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1、 對數(shù)控機床維修五步到位法的探索 中英文對照 For nc machine tool maintenance five-step method in exploration of contrast in both Chinese and English [摘要]隨著國內(nèi)數(shù)控機床的迅速發(fā)展,數(shù)控機床逐步出現(xiàn)故障高發(fā)時段。然而,目前的數(shù)控維修工作混亂無序,根本不能適應(yīng)數(shù)控行業(yè)快速發(fā)展的步伐。為了使數(shù)控維修工作適應(yīng)現(xiàn)代化制造業(yè)的發(fā)展,提高數(shù)控設(shè)備維修質(zhì)量,那么規(guī)范數(shù)控維修行業(yè),已經(jīng)迫在眉睫。本文通過闡述五步到位法,使其具有可利用性、可持續(xù)發(fā)展性,為規(guī)范數(shù)控維修行業(yè)奠定堅實的基礎(chǔ)。 .

2、[abstract] with the rapid development of domestic CNC machine tools, nc machine tool malfunction peak time step by step. Current CNC maintenance work disorder, however, cannot adapt to the pace of the rapid development of nc industry. In order to make the CNC maintenance work adapt to the developmen

3、t of modern manufacturing industry, improve the quality of numerical control equipment maintenance, then the standard CNC maintenance industry, has been imminent. Based on the five steps in place, make its have availability, sustainable, lay a solid foundation for standard CNC maintenance industry.

4、 　　[關(guān)鍵詞]數(shù)控維修 五步到位法 探索 [key words] CNC maintenance method to explore five steps in place 　　 　　一、前言 One, foreword 　　隨著我國機械加工的快速發(fā)展,國內(nèi)的數(shù)控機床也越來越多。由于數(shù)控機床的先進性和故障的不穩(wěn)定性,大部分故障都是以綜合故障形式出現(xiàn),所以數(shù)控機床的維修難度較大,并且數(shù)控機床維修工作的不規(guī)范,使得數(shù)控維修工作處于一種混亂狀態(tài),為了規(guī)范數(shù)控維修工作,提高數(shù)控機床的利用價值,本文提出五步到位數(shù)控維修法。 With the rapid development

5、of the mechanical processing in our country, the domestic nc machine tools are more and more. Due to the instability of the advanced nature of numerical control machine tools and fault, most of the fault is integrated form, so the numerical control machine tool maintenance is difficult, and the nume

6、rical control machine tool maintenance is not standard, making CNC maintenance work is in a state of chaos, in order to standardize the CNC maintenance work, increase the use value of the nc machine tools, CNC maintenance method this paper put forward five steps in place. 　　二、五步到位法 Second, the fi

7、ve steps in place 　　1.故障記錄到位 1. The fault records in place 　　數(shù)控機床發(fā)生故障時,對于操作人員應(yīng)首先停止機床,保護現(xiàn)場,并對故障進行盡可能詳細的記錄,并及時通知維修人員。 Nc machine tool failure occurs, to operating personnel shall, first of all, stop the machine, protect the scene, and the fault are recorded in as much detail as possible, and pro

8、mptly notify the maintenance personnel. 　?、殴收习l(fā)生時的情況記錄 (1) record of failure 　　1)發(fā)生故障的機床型號,采用的控制系統(tǒng)型號,系統(tǒng)的軟件版本號。 1) the failure model of machine tool, control system model, system software version number. 　　2)故障的現(xiàn)象,發(fā)生故障的部位,以及發(fā)生故障時機床與控制系統(tǒng)的現(xiàn)象。 2) the failure phenomenon, failure, and failure phen

9、omenon of machine tool and control system. 　　3)發(fā)生故障時系統(tǒng)所處的操作方式。 3) failure systems operating mode. 　　4)若故障在自動方式下發(fā)生,則應(yīng)記錄發(fā)生故障時的加工程序號,出現(xiàn)故障的程序段號,加工時采用的刀具號等。 4) if a fault occurs in automatic mode, you should record the failure process, failure in the procedures section, and is used when processing

10、cutting tool number, etc. 　　5)若發(fā)生加工精度超差或輪廓誤差過大等故障,應(yīng)記錄被加工工件號,并保留不合格工件。 5) in case of machining accuracy out-of-tolerance or contour error is too large, etc, shall be recorded by machining, and keep the unqualified parts. 　　6)在發(fā)生故障時,若系統(tǒng)有報警顯示,則記錄系統(tǒng)的報警顯示情況與報警號。 6) in the event of a failure, if the

