As we all know, CNC machine tools are the crystallization of the integration of contemporary high-tech machinery, electricity, optics, and gas. The electrical complexity is so complicated that the pipelines are crossed and the CNC system is varied. Products from the 1970s to the 1990s cannot be interchanged, and the fault phenomenon is also strange and strange. The same, especially large-scale, heavy-duty CNC machine tools, are expensive and cost about a few million U.S. dollars each, and installation and adjustment takes a long time (several months to more than a year). There are tens of thousands of components in a large-scale CNC machine tool. If one of the components is faulty, it will cause an abnormal phenomenon of the machine tool, as well as the connection of the wires and the connection of the tubes. If there is a slight oversight, there will be problems. In addition, the large and heavy-duty CNC machine tools are bulky, and they are used under conditions without a constant-temperature plant. Environmental impacts can easily cause failures. For this reason, the problem of "difficult maintenance" of CNC machine tools lies in front of us.
We have introduced and manufactured so many CNC machine tools in our country. How can we quickly identify problems and hidden dangers and eliminate them in time? How can these expensive equipment be repaired? I think we must first have a high sense of responsibility and a spirit that is not afraid of difficulties. Second, we must strive to master CNC technology and contact me for more than 10 years to maintain the practice of CNC machine tools. I think we must look, ask, inquire, and think more. More practice (five more), and gradually improve their technical level and maintenance capabilities, can adapt to a variety of more complex situations, solve difficult problems, and repair CNC machine tools.
First, we must look more 1. To see more numerical data to see more, to understand the characteristics and functions of various CNC systems and PLC programmable controller; to understand the alarm and elimination method of CNC system; to understand the meaning of NC, PLC machine parameter settings; Understand the PLC programming language; to understand the method of numerical control programming; to understand the operation of the control panel and the contents of the various menus; to understand the performance of the spindle and the cutter motor and the characteristics of the driver, etc., often a lot of numerical data, how to see ? I think the main focus is to highlight the ins and outs. The key is to understand the basic composition and structure of the CNC system and master the block diagram. The rest can be “walked†and read through, but every part of the content needs to be understood and mastered. Because the circuit diagram inside the numerical control system is rather complicated, the manufacturer does not provide it. Therefore, it is not necessary to clarify in detail. For example, the NX-154 four-axis five-link blade machining machine adopts the A-B10 system. It is important to understand the role of each part, the functions of each board, the whereabouts of the interface, and the meaning of the LED lights. Now the numerical control system has many models and updates quickly. Different manufacturers and different models often differ greatly. To understand its commonality and personality (specialty). People who are generally familiar with maintenance of SIEMENS CNC systems are not necessarily skilled in troubleshooting A-B systems. Therefore, we must look at them and keep learning and updating them.
2. To look at the electrical diagrams and digested electrical diagrams for each electrical component, such as contactors, relays, time relays, etc., as well as PLC input and output, indicate on the electrical diagram. As a simple example, for example, 1A1 is a contactor for a 1M hydraulic pump motor. Generally, the position of its normally open and normally closed contacts is indicated at the bottom of the figure. Therefore, the corresponding normally open or normally closed contact 1A1 on a certain page can be indicated as the hydraulic pump motor, and there are dozens of pages or even hundreds of pages for the electric diagram of the large-scale numerical control machine tool. To understand, shows that the function of each component has to be a long time. Sometimes, one or two look may not be clear about the role of the component, to see more and then write it later. Therefore, the 1M of the starting hydraulic pump motor, which was just mentioned, should clearly indicate which external output of the PLC will drive the contactor 1A1 to operate. It is necessary to understand the ins and outs. Some of the block diagrams in the electrical circuit diagram, such as the actuators of each axis, are just a block diagram. If you understand a certain control condition (on and off conditions), you can wait for time to study and consider the details. The electrical symbols of different countries are different, so we must first understand clearly. For the thick PLC language statement prepared by the manufacturer, we must look at it, master its programming language, and perform Chinese translation on the basis of understanding. This can greatly reduce the time to troubleshoot in the future. If you wait until you become acquainted with the electrical diagrams and PLC statements, you will need to spend a lot of time, and you will often make mistakes.
