1. Initial position and connection of the main body of the machine Before the machine tool arrives, the machine foundation should be made according to the machine foundation diagram provided by the machine tool builder, and the reserved hole should be prepared in the place where the anchor bolt is installed. When the CNC machine tool is shipped to the user, the machine parts are shipped to the installation site according to the procedure of unpacking. Then, as described in the instructions, the major components that make up the machine tool are placed in place on the foundation. When in place, the horns, adjustment pads, and anchor bolts will be seated accordingly.
Then, the components of the machine tool are assembled so that the cables, tubing, and gas pipes are connected after the assembly of the entire machine components is completed. There are electrical wiring diagrams and gas and hydraulic piping diagrams in the machine tool specification. The relevant cables and piping should be marked with a one-to-one connection.
The precautions at this stage are as follows: 1) After unpacking the machine tool, first find the random file information, find out the packing list of the machine tool, and check whether the parts, cables and data in the packing box are complete according to the packing list.
2) Before assembling the various components of the machine tool, first remove the anti-rust coating on the mounting surface, the guide rails and the moving surfaces, and clean the external surfaces of the components.
3) When connecting, pay special attention to cleaning work and reliable contact and sealing, and check for looseness and damage. After the cable is plugged in, tighten the fastening screws to ensure reliable contact. In the tubing and trachea connection, foreign matter must be prevented from entering the tubing from the interface, causing the entire hydraulic system to fail. Each tubing must be tightened when the tubing is connected. After the cable and tubing are connected, the pipelines must be fixed in place and the protective cover should be installed to ensure a neat appearance.
2. CNC system connection and debugging (1) Unpacking Inspection of CNC System
Whether it is a single purchased CNC system or a CNC system that is purchased with the machine tool, it should be carefully checked after it is delivered. Inspection includes the system body and its associated feed speed control unit and servo motor, spindle control unit and spindle motor.
(2) External cable connection
External cable connection is the connection of index control device and external MDI/CRT unit, power cabinet, machine tool operation panel, feed servo motor power line and feedback line, spindle motor power line and feedback signal line, and hand pulse generator, etc. Connection. These should be made in accordance with the provisions of the supplied connection manual. Finally, the ground connection should also be made.
(3) Connection of power cable of CNC system
The input cable of the primary side of the power transformer of the numerical control cabinet should be connected with the CNC cabinet power switch off.
(4) Confirmation of the setting
There are many short-circuit setpoints on the printed circuit board inside the CNC system that need to be properly set to suit different requirements of various types of machine tools.
(5) Confirmation of input power supply voltage, frequency and phase sequence
All kinds of numerical control systems have DC stabilized power supply inside, to provide the system with the required DC voltage of +5V, ±5V, +24V. Therefore, before the system is powered on, check the load of these power supplies for short circuit to ground. Use a multimeter to confirm.
(6) Check if the voltage output terminal of the DC power supply unit is short-circuited to ground.
(7) Turn on the power of CNC cabinet and check the output voltage
Before turning on the power, the motor power line may be disconnected first to ensure safety. After turning on the power, first check whether each fan in the CNC cabinet rotates, and confirm whether the power is turned on.
(8) Confirm the setting of each parameter in the CNC system
(9) Confirm the interface between the CNC system and the machine side
After completing the above steps, it can be considered that the CNC system has been adjusted and has the conditions for on-line power-on test with the machine tool. At this time, the power supply of the CNC system can be disconnected, the power line of the motor can be connected, and the alarm setting can be restored.
3. Power test machine According to the requirements of the machine tool specification, the machine tool shall be lubricated, the lubrication points shall be filled with the specified oil and grease, the hydraulic oil tank and the filter shall be cleaned, and the specified hydraulic oil shall be poured. Hydraulic oil must be filtered beforehand. Switch on the externally supplied air supply.
The power-on operation of the machine tool can be a complete power supply for each part at a time, or each part can be powered separately, and then make a total power supply test. It is safer to supply power separately, but it takes longer. After power-on, first observe the alarm failure, and then manually start the components in a manual manner. Check whether the safety device works, whether it can work normally and whether it can achieve the rated working index. Total son, according to the machine tool specification data, roughly check the main parts of the machine tool, whether the function is normal and complete, so that the machine tool can operate in all aspects.
Then, adjust the bed level of the machine tool, coarsely adjust the main geometric accuracy of the machine tool, and then adjust the relative position of the reassembled main moving parts and the host machine. Use the quick-drying cement to infuse the anchor bolts of the main machine and each attachment, and put each reserved hole. Flatten, wait for the cement to dry completely.
