有關(guān)數(shù)控機(jī)床常見故障的診斷維修與機(jī)床保養(yǎng)的探析中英文對照

1、有關(guān)數(shù)控機(jī)床常見故障的診斷維修與機(jī)床保養(yǎng)的探析中英文對照About common fault diagnosis of CNC machine maintenance and machine maintenance analysis contrast in both Chinese and English 數(shù)控機(jī)床是集機(jī)、電、液、氣、光高度一體化的現(xiàn)代技術(shù)設(shè)備，就其維修的重要而言，是側(cè)重電子、機(jī)械、液、氣及光學(xué)的交叉點上。數(shù)控機(jī)床維修技術(shù)不僅是保障數(shù)控機(jī)床正常運行的前提，對數(shù)控機(jī)床的發(fā)展和完善也起到了巨大的推動作用。Nc machine tools is the collection mach

2、ine, electricity, liquid, gas, light, highly integrated modern technology and equipment, for the maintenance of important, is focus on electronics, machinery, liquid, gas and optical intersections. Nc machine maintenance technology is not only the premise of protection of the normal running of nc ma

3、chine tools, to the development of numerical control machine tool and perfect also played a huge role. 關(guān)鍵詞：數(shù)控機(jī)床 數(shù)控系統(tǒng) 可編程控制器 伺服驅(qū)動 Key words: CNC machine tool numerical control system PLC servo drive 0 引言0 the introduction 數(shù)控機(jī)床是一種典型的機(jī)電一體化產(chǎn)品，涉及范圍比較廣，在故障診斷和維護(hù)方面與傳統(tǒng)機(jī)床有很大的區(qū)別。因此，學(xué)習(xí)和掌握數(shù)控機(jī)床故障診斷及維護(hù)技術(shù)，及時有效的處理數(shù)控

4、機(jī)床的各種故障，對企業(yè)的維修人員來說非常重要。Numerical control machine tool is a kind of typical electromechanical integration products, involves the range is wide, the fault diagnosis and maintenance aspects has the very big difference with traditional machine tool. Therefore, the study and master the nc machine tool fa

5、ult diagnosis and maintenance technology, timely and effective handling various faults of CNC machine tools, maintenance personnel is very important to the enterprise. 1 數(shù)控機(jī)床的使用與維修1 and the use of nc machine tool maintenance 1.1 數(shù)控機(jī)床的分類和應(yīng)用 隨著數(shù)控技術(shù)的發(fā)展，數(shù)控機(jī)床已經(jīng)越來越普遍地應(yīng)用于企業(yè)的加工生產(chǎn)當(dāng)中。數(shù)控機(jī)床的種類很多，但主要按機(jī)床的加工方式和加工工

6、藝對其進(jìn)行分類?，F(xiàn)代工廠中主要以金屬切削加工為主，大致可以分為數(shù)控銑床，數(shù)控鏜床，數(shù)控立車，數(shù)控磨床以及加工中心等。1.1 classification and application of nc machine tools with the development of nc technology, nc machine tools has been more and more widely applied in the enterprises of processing production. Many different kinds of CNC machine tools, but m

7、ainly by machine tool processing methods and processing technology carries on the classification. Modern factory mainly metal machining, which can be roughly divided into CNC milling machine, CNC boring machine, CNC vertical lathe, CNC grinding machine and machining center, etc. 1.2 數(shù)控機(jī)床的維修的特點 數(shù)控機(jī)床與

8、傳統(tǒng)機(jī)床的維修不同，它是集數(shù)控系統(tǒng)、可編程控制器、伺服系統(tǒng)加精密機(jī)械等多項高新技術(shù)融合于一體的機(jī)電一體化產(chǎn)品。數(shù)控機(jī)床的維修應(yīng)遵循以下幾點：首先，要熟悉數(shù)控系統(tǒng)、位置檢測與伺服驅(qū)動和輔助控制的工作原理、特點及常見故障的處理。其次，要懂得充分利用NC、PLC提供的故障信息來查找故障。做到具體問題具體分析，才能確定故障的準(zhǔn)確處理。1.2 the characteristics of nc machine tool maintenance nc machine tools and traditional machine tool maintenance is different, it is a s

9、et of numerical control system, programmable controller and servo system precision machinery and so on many high technology and new technology integration in the integration of mechanical and electrical integration products. Nc machine tool maintenance should follow the following points: first, to b

10、e familiar with CNC system, position detection and servo drive and auxiliary control the working principle, characteristics and common fault processing. Next, want to knows how to take full advantage of NC and PLC provide fault information to locate the fault. Do specific issues specific analysis, t

