1 Introduction
XK714 milling machine is a simple CNC milling machine of a domestic CNC system purchased by our company in 2003. The system is extremely unstable during use. The size of the processed parts cannot be guaranteed, but the inspection machine is no problem. The company decided to transform it and restore the equipment. Normal use.
2. Proposal for the transformation plan
In order to ensure that the machine tool can realize the original function, without changing the original operation mode, saving resources, and training the personnel technology, the following transformation scheme is proposed: 1 spindle retains the original drive and motor (simulated spindle) 2 The axes are controlled by digital axes (originally analog control).
Under the requirements of the above conditions, Siemens' 802D SL numerical control system was selected, which provides complete functions for the machining center, and its supporting modular drive system provides great flexibility for various applications. The system has built-in multiple standard functions, 10.4′′ TFT color liquid crystal display; high-capacity CF card, support RS232 and Ethernet interface; control axis number 6 (including 4 feed axes, 1 spindle and 1 PLC axis) Tool life monitoring function; large capacity pre-read buffer (up to 100-segment program) integrated in the system, fixed cycle with graphic support for turning, milling and drilling, contour elements, DIN standard and ISO Language programming, greatly facilitates the end user's processing programming, various modules do not need batteries and fans, so no maintenance is required. And the price is moderate, with high cost performance, can meet the requirements of equipment numerical control transformation.
3 hardware configuration
The 802D SL numerical control system controls the coordinate axes and spindle movements respectively. All other motion control of the machine tool is controlled by the PLC control unit that comes with the 802D SL numerical control system. The main hardware configuration of the 802D SL system is: ○1PCU host 1 block (6FC5310-0AA00-2AA0) ○2 full-function vertical keyboard 1 block (6FC5303-0DM13-1AA1) ○3 operation panel 1 block (6FC5303-0AF30-1AA0 ○4MCPA module 1 block (6FC5312-0DA01-0AA0) ○5PP72/48 template 1 block (6FC5611-0CA01-0AA0) ○6 Non-regulated power supply 10KW 1 block (6SL3130-6AE21-0AB0) ○7 Power reactor 1 block (6SL3000-0CE21-0AA0) ○8 single-axis power module 9A 1 block (6SL3120-1TE21-0AA3) ○9 dual-axis power module 2×9A 1 block (6SL3120-2TE21-0AA3) ○10 servo motor 1 set (1FK7063- 5AF71-1DG5) ○11 Servo motor 2 units (1FK7063-5AF71-1DH5) ○12 Motor cable 6 m 2 (6FX5002-5CS01-1AG0) ○13 Motor cable with holding brake 5 m 1 (6FX5002-5DS01-1AF0) ○14 encoder feedback cable 3 (6FX5002-2DC10-1AG0) ○15 PROFIBUS data bus ○16 spindle inverter 1 set Mitsubishi FR-A500 ○17 electronic handwheel 1.
4 software design
First, in accordance with the requirements of the "802D SL Concise Commissioning Manual", the hardware is connected, and the components are connected correctly, and then the system debugging and PLC logic control are entered.
4.1 System initialization
Use RS232 to connect the personal computer to COM1 of 802D SL, and then use the RCS software provided in the CD-ROM provided with the system to transfer the milling machine initialization file to the 802D SL system. After the NCK is reset, the initialization file takes effect and is displayed as the milling interface. (Initialization file path: Toolbox 802D SL\v01040500 echno\Milling\config_simens\plus\setup_t.ini)
4.2 PLC debugging
In general, after the various components of the 802D are connected, you need to start debugging the control logic of the PLC. It is essential that the drive must be commissioned after all the safety functions of the PLC have been prepared. Pass the standard PLC application (milling machine version) provided in the Siemens 802D SL tool tray into the system (standard PLC application milling machine path: Siemens\Programming Tool PLC802\Lib802Dsl\Examples\SAMPLE_MILL.PTP), according to the design input and output Click to modify related parameters. Rewrite the handwheel program to make it valid according to the selected handwheel.
4.3 PLC user alarm
PLC alarm is one of the most effective diagnostic methods. For example, if an operation is prohibited by the PLC logic, or if an output condition is not met, then if the corresponding alarm is activated, the operator or maintenance personnel can immediately know the cause of the operation error or hardware failure.
5, the driver debugging
After the PLC program is correct, enter the drive debugging, the steps are drive firmware upgrade, drive initialization, and drive configuration.
6, machine parameter settings
6.1 General Machine Data (MD10000—MD18999)
The general machine data is mainly used for the definition of the machine axis, the setting and monitoring of the PLC running time, and the setting of the user data custom parameters.
MD10000[0]=X MD10000[1]=Y MD10000[2]=Z MD10000[3]=SP MD11240[2] =1 MD14510[16]=2 MD14510[24]=30 MD14510[16]=1000 MD14510[ 19]=0
6.2 Basic channel type machine data (MD20000-MD28999)
Basic channel type machine data is mainly used for channel setting, setting and selection of geometric axis, and selection of G function.
MD20000=XK714 MD20050[1]=5 MD20050[2]=3 MD20080[0]=X MD20080[1]=YMD20080[2]=Z MD20080[3]=SP MD20070[4]=0
6.3 axis machine data (MD30000-MD38999)
The axis machine data is the parameter setting of the axis speed, direction and positioning of each channel of the machine coordinate, CNC machine protection, error compensation and other parameters (taking the X axis as an example, the Y axis Z axis is set according to the actual situation).
MD30110=1 MD30220=1 MD30130=1 MD30240=1 MD31050=1 MD31060=48 MD32000=8000 MD32010=6000 MD32020=500 MD36200=8800 MD32200=1 MD32300=1 MD36100=-770.0 MD36110=10
7, analog spindle debugging
The machine adopts Mitsubishi inverter FR-A500, which is controlled by SIMENS MCPA card. The SVC port and ES port of the inverter (analog signal of spindle speed control) are respectively connected to pins 1 and 6 of X701 port on MCPA card. Spindle parameters Set MD30110=4 MD30220=4 MD30130=1 MD30240=0 MD32250=0% MD32260=3000 MD36210=100%
When debugging, note that the MCPA output analog voltage is 0-10V. When the inverter is not energized, first check whether the input voltage of X701 is linearly corresponding to the set spindle speed. After correct, turn on the inverter.
8, data backup
It is very important to back up the data after the system has been debugged. SINUMERIK 802D SL provides a variety of data backup methods. System data can be backed up inside the system, data can be backed up to a PC card, or data can be transferred to a computer hard disk. In this way, when the data of the static memory is lost, the system detects that the static memory has been powered down when the self-test can be booted, and the system automatically copies the data stored in the flash memory to the static memory.
9, the conclusion
After the transformation, the machine tool has been put into normal use. Compared with the original machine tool, the machine tool is greatly enhanced, the degree of automation is improved, and the system is stable. The powerful CNC system widens the range of machined parts and better guarantees the quality of part processing. At the same time, a handheld operating unit has been added to allow the operator to select a more suitable operating position in different states. The modified machine tool increases the maintainability. The numerical control system can monitor the movement state and fault of each control component and display it on the display in time. This makes the machine fault detection and maintenance more convenient and quick.
references
1 "Sinamics_S120_sample"
2 802D SL Concise Debugging Manual
3 "802D SL PLC subroutine library description"
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