11、re is alarm system, according to the record system of the alarm display and alarm number. 　　7)記錄發(fā)生故障時,各坐標軸的位置跟隨誤差的值。 7) record a failure occurs, the axes position follow error value. 　　8)記錄發(fā)生故障時,各坐標軸的移動速度、移動方向,主軸轉(zhuǎn)速、轉(zhuǎn)向等。 8) recording a failure occurs, the axis of moving velocity, moving directi

12、on, spindle speed, steering, etc. 　?、乒收习l(fā)生的頻繁程度記錄 2 failure frequency of record 　　1)故障發(fā)生的時例與周期。 1) the failure cases and cycle. 　　2)故障發(fā)生時的環(huán)境情況。 2) failure of environmental conditions. 　　3)若為加工零件時發(fā)生的故障,則應(yīng)記錄加工同類工件時發(fā)生故障的概率情況。 3) for processing parts failure occurs, you should record the prob

13、ability of failure happens when processing the same workpiece. 　　4)檢查故障是否與“進給速度”、“換刀方式”或是“螺紋切削”等特殊動作有關(guān)。 4) check if failure and "feed rate", "transfer mode" or "thread cutting and other special action. 　　⑶故障的規(guī)律性記錄。 (3) failure regularity of record. 　?、裙收蠒r的外界條件記錄。 (4) failure of external con

14、ditions. 　　2.故障檢查到位 2. The fault inspection in place 　　維修人員故障維修前,應(yīng)根據(jù)故障現(xiàn)象與故障記錄,認真對照系統(tǒng)、機床使用說明書進行各頂檢查以便確認故障的原因。當數(shù)控設(shè)備出現(xiàn)故障時,首先要搞清故障現(xiàn)象,向操作人員了解第一次出現(xiàn)故障時的情況,在可能的情況下觀察故障發(fā)生的過程,觀察故障是在什么情況下發(fā)生的,怎么發(fā)生的,引起怎樣的后果。搞清了故障現(xiàn)象,然后根據(jù)機床和數(shù)控系統(tǒng)的工作原理,就可以很快地確診并將故障排除,使設(shè)備恢復正常使用。故障檢查包括: Maintenance personnel before the breakdown

15、 maintenance, should according to the fault phenomena and fault recording, seriously control system and machine tool operating instructions for all inspection in order to identify the cause of failure. When nc equipment fault occurs, the first to find out fault phenomenon, to operating personnel und

16、erstand the failure for the first time, where possible, observe the failure process, observe the fault is in what circumstances happen, happened, cause what kind of consequences. Clarified the failure phenomenon, and then according to the working principle of machine tool and numerical control syste

17、m, can be quickly diagnosed and troubleshooting, make the equipment return to normal use. Fault inspection include: 　?、艡C床的工作狀況檢查。 (1) the working conditions of machine tool inspection. 　　⑵機床運轉(zhuǎn)情況檢查。 2 the workings of the machine tool inspection. 　?、菣C床和系統(tǒng)之間連接情況檢查。 (3) check connections betwee

18、n machines and systems. 　　⑷CNC裝置的外觀檢查。 (4) the appearance of the CNC device check. 　　維修時應(yīng)記錄檢查的原始數(shù)據(jù)、狀態(tài),記錄越詳細,維修就越方便,用戶最好編制一份故障維修記錄表,在系統(tǒng)出現(xiàn)故障時,操作者可以根據(jù)表的要求及時填入各種原始材料,供維修時參考。 Maintenance should be recorded when checking the raw data, status, record the more detailed, maintenance is more convenient,

19、 users had better prepare a breakdown maintenance records, failure in the system, the operator can according to the requirements of table to fill in the various raw materials, for reference in maintenance. 3. 診斷故障到位 3. The fault diagnosis in place 　　故障診斷是進行數(shù)控機床維修的第二步,故障診斷是否到位,直接影響著排除故障的快慢,同時也起到

20、預(yù)防故障的發(fā)生與擴大的作用。首先維修人員應(yīng)遵循以下兩條原則: Fault diagnosis is the second step in the numerical control machine tool maintenance, fault diagnosis is in place, directly affects the speed of troubleshooting, but also have the effect of prevent the happening of the fault and expansion. First of all maintenance per