3, to see more hydraulic, pneumatic diagrams, and in-depth digestion of CNC machine tools for the mechanical, hydraulic, pneumatic diagram, to figure out its role and context. And note on the drawings, such as the German COBURG CNC gantry milling accessories, tool installation moves more complex, to decompose the map, such as locking solenoid valve which is the action of which? What are the corresponding PLC output and input? In the figure, it is stated that this way from the electrical to the mechanical action will be fully understood. At the same time, it is particularly important to understand the close relationship between the machine and the electricity. For example, the Italian INNSE CNC boring and Milling Machine adopts the electro-hydraulic proportional valve technology, and it is important to understand its role and Function, especially to understand the adjustment method and adjust the data, static and dynamic proportional valve current and the pressure of the corresponding balanced pump, both understand the electricity and understand the machine, mechanical and electrical integration, master a variety of skills, so that the ability to solve the problem is large Now.
4. To read more foreign language, to improve their professional foreign language reading ability do not know foreign languages, especially English. You can't read a lot of foreign language technical data, and relying on translation alone is often not ideal. Looking at the foreign language version of the technical data, it was hard at the beginning, and there were many new characters. After reading more and more notes, there were only so many professional words used. It seemed to be smooth afterwards. A qualified maintenance person must basically master the language tools.
Second, ask more questions 1. Ask foreign experts if you can have the opportunity to go abroad for training or foreign experts to your factory installation and commissioning machine tools, you'd better have the opportunity to participate. This is the best opportunity for learning, because you can get a lot of first-hand information and machine debugging methods and techniques. For example, after the accuracy of each axis is measured by a laser, how to correct the electric current. To ask more, do not understand it is necessary to make it clear. Through this period of time, there will be great gains, and you will have access to many internal materials and manuals (which are confidential to users). When the machine tool is put into formal production, it should always maintain close contact with foreign experts. Through FAX, E-MALL, inquires to obtain further solutions and relevant information for solving difficult problems in machine tools, and special and special spare parts can also be obtained. This is very beneficial. At the same time, agents of numerical control systems, such as SIEMENS, FANUC, etc. Should also maintain a good relationship, more inquiries, but also in a timely manner to get a step-by-step information on the CNC system and related spare parts, but also have the opportunity to participate in special training courses on the CNC system.
2. After a failure occurs, ask the operator to inquire about the whole process of the failure, and don't ask or just ask, so often the failure to obtain correct site information will cause erroneous judgments and complicate the problem. Therefore, To ask more, ask a detailed point, understand the whole process of the fault (beginning, middle, end), what alarm number was generated, what elements were operated, what had been touched, what had been changed, and what was the external environment? To fully investigate the site to master first-hand materials and to list the faults correctly, it has actually solved half of the problems, and then analyzed and solved them. For experienced and skilled operators, they operate the machine tool. Familiar with the familiarity of the processing program, common understanding of the common diseases of the machine tool, and close cooperation with them, is very beneficial for the rapid troubleshooting.
3. Ask other maintenance personnel when other maintenance personnel are working on the machine and you are not going. After they return, they should ask for more questions. What has happened just now? How is he excluded? Ask him to introduce their exclusion method. This is also a good learning opportunity. Learn the skills and methods of correcting others' problems, especially learning from experienced old maintenance staff, learning their skills and improving their knowledge and skills.
Third, to remember more . To record the relevant parameters, it is important to record all relevant parameters after the machine tool is adjusted, such as NC machine parameters, PLC machine parameters, PLC programs (the above may exist in the disk), as well as the current, voltage, rotation speed, etc. of the spindle and each cutting motor. data. Also note the status of the relays, contactors, etc. in the panel during power on and formal processing (suction or disconnection) and status of all LED inputs and outputs of the PLC (bright and dim, flashing) or record the PLC on the screen The status IB (input bit) and QB (output bit) are 0 or 1, for example, IB1=, that is, I1.0=1 and I1.1-1.7=0. This record is very good for future analysis of faults. For example, the German SCHIESS CNC vertical crane Z-axis motor current relay action, we check the Z-axis motor normal operation when the PLC status (0,1) and abnormal conditions compared to quickly find the cause of the failure, because there is a comparison The status of the relay is incorrect. After adjustment, the fault is immediately eliminated.