When the numerical control system and the machine tool are powered on and on-line, although the numerical control system has confirmed that there is no alarm in normal operation, it should be ready to press the emergency stop button at the same time when the power is turned on, so as to cut off the power at any time.
When checking the operation status of each axis of the machine tool, apply manual continuous feed to move each axis and check the direction of movement of the machine part by the display value of the CRT or DPL (digital display). Then check whether the movement distance of each axis matches the movement command. If they do not match, check whether the relevant commands, feedback parameters, and position control loop gains are correct.
Then, the manual feed is used to move the axes at a low speed, and they are contacted with an overtravel switch to check whether the overtravel limit is valid or not, and whether the numerical control system gives an alarm when overtraveling.
Finally, a return to the reference point should also be performed. The reference point of the machine tool is the program reference position after the machine tool is processed. Therefore, it is necessary to check whether the reference point function and the position of each return reference point are exactly the same.
4. Machine tool accuracy and function debugging On the solidified foundation, finely adjust the level of the main bed of the machine tool with the anchor bolts and horns. After the level is found, move the moving parts of the bed (main column, slide plate, table, etc.) to observe the full stroke of each coordinate. The horizontal transformation of the machine tool and the corresponding adjustment of the machine's geometric accuracy to within the allowable error range. The testing tools used are precision level gauges, standard square gauges, flat gauges, collimator tubes, etc. When adjusting, the main horn is mainly adjusted, if necessary, can be slightly changed on the guide rails and pre-tightening roller.
Move the machine tool to the tool exchange position (such as G28 Y0 Z0 or G30 Y0 Z0) and adjust the position of the loading robot and the unloading robot relative to the spindle manually. In the adjustment, a proofreading mandrel is used for detection. When there is an error, the manipulator's stroke can be adjusted, the manipulator's position can be moved, the position of the magazine can be changed, and if necessary, the setting of the tool changer position can also be modified. (Change the parameter setting in the numerical control system. ). After the adjustment is completed, tighten the adjustment screws and the anchor bolts of the tool magazine, and then install several tool holders that are close to the specified allowable weight, and perform multiple reciprocal automatic exchanges from the tool magazine to the spindle. The actions are required to be accurate and correct, and no impact is applied. Knife off.
The machine tool with APC exchange table shall move the table to the exchange position, adjust the relative position of the tray station and the exchange table, and achieve smooth, reliable and correct movement of the table during automatic tool change. Then load 70 to 80% of the allowable load on the work surface, and perform multiple automatic exchange operations, and then tighten the relevant screws after they are correct.
Carefully check whether the parameter settings in the CNC system and the PLC device meet the data specified in the random data, and then test the main operating functions, safety measures, and the execution status of common instructions. For example, various operating modes (manual, jog, MDI, automatic mode, etc.), spindle phasing instructions, and various levels of speed commands are correct.
In the process of machine tool adjustment, it is generally necessary to modify the NC parameters related to the machine, such as the position of the origin of each axis and the related parameters such as the position of the relevant position of the machine tool, such as the coordinate position of the tool magazine. The modified parameters should be recorded after the acceptance or stored on the media.
Check the normal operation of auxiliary functions and accessories, such as the lighting of the machine tool, whether the various shields of the cooling shield box are complete; add the cutting fluid to the cutting fluid tank, and check whether the nozzle can spray the cutting fluid normally; Whether the cutting fluid leaks under the protective cover condition; whether the chip remover can work properly; whether the constant temperature oil tank of the headstock of the machine tool can work or not.
5. Trial operation After the CNC machine tools are installed and tested, it is required that the machine should fully check the function and reliability of the machine tool after a relatively long period of automatic operation under certain load conditions. There is no uniform requirement for the running time. Generally, the operation is performed every day for 8 hours and continuous operation for 2 to 3 days; or 24 hours for continuous operation for 1 to 2 days. This process is called post-installation commissioning.
The assessment procedure shall include: the use of the functions of the main CNC system, the automatic replacement of two-thirds of the tools in the tool magazine, the maximum, minimum and common spindle speeds, rapid and commonly used feedrates, and automatic exchange of the worktops. , the use of major M instructions, etc. During the test run, the tool shank of the machine tool should be fully loaded with the handle, and the weight of the handle should be close to the specified weight, and the exchange work table should also be responsible for. During the test run time, the machine tool is not allowed to malfunction except for the malfunction caused by the operation error. Otherwise, it indicates that there is a problem with the installation and debugging of the machine tool.