11、o determine the fault accurate processing. 1.3 數(shù)控機(jī)床故障診斷維修的基本步驟 數(shù)控機(jī)床的維修過程主要分為三個階段。首先，到達(dá)現(xiàn)場后進(jìn)行現(xiàn)場的調(diào)查和故障信息的采集。仔細(xì)詢問機(jī)床操作者故障表面的指示情況以及產(chǎn)生故障的背景情況，對故障現(xiàn)象做出初步的判斷。其次，根據(jù)現(xiàn)場的調(diào)查結(jié)果和故障現(xiàn)象進(jìn)行具體的維修。從易到難、由外向內(nèi)，逐漸縮小查找范圍，確定故障存在的位置從而采取正確的維修措施。最后，機(jī)床的故障排除后及時向操作者交代清楚本次故障的起因以及發(fā)生故障的信息和環(huán)節(jié)，告其今后操作的注意事項，避免今后再次發(fā)生同類故障。同時做好維修記錄，為以后維修做好儲備。1.

12、3 maintenance nc machine tool fault diagnosis of the basic steps of the numerical control machine tool maintenance process is mainly divided into three stages. First of all, on the scene after scene investigation and fault information collection. Carefully inquired about fault indication on the surf

13、ace of the machine tool operators and malfunction of the background to the case, make a preliminary judgment of fault phenomenon. Secondly, according to the survey results for specific maintenance and fault phenomena. From easy to difficult, outside-in, gradually narrow the search range, determine t

14、he fault location to take the correct maintenance measures. Finally, after the machine troubleshooting timely account to the operator at the causes of the failure and malfunction information and links to its future operation matters needing attention, to avoid recurrence of similar failures in the f

15、uture. Make repair record at the same time, the reserves for future maintenance. 2 數(shù)控機(jī)床常見故障診斷與檢修2 the common nc machine tool fault diagnosis and maintenance 數(shù)控機(jī)床的故障主要集中在主軸部分和進(jìn)給伺服系統(tǒng)方面，一些輔助控制器件的故障以及控制回路斷路等問題也是常見的，下面就具體介紹一下數(shù)控機(jī)床中常見故障的檢修。Nc machine tool fault mainly concentrated in the main part and feed

16、 servo system, some auxiliary control device of fault circuit and control circuit are common problems in the following specific introduce common faults in the numerical control machine tool maintenance. 2.1 主軸部分常見故障的檢測方法 數(shù)控機(jī)床主軸驅(qū)動系統(tǒng)主要用于機(jī)床的主軸旋轉(zhuǎn)運動。一般主軸驅(qū)動系統(tǒng)應(yīng)具有較寬的恒功率范圍，較短的加速和減速時間，調(diào)速范圍要寬，過載能力強(qiáng)，電機(jī)溫度低及噪聲小等。

17、主軸一般常見的故障主要集中在主軸驅(qū)動系統(tǒng)的故障和主軸液壓、主軸流量檢測方面的故障。2.1 spindle part of the common failure detection method of nc machine tool spindle drive system is mainly used for machine tool spindle rotation motion. General spindle drive system should have wide constant power range, short acceleration and deceleration ti

18、me, speed range is wide, overload capacity is strong, low temperature and low noise motor, etc. Line general common fault is mainly focused on the main drive system of the fault and the spindle's hydraulic pressure, flow rate of fault detection. 2.2 主軸系統(tǒng)常見故障實例2.2 the spindle system common fault

19、instance 例1一臺德國產(chǎn)13米數(shù)控龍門銑床主軸松刀松不開！檢查PLC發(fā)現(xiàn)輸入輸出信號都有，說明24V電源已經(jīng)輸出，檢查電磁閥發(fā)現(xiàn)閥得電后并沒有吸合，確定閥體損壞！更壞電磁閥后正常。example 1 a German 13 meters CNC gantry milling machine spindle knife don't come loose! Check the PLC input and output signals are found, the 24 v power supply has output, after inspection found valve s

20、olenoid electric didn't suck, determine the body is damaged! Worse after the solenoid valve is normal. 例2一臺國產(chǎn)六米三數(shù)控立車主軸流量壓力檢測點報警。檢查發(fā)現(xiàn)該主軸流量檢測單元由四個壓力流量檢測點構(gòu)成，PLC程序顯示其中一個檢測點報警，用萬用表量各個檢測點處均為導(dǎo)通，故判斷為該油管通路不暢，疏通油管后報警清除恢復(fù)正常。example 2 a domestically produced 6 m 3 CNC vertical lathe spindle flow pressure al

21、arm. Inspection found that the main flow testing unit consists of four pressure flow testing point, PLC program shows one of the first alarm, each testing point in the multimeter is both for conduction, so the judgment for the tubing channel impeded, dredge pipe after police cleared back to normal.