2. To record the state of hydraulic and pneumatic, we also record the pressure of various pressure gauges and barometers when the hydraulic pressure and pneumatic pressure are formally processed or not, and the suction state of the solenoid valve, which is very helpful for adjustment and judgment. Such as the United States INGERSOLL OPENsIDE MASTERHEAD CNC boring mill static pressure using double-film technology, there are more than 100 pressure measurement points, the level of pressure directly affect the normal function of the machine tool or not, it is important to record static and dynamic pressure.
3. Take a notebook with you and record the daily breakdown and how to eliminate it. The person's brain has a long time and is easy to forget. It is very easy to remember. We have found that the failures of CNC machine tools are often repetitive, and that these failures are always just a matter of looking at how they were resolved at that time. In a few minutes, they can be eliminated quickly and well. Our company has a "Diary of Operation of CNC Machine Tools" and a "Recording Record of CNC Machine Tools". It is necessary to record these two documents. This is a complete history file of a CNC machine tool.
Fourth, to think more . To think more, to broaden their horizons, sometimes to repair, not calm enough, not well analyzed, to drill. I remember that once the CO gantry milling Y-axis was suddenly stopped during machining, the 1361 Y-axis raster dirty alarm appeared on the screen several times. At that time, we cleaned the grating scale and the grating head twice, and the result was still down. It has not been resolved for several days, and finally the real reason was found. The reason is that the wire between the Y-axis raster head and the EXE amplifier has a problem. Because the snake skin is bent for a long time due to the movement of the Y axis, one position feedback line is not Well, breaking to a location causes the machine to shut down. At the time, we only paid attention to statics, neglected the dynamics, and there had been 1321 open-circuit control loops, but did not cause us enough attention. Therefore, we should list all the alarms and failures that have occurred. We can use the table and the in-between to falsify the truth, perform comprehensive judgments and screenings, and predict the maximum likelihood of failures, and then eliminate them. "The mountains and rivers have no way to go, and the village is full of flowers and bright trees," and it gives you a direction.
2. To think more about it, to know why it often happens, we sometimes fail to find the real cause of the fault when troubleshooting, and the fault will continue to occur afterwards. I remember the INGERSOLL rotor blade root slot milling machine, spindle Sl failure occurred two hours after the operation of the "auto stop", when foreign experts replaced a sequence of plates, the problem seems to be resolved, but after more than a month, the old fault has committed The replacement board of the order board is also good, but the reason for the damage is not clear. We carefully checked that with the help of an oscilloscope, we found that the optocoupler corresponding to the “startup†instruction has a particularly high peak back-to-peak voltage. After a separate grounding line is added, the optocoupler reverse peak voltage is greatly reduced. From then on, There has never been a failure of “auto-stopping†because the counter-peak voltage is too high and the optocoupler gradually fails after a long time.
3. To think more about it, consider taking a step ahead based on the frequency, repeatability, and the life of the mechanical device. This is an important task to ensure the continuous and normal operation of the machine tool. At the same time, for some devices, as the time has been delayed and eliminated, the market has been unable to buy or purchase is very expensive, what should I do? Considering in advance, for example, there is an optical-electric reader for numerical control machines in the early 1980s. The LOOP method is used to read in the machining program, and the SPOOL method can be used to select the original tape (machine setting data). In case of failure to send in, the entire machine The machine tool will become a "dead" machine, and the consequences are very serious. Because we took a step forward and cooperated with the relevant units, after many tests, a floppy disk processor was used to solve this problem and ensure that the machine tool can be used today. Duo Si, must consider in advance, give rational advice to leaders, and strive to improve the external environment of CNC machine tools, from the temperature, dust, humidity and other aspects to find a way to use the installation of power regulators, retrofitting air conditioners and other small houses Measures to greatly reduce machine tool failures.