21、sonnel should follow the following two principles: 　　(1)充分調(diào)查故障現(xiàn)場。這是維修人員取得維修第一手材料的一個重要手段。 (1) full investigation failure on site. This is the maintenance personnel maintenance first-hand material is an important means. 　　(2)認真分析故障的原因。分析故障時,維修人員不應(yīng)局限于 CNC部分,而是要對機床強電、機械、液壓、氣動等方面都作詳細的檢查,并進行綜合判斷,達到確珍

22、和最終排除故障的目的。 (2) carefully analyse the causes of failure. Failure analysis, maintenance personnel should not be limited to the CNC parts, but to heavy current of nc machine tools, mechanical, hydraulic, pneumatic, etc all details of the inspection, and make a comprehensive judgment, to Jane and ulti

23、mately the purpose of troubleshooting. 　　1)直觀法。2)系統(tǒng)自診斷法。3)參數(shù)檢查法。4)功能程序測試法。5)部件交換法。6)測量比較法。7)原理分析法。8)敲擊法。9)局部升溫法。10)轉(zhuǎn)移法。 1) the intuitive method. 2) since the diagnosis system. 3) parameter test. 4) function test program. 5) component exchange method. 6) measurement comparison method. 7) principle

24、 analysis. 8) tapping method. 9) local ShengWenFa. 10) transfer method. 　　除了以上介紹的故障檢測方法外,還有插拔法、電壓拉偏法、敲擊法等等,這些檢查方法各有特點,維修人員可以根據(jù)不同的現(xiàn)象對故障進行綜合分析,縮小故障范圍,排除故障。 In addition to the above introduction of fault detection method, insertion method, voltage deviation, tapping and so on, these inspection metho

25、ds have different characteristics, maintenance personnel can according to different phenomenon to comprehensive analysis of fault, narrowing the scope of failure and troubleshooting. 　　4.維修方法到位 4. Maintenance method in place 　　在數(shù)控機床維修中,維修方法的選擇到位不到位直接影響著機床維修的質(zhì)量,在維修過程中經(jīng)常使用的維修方法有以下幾種: In CNC mach

26、ine maintenance, maintenance methods of choice in place does not reach the designated position directly influences the quality of machine maintenance, the maintenance is often used in the process of maintenance method has the following kinds: 　　(1)初始化復位法。由于瞬時故障引起的系統(tǒng)報警,可用硬件復位或開關(guān)系統(tǒng)電源依次來清除故障,若系統(tǒng)工作存貯區(qū)

27、由于掉電、拔插線路板或電池欠壓造成混亂,則必須對系統(tǒng)進行初始化清除,清除前應(yīng)注意作好數(shù)據(jù)拷貝記錄,若初始化后故障仍無法排除,則進行硬件診斷。 (1) initializes the reset method. Caused by transient fault alarm system, available hardware reset or power switch system in order to clear the fault, if the system working storage area due to power off, the circuit board or the

28、 battery voltage cause confusion, it must be initialized to the system clear, should be paid attention to clear before to make a good record of data copy, if still cannot be ruled out after initialization failure, hardware diagnosis. 　　(2)參數(shù)更改,程序更正法。系統(tǒng)參數(shù)是確定系統(tǒng)功能的依據(jù),參數(shù)設(shè)定錯誤就可能造成系統(tǒng)的故障或某功能無效。有時由于用戶程序錯誤

29、亦可造成故障停機,對此可以采用系統(tǒng)搜索功能進行檢查,改正所有錯誤,以確保其正常運行。 (2) the parameter changes, more understand the program. Is to determine the system function on the basis of system parameters, parameter setting error can cause system fault or some function is invalid. Sometimes also can cause downtime due to user program

30、 error, this search function can be used for inspection, correct all errors and to ensure its normal operation. 　　(3)調(diào)節(jié)、最佳化調(diào)整法。調(diào)節(jié)是一種最簡單易行的辦法。通過對電位計的調(diào)節(jié),修正系統(tǒng)故障。 (3) the adjustment and optimization of control. Regulation is one of the most simple way. Through to the potentiometer adjustment, correct