22、例3一臺國產(chǎn)數(shù)控十米立車主軸不轉(zhuǎn)。經(jīng)檢查沒發(fā)現(xiàn)任何報警。該立車進(jìn)給軸由左右兩個刀架子組成，左刀架為數(shù)控軸還能繼續(xù)開動，但右刀架為普通數(shù)顯軸卻動不了，檢查PLC程序發(fā)現(xiàn)右手持單元選擇按鈕選擇不上，故檢查手持單元發(fā)現(xiàn)按鈕24V電源線斷路，由于PLC程序中將手持單元停止與主軸停止是串聯(lián)在一起的，因此導(dǎo)致主軸啟動不了，恢復(fù)手持單元24V電源線后一切恢復(fù)正常。example 3 a domestic ten meters CNC vertical lathe spindle is not turn. JingJian seizure found any alarm. The vertical lathe

23、 feed shaft is composed of left and right two knife rack, can continue to start the left head for CNC axis, but the right tool post for ordinary digital display shaft but can't move, check the PLC program found that right hand held unit on the select button to choose not to, so check the handhel

24、d unit find button 24 v power cut-off, handheld unit due to the PLC program will stop and the shaft is in series with the stop, so lead to the spindle won't start, everything is back to normal after returning to handheld unit 24 v power supply cord. 例4一臺國產(chǎn)數(shù)控十米立車主軸屏幕數(shù)顯不動，經(jīng)檢查發(fā)現(xiàn)連接主軸編碼器和驅(qū)動器的線沒有損壞斷路處

25、，拆下主軸編碼器檢查發(fā)現(xiàn)編碼器損壞，更換新的編碼器后數(shù)顯恢復(fù)正常。example 4 a domestically produced ten meters CNC vertical lathe spindle screen digital display, through inspection found no damage to the connection shaft encoder and the drive line break place, remove the shaft encoder inspection found that the encoder is damaged, r

26、eplace the display returns to normal after the new encoder. 2.3 進(jìn)給伺服部分常見故障的檢測方法 進(jìn)給伺服系統(tǒng)不僅是數(shù)控機(jī)床的一個重要組成部分，也是數(shù)控機(jī)床區(qū)別一般機(jī)床的一個特殊部分，它的定位精度高，跟蹤指定信號響應(yīng)快，穩(wěn)定性好，保證進(jìn)給伺服系統(tǒng)的正常工作對充分發(fā)揮數(shù)控機(jī)床的作用至關(guān)重要。進(jìn)給伺服系統(tǒng)控制機(jī)床移動部件的位移，以直線運動為主。其常見故障主要集中在伺服控制單元的故障、位置反饋部分的故障和伺服電機(jī)的故障這幾個方面。一般的檢測流程為先看其是否有伺服使能信號，即根據(jù)PLC程序檢查使能條件是否滿足。再看屏幕軸數(shù)值是否變化，伺服軸

27、是否移動了以及伺服單元上是否有指令電壓，從而可以確定是位置反饋的問題或是伺服電機(jī)或機(jī)械方面的問題。2.3 feed servo portion of the common failure detection method of feed servo system is an important part of nc machine tool not only, also is a special part of the nc machine tools the difference between general machine tools, its high positioning accu

28、racy, tracking specified signal fast response, good stability and guarantee the normal work of the feed servo system is very important to give full play to the role of the nc machine tools. Machine tool feed servo system control the displacement of the moving parts is given priority to with straight

29、 line. Its common faults are mainly concentrated in the servo control unit fault, position feedback part of the fault and fault this a few aspects of servo motor. General test process of the first to see if it has servo enabled signal, namely, according to the PLC program to check whether meet the e

30、nabling conditions. Again to see if the screen shaft numerical change, does the servo axis movement servo unit, and whether there is voltage directive, which is the issue of position feedback can be determined or servo motor or mechanical problems. 2.4 進(jìn)給伺服系統(tǒng)常見故障實例2.4 feed servo system common fault

31、instance 例1一臺國產(chǎn)數(shù)控200鏜床Y軸開動時飛車。初步判斷其反饋不正常。經(jīng)檢查發(fā)現(xiàn)光柵尺尺頭損壞導(dǎo)致全閉環(huán)反饋已不起作用，系統(tǒng)已變成半閉環(huán)導(dǎo)致飛車。更換光柵尺尺頭后Y軸恢復(fù)正常。example 1 when a home-made numerical control boring machine 200 Y train speed. Preliminary judgment of the feedback is not normal. End damage caused after inspection found that the grating ruler full closed