We have introduced and manufactured so many CNC machine tools in our country. How can we quickly identify problems and hidden dangers and eliminate them in time? How can these expensive equipment be repaired? I think we must first have a high sense of responsibility and a spirit that is not afraid of difficulties. Second, we must strive to master CNC technology and contact me for more than 10 years to maintain the practice of CNC machine tools. I think we must look, ask, inquire, and think more. More practice (five more), and gradually improve their technical level and maintenance capabilities, can adapt to a variety of more complex situations, solve difficult problems, and repair CNC machine tools.
First, we must look more 1. To see more numerical data to see more, to understand the characteristics and functions of various CNC systems and PLC programmable controller; to understand the alarm and elimination method of CNC system; to understand the meaning of NC, PLC machine parameter settings; Understand the PLC programming language; to understand the method of numerical control programming; to understand the operation of the control panel and the contents of the various menus; to understand the performance of the spindle and the cutter motor and the characteristics of the driver, etc., often a lot of numerical data, how to see ? I think the main focus is to highlight the ins and outs. The key is to understand the basic composition and structure of the CNC system and master the block diagram. The rest can be “walked†and read through, but every part of the content needs to be understood and mastered. Because the circuit diagram inside the numerical control system is rather complicated, the manufacturer does not provide it. Therefore, it is not necessary to clarify in detail. For example, the NX-154 four-axis five-link blade machining machine adopts the A-B10 system. It is important to understand the role of each part, the functions of each board, the whereabouts of the interface, and the meaning of the LED lights. Now the numerical control system has many models and updates quickly. Different manufacturers and different models often differ greatly. To understand its commonality and personality (specialty). People who are generally familiar with maintenance of SIEMENS CNC systems are not necessarily skilled in troubleshooting A-B systems. Therefore, we must look at them and keep learning and updating them.
2. To look at the electrical diagrams and digested electrical diagrams for each electrical component, such as contactors, relays, time relays, etc., as well as PLC input and output, indicate on the electrical diagram. As a simple example, for example, 1A1 is a contactor for a 1M hydraulic pump motor. Generally, the position of its normally open and normally closed contacts is indicated at the bottom of the figure. Therefore, the corresponding normally open or normally closed contact 1A1 on a certain page can be indicated as the hydraulic pump motor, and there are dozens of pages or even hundreds of pages for the electric diagram of the large-scale numerical control machine tool. To understand, shows that the function of each component has to be a long time. Sometimes, one or two look may not be clear about the role of the component, to see more and then write it later. Therefore, the 1M of the starting hydraulic pump motor, which was just mentioned, should clearly indicate which external output of the PLC will drive the contactor 1A1 to operate. It is necessary to understand the ins and outs. Some of the block diagrams in the electrical circuit diagram, such as the actuators of each axis, are just a block diagram. If you understand a certain control condition (on and off conditions), you can wait for time to study and consider the details. The electrical symbols of different countries are different, so we must first understand clearly. For the thick PLC language statement prepared by the manufacturer, we must look at it, master its programming language, and perform Chinese translation on the basis of understanding. This can greatly reduce the time to troubleshoot in the future. If you wait until you become acquainted with the electrical diagrams and PLC statements, you will need to spend a lot of time, and you will often make mistakes.
3, to see more hydraulic, pneumatic diagrams, and in-depth digestion of CNC machine tools for the mechanical, hydraulic, pneumatic diagram, to figure out its role and context. And note on the drawings, such as the German COBURG CNC gantry milling accessories, tool installation moves more complex, to decompose the map, such as locking solenoid valve which is the action of which? What are the corresponding PLC output and input? In the figure, it is stated that this way from the electrical to the mechanical action will be fully understood. At the same time, it is particularly important to understand the close relationship between the machine and the electricity. For example, the Italian INNSE CNC boring and Milling Machine adopts the electro-hydraulic proportional valve technology, and it is important to understand its role and Function, especially to understand the adjustment method and adjust the data, static and dynamic proportional valve current and the pressure of the corresponding balanced pump, both understand the electricity and understand the machine, mechanical and electrical integration, master a variety of skills, so that the ability to solve the problem is large Now.