6. Inspection and acceptance of CNC machine tools Acceptance of CNC machine tools can be broadly classified into two categories: one is the acceptance of a prototype of a new type of CNC machine tool, which is performed by a nationally designated testing center for machine tools; the other is the acceptance of general-purpose CNC machine tools by users of CNC machines.
For the acceptance of a new type of numerically-controlled machine tool prototype, a full range of test tests is required. It needs to use a variety of high-precision instruments to test the overall performance and individual performance of machine parts, electricity, liquid, gas and other parts of the machine tool, including a series of machine tool tests such as stiffness and thermal deformation. Comprehensive evaluation of the machine.
For general CNC machine tools users, their acceptance work is mainly based on the acceptance conditions stipulated on the machine tool's factory inspection certificate and the actual test methods that can be provided to partially or completely determine the technical indicators of the machine tool certificate. After passing the test, it will serve as a basis for technical indicators for future maintenance. The main work is as follows:
(1) Machine appearance inspection
Before making a detailed inspection and acceptance of the CNC machine tools, the inspection and acceptance of the appearance of the CNC cabinet shall also be carried out, which shall include the following aspects:
1) Appearance inspection Visually inspect each unit in the CNC cabinet for damage, contamination, breakage of the connection cable bundle, and peeling of the shield.
2) Checking the tightening condition of components inside the CNC cabinet Including screw fastening inspection, connector tightening inspection, and printed circuit board fastening inspection.
3) Inspection of the appearance of the servo motor In particular, the housing of the servo motor with a pulse encoder should be carefully checked, especially the rear end.
(2) Test of machine performance and NC function
A vertical machining center is used as an example to illustrate some of the major projects.
1) Spindle system performance
2) Feed system performance
3) Automatic Tool Change System
4) Machine noise The total noise when the machine is running is not to exceed the standard (80dB).
5) Electrical devices
6) Digital Control Device
7) Safety device
8) Lubrication device
9) Gas and liquid devices
10) Attachments
11) CNC function
12) Continuous No-load Operation The machine tool is continuously operated for a long time (such as 8h, 16h and 24h, etc.), which is the best way to comprehensively check the reliability of various functions of the entire machine tool.
(3) Machine geometry check
The geometric accuracy of CNC machine tools is a comprehensive reflection of the key mechanical components of the equipment and the errors in the assembled geometry. The following lists the geometric accuracy test contents of a normal vertical machining center:
1) The flatness of the work surface
2) The mutual squareness of the movement in each coordinate direction
3) The parallelism of the work surface when the X coordinate moves
4) The parallelism of the work surface when the Y coordinate moves
5) The parallelism of the side of the T-slot of the table top when the X coordinate direction is moved
6) Axial movement of the spindle
7) Radial runout of spindle hole
8) Parallelism of the spindle axis when the spindle head moves in the Z coordinate direction
9) The verticality of the axis of rotation of the spindle to the worktable
10) Straightness of headstock moving in Z coordinate
(4) Inspection of machine positioning accuracy
It is the accuracy that can be achieved by measuring the movement of each moving part of the machine tool under the control of the numerical control device. The main contents of positioning accuracy check are:
1) Linear motion positioning accuracy (including X, Y, Z, U, V, W axis)
2) Linear motion repeat positioning accuracy
3) Return accuracy of the mechanical origin of the linear motion axis
4) Determination of Involuntary Movement in Linear Motion
5) Positioning accuracy of rotary motion (table A, B, C axis)
6) Repeated positioning accuracy of rotary motion
7) Return accuracy of rotary axis origin
8) Determination of Inverse Axial Movement Insufficiency
(5) Inspection of machine tool cutting accuracy
The inspection of machine tool cutting accuracy is essentially a comprehensive assessment of the machine's geometric accuracy and positioning accuracy under cutting and machining conditions. Most of the domestic single-based processing. For machining centers, the main single precisions are:
1) Boring accuracy
2) Accuracy of Milling Plane Face Milling (X-Y Plane)
3) Hole pitch accuracy and hole diameter dispersion
4) Linear Milling Accuracy
5) Slant milling accuracy
6) Arc Milling Accuracy
7) Concentricity of boring hole in box body (for horizontal machine tools)
8) Horizontal turret rotation 90° milling square machining accuracy (for horizontal machine tools)
Food Bottle
Food Bottle,Oil Bottle,Vinegar Bottle,Sauce Bottle
Berlin Packaging (Qingdao) Co.,Ltd , https://www.berlinpacksupplier.com