32、 loop feedback have no effect, the system has become a half closed loop in speed. End after the replacement of raster ruler Y back to normal. 例2一臺國產(chǎn)17米數(shù)控龍門銑床Y軸伺服系統(tǒng)報警顯示Y軸驅(qū)動過載。經(jīng)檢查發(fā)現(xiàn)機(jī)械負(fù)載方面沒有問題，再進(jìn)一步檢查發(fā)現(xiàn)機(jī)床漏油流進(jìn)電機(jī)導(dǎo)致電機(jī)損壞。更換Y軸伺服電機(jī)后伺服系統(tǒng)恢復(fù)正常。example 2 a domestic 17 meters CNC gantry milling machine Y axis serv

33、o system overload alarm display Y drive. Through inspection found that the mechanical loading no problem, will have a further check found machine oil flow into the motor lead to motor damage. After replace the Y axis servo motor servo system is back to normal. 例3一臺國產(chǎn)1680數(shù)控臥車Z軸回不了參考點。經(jīng)檢查發(fā)現(xiàn)該軸設(shè)置為正向回參考點

34、，但回參考點的時候Z軸往負(fù)方向走，故判斷系統(tǒng)默認(rèn)已壓上參考點檔塊。進(jìn)一步檢查發(fā)現(xiàn)零點操作線與24V相連，常開點變常閉點。用備用線換參考點操作線后恢復(fù)正常。example 3 a domestic 1680 Z axis CNC sleeping car back to the reference point. Through inspection found that the shaft is set to forward to reference points, but back to the reference point Z axis to negative direction, so

35、the system default judgment has pressure reference points on the block. Further examination showed zero line connected with 24 v operation, normally open points become normally closed. Use spare line reference point line back to normal after the operation. 2.5 其它常見故障的檢修2.5 maintenance of other commo

36、n faults 普通交流三相異步電動機(jī)缺相或接地導(dǎo)致電機(jī)損壞是數(shù)控機(jī)床最常見的故障。電機(jī)接地會導(dǎo)致電流瞬間增大使斷路器斷開。輔助回路輸入輸出點的斷路也很常見。下面具體介紹幾個常見故障。Ordinary ac three-phase asynchronous motor open phase or grounding lead to motor damage is the most common nc machine tool failure. Electrical grounding will cause current moment circuit breakers to disconne

37、ct. Auxiliary circuit input and output points of circuit is also common. Here introduces several common faults. 例1一臺數(shù)控1680臥式車床主油泵啟動不起來。檢查發(fā)現(xiàn)斷路器已斷開。用萬用表量電機(jī)發(fā)現(xiàn)電機(jī)繞組接地，故判斷該電機(jī)損壞，更換電機(jī)后正常。example 1 a CNC horizontal lathe main oil pump start up 1680. Inspection found that circuit breaker has been disconnected

38、. Motor found motor winding grounding by the multimeter, determine whether the motor is damaged, replace the motor after normal. 例2一臺數(shù)控260鏜床轉(zhuǎn)臺后退沒有。經(jīng)檢查發(fā)現(xiàn)其向前正常，但后退沒有并同時輸入指示燈也不亮。進(jìn)一步檢查其PLC輸入點也沒有，檢查按鈕站發(fā)現(xiàn)該電鈕24V電源正常，用萬用表量該按鈕沒有損壞。所以確定該按鈕操作線斷路，用備用線更換該操作線后正常。example 2 a CNC boring machine 260 turntable back n

39、o. Through inspection found that the normal forward, but not backward and the input indicator is not on at the same time. Check the PLC input point and no further, check button station found the button 24 v power supply is normal, no damage in the button by the multimeter. So make sure the button li

40、ne open circuit operation, with spare change to normal after the operation line. 3 數(shù)控機(jī)床的保養(yǎng)Three numerical control machine tool maintenance 為了使數(shù)控機(jī)床各部件保持良好狀態(tài)，除了發(fā)生故障使應(yīng)及時修理外，堅持做好機(jī)床的日常保養(yǎng)也是十分重要的。堅持做好數(shù)控機(jī)床的日常保養(yǎng)可以減少機(jī)床故障率的發(fā)生，從而保證機(jī)床的生產(chǎn)加工效率。數(shù)控機(jī)床的保養(yǎng)主要包括以下幾個方面。In order to make the CNC machine components in good c

41、ondition, in addition to failure made shall promptly repair, conduct the daily maintenance of machine tool is also very important. To do daily maintenance of CNC machine can reduce the machine failure rate, so as to ensure the production of machine tool processing efficiency. Numerical control machine tool maintenance mainly includes the following several aspects. 對直流電動機(jī)定期進(jìn)行電刷和換向器的檢查、清洗和更換。適時對各坐標(biāo)軸進(jìn)行超程限位試驗。尤其是對于硬件限位開關(guān)檢查時要用手按一下看是否出現(xiàn)超程報警。定期檢查電器柜里的空調(diào)設(shè)備，已保證電器柜內(nèi)的冷卻達(dá)標(biāo)，防止由于