4. To read more foreign language, to improve their professional foreign language reading ability do not know foreign languages, especially English. You can't read a lot of foreign language technical data, and relying on translation alone is often not ideal. Looking at the foreign language version of the technical data, it was hard at the beginning, and there were many new characters. After reading more and more notes, there were only so many professional words used. It seemed to be smooth afterwards. A qualified maintenance person must basically master the language tools.
Second, ask more questions 1. Ask foreign experts if you can have the opportunity to go abroad for training or foreign experts to your factory installation and commissioning machine tools, you'd better have the opportunity to participate. This is the best opportunity for learning, because you can get a lot of first-hand information and machine debugging methods and techniques. For example, after the accuracy of each axis is measured by a laser, how to correct the electric current. To ask more, do not understand it is necessary to make it clear. Through this period of time, there will be great gains, and you will have access to many internal materials and manuals (which are confidential to users). When the machine tool is put into formal production, it should always maintain close contact with foreign experts. Through FAX, E-MALL, inquires to obtain further solutions and relevant information for solving difficult problems in machine tools, and special and special spare parts can also be obtained. This is very beneficial. At the same time, agents of numerical control systems, such as SIEMENS, FANUC, etc. Should also maintain a good relationship, more inquiries, but also in a timely manner to get a step-by-step information on the CNC system and related spare parts, but also have the opportunity to participate in special training courses on the CNC system.
2. After a failure occurs, ask the operator to inquire about the whole process of the failure, and don't ask or just ask, so often the failure to obtain correct site information will cause erroneous judgments and complicate the problem. Therefore, To ask more, ask a detailed point, understand the whole process of the fault (beginning, middle, end), what alarm number was generated, what elements were operated, what had been touched, what had been changed, and what was the external environment? To fully investigate the site to master first-hand materials and to list the faults correctly, it has actually solved half of the problems, and then analyzed and solved them. For experienced and skilled operators, they operate the machine tool. Familiar with the familiarity of the processing program, common understanding of the common diseases of the machine tool, and close cooperation with them, is very beneficial for the rapid troubleshooting.
3. Ask other maintenance personnel when other maintenance personnel are working on the machine and you are not going. After they return, they should ask for more questions. What has happened just now? How is he excluded? Ask him to introduce their exclusion method. This is also a good learning opportunity. Learn the skills and methods of correcting others' problems, especially learning from experienced old maintenance staff, learning their skills and improving their knowledge and skills.
Third, to remember more . To record the relevant parameters, it is important to record all relevant parameters after the machine tool is adjusted, such as NC machine parameters, PLC machine parameters, PLC programs (the above may exist in the disk), as well as the current, voltage, rotation speed, etc. of the spindle and each cutting motor. data. Also note the status of the relays, contactors, etc. in the panel during power on and formal processing (suction or disconnection) and status of all LED inputs and outputs of the PLC (bright and dim, flashing) or record the PLC on the screen The status IB (input bit) and QB (output bit) are 0 or 1, for example, IB1=, that is, I1.0=1 and I1.1-1.7=0. This record is very good for future analysis of faults. For example, the German SCHIESS CNC vertical crane Z-axis motor current relay action, we check the Z-axis motor normal operation when the PLC status (0,1) and abnormal conditions compared to quickly find the cause of the failure, because there is a comparison The status of the relay is incorrect. After adjustment, the fault is immediately eliminated.
2. To record the state of hydraulic and pneumatic, we also record the pressure of various pressure gauges and barometers when the hydraulic pressure and pneumatic pressure are formally processed or not, and the suction state of the solenoid valve, which is very helpful for adjustment and judgment. Such as the United States INGERSOLL OPENsIDE MASTERHEAD CNC boring mill static pressure using double-film technology, there are more than 100 pressure measurement points, the level of pressure directly affect the normal function of the machine tool or not, it is important to record static and dynamic pressure.
3. Take a notebook with you and record the daily breakdown and how to eliminate it. The person's brain has a long time and is easy to forget. It is very easy to remember. We have found that the failures of CNC machine tools are often repetitive, and that these failures are always just a matter of looking at how they were resolved at that time. In a few minutes, they can be eliminated quickly and well. Our company has a "Diary of Operation of CNC Machine Tools" and a "Recording Record of CNC Machine Tools". It is necessary to record these two documents. This is a complete history file of a CNC machine tool.
