Maintenance of economical CNC machine tools
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â–¡ Wu Zhihua's method for judging machine tool failures, common causes, reasons and troubleshooting measures.
Xi'an Aerospace Engine Factory has 38 domestically produced economical CNC lathes and 5 turning and milling centers. Most of these economical CNC machine tools 0 systems use transcripts, gray scale 010, followed by the use of the ball step 0 elm 181721; and Siemens 8101 and there are several, people 刖 03177 elbow system. We have summarized some maintenance experience through the maintenance practice of economical CNC machine tools for many years. The following typical maintenance examples and fault diagnosis methods for CNC machine tools often appear in a comprehensive form. Determine whether the fault phenomenon is caused by mechanical part fault or electrical part fault. It is to find the root cause of the fault by means of the numerical control system self-diagnosis function. The system has a complete self-diagnosis system. When the power is initialized, the reference point changes. Exceeding the allowable range of movement of the tool change point, an alarm will occur when the tool is changed, and the tool change will be aborted, but will not cause a larger malfunction. The tool change point used in this machine belongs to the latter. The range of allowable movement of the tool change point is determined by the relative position of the collision blocks of the switches 5131 and 332. The difficulty in the 2 is 4, and the 4 is less than 0.5. Obviously, the tool change point of the machine tool is closely related to the reference point of a certain axis of the machine tool.
For this faulty machine, the 2-axis reference point has a large effect on the automatic tool change. Under normal circumstances, the machine is turned on manually; After the axis returns to the reference point, the normally open switch 8131 has been pressed by the collision block, its contact is closed, and the collision block of the normally closed switch has not yet functioned, and the contact is still in the closed state, so the input to the machine programmable controller Under the premise that the input point 20.6 is good, if the reference point moves up or down more than the fixed range 4131 and 3132, the signal of the two switch contacts can not be 1 state, the tool change condition is not satisfied, then if the tool change will be Alarm No. 1019 appears.
The so-called machine tool reference point is that the electrical origin of the machine tool coincides with the mechanical origin. How to determine the electrical origin and make it coincide with the mechanical origin? Since the servo motor and the photoelectric encoder are coaxial, the encoder will send a zero every revolution. Bit pulse signal. In the process of starting the manual return to the origin, when the deceleration block is pressed to the deceleration switch, the switch 3130 detects the signal feedback, and the servo motor decelerates. When the block releases the deceleration switch, the deceleration switch 3130 returns to its original state, and since then, the numerical control system detects When the zero pulse of the encoder is reached, the servo motor stops and the electrical origin is established. But this point may coincide with the mechanical origin. There are two ways to make the two origins coincide by moving the switch block position; it is solved by adjusting the relevant parameters of the CNC system on the CRT screen. Obviously the latter is simpler and more effective.
When there is abnormal operation in any part of the transmission chain from the servo motor to the spindle head, various alarm information can be made to itself or the interface, and analysis is performed according to the specification to determine the fault range.
Detailed adjustment of the fault phenomenon, once a fault occurs, first try to maintain the fault phenomenon and understand to the operator the symptoms caused by the fault, which process and time, the operation method is appropriate. Secondly, check the components such as the button fuse terminal, whether the screw is tightened during wiring, whether the plug on the circuit board is tightened, whether the operation mode of each dial switch is correct, etc., and then judge whether the machine control device system is normal or not; Whether the program can run normally, whether other function keys are normal; check whether the servo motor or stepper motor is running normally, whether there is intermittent or jitter phenomenon; and according to the characteristics of mechanical faults, when the machine is overloaded and overheated When first, check whether the slug of the skateboard is too tight, so that the friction between the slide and the bed rail increases, the motor runs hard; and whether the ball screw and the bracket are concentric, such as in the screw Ball wear causes the lead screw to be too tight, which can also overload the motor and cause electrical failure. For some non-destructive faults, when the fault can be replayed in order to verify the offset, the electrical origin will be offset, and the CNC system parameters need to be re-adjusted to coincide with the mechanical origin.
Since the relative position of the 2-axis reference point deceleration switch 3130 and the two tool change switches 51313132 is fixed after the machine adjustment, the operation program remains unchanged according to the design requirements, and the machine tool works normally. When the reference point switches and the collision block appear, it will affect the normal progress of the automatic tool change.
Through the above analysis and on-site inspection, the reason why the tool change appeared 1019 is that there is a relative offset in the mechanical transmission chain. The troubleshooting steps are as follows: The machine is shut down, and the shaft mechanical transmission components are checked. After tightening, the machine power is turned on.
The mode switch is placed in the reference point return mode and manually returned to the 2-axis reference point. After returning to the reference point, observe in which direction the reference point drifts relative to the tool change point.
The mode switch is placed in the handwheel mode, press the function key 0 on the 017, 1 panel, the human 1 display diagnostic screen, place the handwheel in the first gear, move the two axes in the opposite direction of the drift, and carefully observe the change of 20.6. When it is found that 20.6 is changed to 1 day, stop moving, press function key, 05, and record down; position information of the axis.
Press function key 0, 5 people like elbow, set, to set the position data of the axis to be input. In the 510 parameter, set to 0.
Stop the 2 axial negative direction by 200 or more. After rebooting, the 2-axis manual reference point is returned. Observe whether the magic 0.6 changes to 1. If it is for the test, the tool change is normal; if it is 0, then repeat the steps of 2 to 4 above until it is successful.
Set the correctness of the analysis and the conclusion of the 2001 analysis. Use the PLC program to locate the interface between the machine tool and the CNC system. If the control system has built-in control, the system can directly see the system input and output according to the trapezoid. 10. State. Through, the program diagnostic screen, with the muscle 07 in the system, etc.