31、ion system failure. 　　(4)備件替換法。用好的備件替換診斷出壞的線路板,并做相應(yīng)的初始化啟動,使機床迅速投入正常運轉(zhuǎn),然后將壞板修理或返修,這是目前最常用的排故辦法。 (4) spare parts replacement. Diagnosed with bad PCB replace with good parts, and do the corresponding initialization, make the machine tool quickly put into normal operation, then repair or repair the b

32、ad board, this is by far the most common troubleshooting methods. 　　(5)改善電源質(zhì)量法。目前一般采用穩(wěn)壓電源,來改善電源波動。對于高頻干擾可以采用電容濾波法,通過這些預(yù)防性措施來減少電源板的故障。 (5) to improve power supply quality standard. At present generally adopts the regulated power supply, to improve the power supply fluctuations. Capacitance filteri

33、ng method can be used for high frequency interference, through these preventive measures to reduce the power board failure. 　　(6)維修信息跟蹤法。一些大的制造公司根據(jù)實際工作中由于設(shè)計缺陷造成的偶然故障,不斷修改和完善系統(tǒng)軟件或硬件。這些修改以維修信息的形式不斷提供給維修人員 (6) maintenance information tracking method. Some of the biggest manufacturing company accordi

34、ng to the practical work of accidental failure due to design flaws, constantly modify and improve the system of software or hardware. These changes in the form of maintenance information constantly available to maintenance personnel 　　(7)修復法。對數(shù)控機床的故障進行恢復性修復、調(diào)整、復位行程開關(guān)、修復脫焊、斷線、修復機械故障等。 (7) the repa

35、ir method. Restorative for nc machine tool fault repair, adjust, reset the switch, repair welding, bolt and repair of mechanical failure, etc. 　　5.維修記錄到位 5. Maintenance records in place 　　維修時應(yīng)記錄、檢查的原始數(shù)據(jù)、狀態(tài)較多,記錄越詳細,維修就越方便,用戶最好根據(jù)本廠的實際清況,編制一份故障維修記錄表,在系統(tǒng)出現(xiàn)故障時,操作者可以根據(jù)表的要求及時填入各種原始材料,供再維修時參考。 Mainten

36、ance, check the raw data, we should record when state is more, record the more detailed, maintenance is more convenient, users had better according to our actual conditions, preparation of a fault maintenance records, failure in the system, the operator can according to the requirements of table to

37、fill in the various raw materials, reference for repair again. 　　通常維修記錄包括以下幾方面的內(nèi)容;(1)現(xiàn)場記錄;(2)故障原因;(3)解決方法;(4)遺留的問題;(5)日期和停工的時間;(6)維修人員情況;(7)資料記錄。 Usually the content of the maintenance records include the following aspects; (1) the record; (2) the cause of the problem; (3) solution; (4) the legac

38、y of problems; (5) the date and the shutdown of the time; (6) maintenance personnel; (7) data record. 　　三、結(jié)束語 Third, the conclusion 　　五步到位法的實施,提高重復性故障的維修速度,提高維修者的理論水平和維修能力,有利于分析設(shè)備的故障率及可維修性,改進操作規(guī)程,提高機床壽命和利用率,并能充分實現(xiàn)資源共享。使其具有可利用性、可持續(xù)發(fā)展性,為規(guī)范數(shù)控維修行業(yè)奠定堅實的基礎(chǔ)。 Five steps in the implementation of the me

39、thod, speed up the repair of repeated failure and improve the theory level of WeiXiuZhe and repair ability, is advantageous to the analysis of equipment failure rate and maintainability, improve operational procedures, improve the utilization rate of machine tool life and and can be fully realized r

40、esources sharing. Has the availability, sustainable development, lay a solid foundation for standard CNC maintenance industry. 　　 　　參考文獻: References: 　　[1]沈兵,歷承兆.數(shù)控系統(tǒng)診斷與維修手冊.北京機械工業(yè)出版社, 2009. Carried out [1], through ChengZhao. CNC system diagnosis and maintenance manuals. Machinery industr

41、y press, 2009. 　　[2]楊中力.數(shù)控機床故障診斷與維修.天津:天津理工大學出版社, 2008. [2] Yang Zhongli. Nc machine tool fault diagnosis and maintenance. Tianjin: tianjin university of science and technology press, 2008. 　　[3]孫偉.數(shù)控設(shè)備故障診斷與維修技術(shù).北京國防工業(yè)出版社, 2008. [3]. Sun nc equipment fault diagnosis and maintenance technology. Beijing national defence industry press, 2008.