Fourth, to think more . To think more, to broaden their horizons, sometimes to repair, not calm enough, not well analyzed, to drill. I remember that once the CO gantry milling Y-axis was suddenly stopped during machining, the 1361 Y-axis raster dirty alarm appeared on the screen several times. At that time, we cleaned the grating scale and the grating head twice, and the result was still down. It has not been resolved for several days, and finally the real reason was found. The reason is that the wire between the Y-axis raster head and the EXE amplifier has a problem. Because the snake skin is bent for a long time due to the movement of the Y axis, one position feedback line is not Well, breaking to a location causes the machine to shut down. At the time, we only paid attention to statics, neglected the dynamics, and there had been 1321 open-circuit control loops, but did not cause us enough attention. Therefore, we should list all the alarms and failures that have occurred. We can use the table and the in-between to falsify the truth, perform comprehensive judgments and screenings, and predict the maximum likelihood of failures, and then eliminate them. "The mountains and rivers have no way to go, and the village is full of flowers and bright trees," and it gives you a direction.
2. To think more about it, to know why it often happens, we sometimes fail to find the real cause of the fault when troubleshooting, and the fault will continue to occur afterwards. I remember the INGERSOLL rotor blade root slot milling machine, spindle Sl failure occurred two hours after the operation of the "auto stop", when foreign experts replaced a sequence of plates, the problem seems to be resolved, but after more than a month, the old fault has committed The replacement board of the order board is also good, but the reason for the damage is not clear. We carefully checked that with the help of an oscilloscope, we found that the optocoupler corresponding to the “startup†instruction has a particularly high peak back-to-peak voltage. After a separate grounding line is added, the optocoupler reverse peak voltage is greatly reduced. From then on, There has never been a failure of “auto-stopping†because the counter-peak voltage is too high and the optocoupler gradually fails after a long time.
3. To think more about it, consider taking a step ahead based on the frequency, repeatability, and the life of the mechanical device. This is an important task to ensure the continuous and normal operation of the machine tool. At the same time, for some devices, as the time has been delayed and eliminated, the market has been unable to buy or purchase is very expensive, what should I do? Considering in advance, for example, there is an optical-electric reader for numerical control machines in the early 1980s. The LOOP method is used to read in the machining program, and the SPOOL method can be used to select the original tape (machine setting data). In case of failure to send in, the entire machine The machine tool will become a "dead" machine, and the consequences are very serious. Because we took a step forward and cooperated with the relevant units, after many tests, a floppy disk processor was used to solve this problem and ensure that the machine tool can be used today. Duo Si, must consider in advance, give rational advice to leaders, and strive to improve the external environment of CNC machine tools, from the temperature, dust, humidity and other aspects to find a way to use the installation of power regulators, retrofitting air conditioners and other small houses Measures to greatly reduce machine tool failures.
Single two three four spindles CNC high speed Drilling Machine for metal plate, clapboard, flange, tube plate, in the filed of petrochemical boiler and power flange industry, also for plate in building, bridge, iron tower etc.
1) High-speed internal cooling, high efficient processing
2) High rigidity, anti-shake resistance, high precision
3) Identify the CAD graphic files intelligently, and automatically convert into the processing programm; Support off-line programming
4) The most optimal processing sequencing, the most optimal path control
This equipment is an improved version double power heads drilling machine with high accuracy, high efficiency, high rigidity, high reliability, the work table is divided into four processing zones, and you can load and unload the workpiece and program while drilling. It can be used to drilling connecting plates, foundation plates, end panels, templates, flanges, structural components and other parts in steel structures, bridge building, power communication tower, heat boiler, etc.
This machine is mainly composed of movable gantry, base, table, support frame, movable support, left/right bracket, power head, automatic chip conveyor, circulation cooling device and electrical system etc.
Clapboard Drilling Machine,Multi Spindle Drilling Machine,High Speed Drilling Machine,CNC Clapboard Drilling Machine
Shandong Sunrise CNC Machine Co., Ltd , https://www.scmcnc.com