Drive chain failures are often reflected in the machining of parts. If the positioning accuracy is not allowed, the backlash is too large, and the crawling feed drive is not in place. The inspection can be performed by manual function or manual cooperation. At this time, if the operation error is less than 0.0051, it is mostly a mechanical failure. If the error is large and disordered, it can be determined that the control part is faulty.
From the perspective of application, the faults can be divided into machine tool control device faults and mechanical faults; from the overall aspect of the system, faults are classified into software faults and hardware faults.
Mechanical failure and its troubleshooting method System overload report XH71.6 CNC vertical machining center, the system is FANUCOM system, this machine often has overload alarm during processing, the alarm number is 434, now the form is 2 axis vertical direction motor current Large, the motor is hot, and the alarm stops after 4,1 stops. Then work again, and similar alarms appeared.
After inspection and analysis, it is considered that the electrical servo system is fault-free, and it is estimated that the load is too heavy and does not move. In order to distinguish whether it is an electrical fault or a mechanical fault, the 2-axis motor is removed and mechanically disengaged, and the fault no longer occurs when operating again. This confirms that the screw or moving parts are too tight. After adjusting the 2-axis screw locknut, the effect is not obvious. Later, the 2-axis guide rail is adjusted, the machine load is obviously reduced, and the fault is eliminated.
The dimensional instability table of the machined parts adopts the CNC turret lathe of the FAUNC3T system. When machining parts, the radial size is often large and small.
The inspection, control system and machining program are normal, then check, to the connection between the motor and the lead screw in the transmission chain, and find that the motor coupling fastening screw is loose. In the case of no load, especially load, the motor shaft screw may have relative motion, because the semi-closed-loop control position detecting element is on the motor side, and the actual amount of rotation of the lead screw cannot be detected, resulting in dimensional instability. The problem is eliminated after tightening the motor coupling.
Control device failure and its elimination method CNC system hardware failure station industrial control machine as the main control, Spain, the system as the numerical control part of the CNC profile boring and milling machine, when the sub-machined parts replace the new machining program, suddenly crashes, and Nothing. After the system is shut down forcibly, the system is restarted. At this time, the self-test cannot pass, the host cannot be started, and the black screen of the display appears at the same time. Check, the display is normal, the processing program is correct, and the replacement of the graphics card and memory failure still exists. After analysis and judgment, it may be that the motherboard has a question.
After replacing the new motherboard, the main engine starts normally and the machine is running normally.
0, low orange ç ‘, 惶 惶 æŽèŒ« æŽèŒ«, the machining center of the wire 01 system, the secondary machining program can not be executed normally, the tool change and the 2-axis vertical direction function are lost, the machine parameters are confusing, and 910 alarms appear at the same time. The alarm in the service manual indicates that the elbow storage board is faulty. In order to confirm whether the fault is caused by hardware or software, the following check is taken. Step 8. First check, the backup battery voltage is normal. Record the system memory parameters and then clear all the machine parameter files that were previously backed up using the 3232 interface. After the machine parameters are restored, the machine will be restarted after the power is turned off, and the result will return to normal. This fault is caused by chaotic machine parameters. The handling of such faults does not require El to set up the window and the male, 2001 free 6 fault category fault phenomenon failure cause 1. Tool holder system 1 factory power frame can not be 2. The tool holder can not be changed normally, the line cable connection is poor 3. The frame is not in place. The signal detection system is lost. 4. The tool post is not rotating. The signal line of the knife is not falling. The Hall element is burned out to the axial feed system. 1. The workpiece 352 axis is not machined, the machine tool work accuracy is 1 standard, zero. Parts loose 24 or 2 axis reporter 1 bad 17 or 2 axis homing is not allowed 妄 transport parts return to zero or 2 axis overtravel shift position overtravel 5. or 2 direction feed abnormal parts damage melon. Power supply no power 1 fuse off gas open Wu jump, component damage line cable connection bad line electric circuit open Han system 1 Yizhou ginseng error alarm 01 memory function disorder 2., bad cloth, αT malfunction 7 can not return to zero main movement The component returns to zero, the CNC system can't work or work abnormally. The CNC system has no power connection line. The broken connector has a falling off V electrical system. 1. The machine tool can't work normally. 0 The fuse is broken, the air is turned on, the component is damaged, and the operation panel is damaged. Damaged line cable connection is bad. The 2 factory machine tool can't start the line cable. The road is rushed to replace the hardware, but should be from the software.
The faulty table caused by external hardware damage adopts Siemens 810 CNC vertical lathe. When the secondary tool holder moves up and down, the oil inlet pipe at the top of the tool post is abnormally continuously oiled, and the system alarm oil pressure is too low. Inspection, hydraulic system piping is not damaged 10 control system is normal. Progressive inspection, hydraulic system control components, found that the two-position solenoid valve coil in the tool holder lubricating oil circuit burned out, the valve core could not be returned, so that the tool holder lubrication oil supply was always in the normally open state. After replacing the solenoid valve, the fault is eliminated.
CNC lathe failure phenomenon and cause 1 From the fault statistics, the failure rate of the tool holder is the highest. The following is the electrical system and the 2-axis radial axial feed system power supply cooling system hydraulic system. Although the 0 system is more frequent, The fatality is very small. The failure of this system is mostly caused by human factors. After the failure, it does not cause a big harm. The fault is mostly wrong. If the quality of maintenance personnel and operators is improved, the 0,0 system will have Higher reliability.
Although the economical CNC machine tool failure is more frequent than the full-function CNC machine tool, the maintenance difficulty is relatively small. Therefore, as long as more learning and practice, accumulating experience and mastering maintenance skills, we will be able to repair the CNC equipment by our own strength. Use it well.
Xi'an 58 letter box 60 minutes 710061 edit Wu Siming