzes the comparison between Taiwan and the mainland machine tool industry in China, which shows that Taiwan’s competitiveness is strong and the competitiveness of the mainland is weak. The direction of efforts should be.
1. Understand the characteristics of the machine tool industry and the law of development, and have the scientific spirit of seeking truth from facts. It is closely integrated with the actual conditions of Taiwan Island and social needs, and the guiding ideology is correct and the methods are right. Paying attention to "practical, practical and affordable", the economic effect is better, and the competitiveness is constantly improving. The lack of resources in Taiwan, the small number of people and the small foundation, the weak foundation, the poor conditions in all aspects, far less than the mainland, but from Japan, I have learned from Japan's experience in developing machine tool industry, developed precision machine tools from ordinary machine tools, and developed NC machine tools. There are a group of experts who study Japanese machine tool technology, understand the characteristics and development rules of machine tools, down-to-earth, solid advancement, and persist in seeking truth from facts and scientific spirit. Seriously cultivate talents, strictly manage, pay attention to quality, strengthen services, carefully calculate everywhere, and pay attention to economic benefits.
Never blindly catch up with the world's advanced level, but combine the market demand to develop a lower-cost, more extensive, cheaper and more practical NC machine tool than Japan, occupying the vast markets of the United States, Europe and Asia. Guide the thinking correctly, the method is right, pay attention to "practical, practical, and affordable." Therefore, better economic benefits are obtained and the competitiveness is rapidly increasing.
2. The Chinese Taiwan authorities attach importance to the machine tool industry and are relatively correct in terms of policies and policies. Governments, associations, and enterprises have good cooperation with each other, and can play an individual and collective fighting role, showing strong competitiveness. Taiwan has a clear policy on the development of the machine tool industry. For example, "industrial promotion of agriculture, agricultural state industry, mutual integration, and common development" proposes two high developments (high technology intensity, high technology added value), two major (large relationship with production, large market potential), and two lows. There is a clear policy such as low energy demand and low pollution level, and “meeting domestic demand and expanding exportsâ€. From 1988 to 1990, the output of NC machine tools was 3,600, 6,258, 5,670 units, and the exports were 2,148, 3,595, and 3,621 units. The export accounted for 53%-63% of the output. In 1999-2001, the processing center's output reached the guidelines and policies, and the association The market demand is actively investigated, analyzed and organized. The scientific research unit (Institute of Machinery Industry) tries its best to cooperate with enterprises from the development of varieties. The enterprises cooperate with each other to implement specialized production, with sound organization and high efficiency, so the export competitiveness is strong.
3. Persevere in cultivating talents and improving quality; strengthen scientific research and strive to develop new varieties; pay attention to product quality and thoughtful service, and establish a permanent global reputation. Taiwanese enterprises are short and lean, adopt modern management methods, attach importance to cultivating talents, and improve Quality, strict assessment, such as technical cadres to assess business, foreign language, organizational skills, technical staff assessment of professional knowledge and practical skills, according to the piece-rate system more work and more. When the Machinery Industry Research Institute cooperates with the enterprise, the NC machine tool high-speed spindle, the guide rail positioning accuracy, and the manipulator's operation reliability are all rigorously tested and innovated. Pay attention to product quality everywhere.
The key components and the main shaft are assembled and inspected in the constant temperature room and recorded seriously. Attentive service, proactive contact with users, responsible for the user, establish a permanent reputation. Therefore, the sales volume of the products is large.
4. Taiwan's machine tool enterprise system and mechanism adapt to the market economy, division of labor and cooperation, specialized production, strict organization, responsiveness, few personnel, strong combat strength. Taiwanese enterprises are small and specialized, for joint-stock or private ownership, well-organized, efficient High, adapt to the competition system of the world market economy, stimulate the initiative, enthusiasm and creativity in the mechanism, and achieve good economic benefits.
Finally, we must especially emphasize that the above analysis is by no means a matter of seeking truth from facts, but all objective facts. Many numbers are quite contrasting. Taiwanese machine tools are highly competitive in the world market and are by no means a day's work. The mainland machine tool industry must pay close attention to major contradictions, lay a good foundation for technology, make basic efforts too hard, and effectively solve six problems of "talent, scientific research, innovation, quality, cooperation, and credibility", and effectively solve social needs, technology, and personnel on products. The three qualities are closely combined, adhere to the "people-oriented", "quality first", "professional cooperation", through long-term unremitting struggle, China's machine tool industry can revitalize, competitiveness can be continuously improved!
(Continued from page 32) A slight modification of the mechanical device can also achieve automatic feeding, which has strong practicability and adaptability.