數(shù)控技術(shù)-外文翻譯-外文文獻(xiàn)-英文文獻(xiàn)-數(shù)控技術(shù)的發(fā)展與維修(常用版)

數(shù)控技術(shù)外文翻譯外文文獻(xiàn)英文文獻(xiàn)數(shù)控技術(shù)的發(fā)展與維修（常用版）(可以直接使用，可編輯完整版資料，歡迎下載）

DevelopmentandmaintenanceofCNCtechnology數(shù)控技術(shù)外文翻譯外文文獻(xiàn)英文文獻(xiàn)數(shù)控技術(shù)的發(fā)展與維修（常用版）(可以直接使用，可編輯完整版資料，歡迎下載）Numericalcontroltechnologyandequipmentisthedevelopmentofnewhigh-techindustryandcutting-edgeenablingtechnology,industryandthemostbasicequipment.Theworldinformationindustry,biologicalindustry,aviation,aerospaceandotherdefenseindustrywidelyusednumericaltechniquestoimprovemanufacturingcapacityandlevel,toimprovetheadaptabilityofthemarketandcompetitiveness.IndustrialcountriesandCNCnumericalcontroltechnologyandequipmentwillalsobelistedascountriesofstrategicmaterials,notonlytodeveloptheirownnumericalcontroltechnologyandindustry,andin"sophisticated"technologyandequipment,numericalcontrolkeyaspectsofthepolicyofclosuresandrestrictions.Therefore,effortstodevelopadvancednumericalcontroltechnologyasthecoremanufacturingtechnologyhasbecometheworld'sdevelopedcountriestoaccelerateeconomicdevelopment,enhancethecomprehensivenationalstrengthandanimportantwaytostatehood.

PartI:thedevelopmentofCNCmachinetoolstrendsinindividual

1.Highspeed,highaccuracy,highreliability

Highspeed:Toimprovethespeedandincreasefeedspindlespeed.

Highprecision:theprecisionfrommicrontosub-micronlevel,andeventhenano-level(highreliability:thereliabilityofnumericalcontrolsystemgenerallyhigherthanthereliabilityofnumericalcontrolequipmentmorethananorderofmagnitude,butnotthehigherthebetterreliabilitybecausethegoodsbythecostperformanceconstraints.

2.Composite

CompositefunctionCNCmachinetooldevelopment,itscoreisinasinglemachinetocompletetheturning,milling,drilling,tapping,reamingandreamingandotheroperatingprocedures,therebyincreasingtheefficiencyandprecisionmachinetoolstoimproveproductionflexibility.

3.Intelligent

Intelligentcontentincludedinallaspectsofthenumericalcontrolsystem:thepursuitofprocessingefficiencyandprocessingqualityofintelligence;toimprovetheperformanceandtheuseofconvenientconnectionsandotheraspectsofintelligence;simplifyprogramming,simplifyingoperationalintelligence;alsoliketheintelligentautomaticprogramming,intelligentman-machineinterface,aswellasintelligentdiagnostics,intelligentmonitoringandotheraspects,tofacilitatesystemdiagnosticsandmaintenance.

4.Flexible,integrated

TheworldofCNCmachinetoolstothedevelopmenttrendofflexibleautomationsystemsare:fromthepoint(CNCsingle,compositemachiningcentersandCNCmachinetools),line(FMC,FMS,FTL,FML)tothesurface(SectionworkshopindependentmanufacturingislandFA),body(CIMS,distributednetworkintegratedmanufacturingsystem)direction,theothertofocusonappliedandeconomicdirection.Flexibleautomationtechnologyistheindustrytoadapttodynamicmarketdemandsandquicklyupdatetheprimarymeansofproductisthemaintrendofnationalmanufacturingindustryisthebasisforthefieldofadvancedmanufacturingtechnology.

Second,personalizationistheadaptabilityofthemarkettrends

Today'smarket,graduallyformedthepatternofinternationalcooperation,theproductsbecomingmorecompetitive,efficientandaccurateprocessingoftheescalatingdemandmeans,theuser'sindividualrequirementsbecomeincreasinglystrong,professional,specialization,moreandmorehigh-techmachinetoolsbytheusersofallages.

Third,theopenarchitecturetrendis

ThecoreofanewgenerationofCNCsystemdevelopmentisopen.Opensoftwareplatformandhardwareplatformsareopensystems,modular,hierarchicalstructure,andthroughouttheformtoprovideaunifiedapplicationinterface.

CNCsystemtoaddresstheclosureofthetraditionalCNCapplicationsandindustrialproductionproblems.Atpresent,manycountriesofopenCNCsystem,CNCsystemhasbecomeanopennumericalcontrolsystemofthefutureoftheroad.Theopennumericalcontrolsystemarchitecturespecification,communicationspecifications,configurationspecifications,operatingplatform,functionlibrariesandCNCnumericalcontrolsystemsoftwaredevelopmenttools,systemfunctionisthecoreofthecurrentstudy.Networknumericalcontrolequipmentisnearlytwoyearsofanewfocus.NCnetworkequipmentwillgreatlysatisfytheproductionlines,manufacturingsystems,manufacturinginformationintegrationneedsofenterprises,butalsoachievenewmanufacturingmodel,suchasagilemanufacturing,virtualenterprises,globalmanufacturingthebaseunit.Somewell-knownathomeandabroad,andCNCCNCmachinetoolsmanufacturingcompanyin

PartII:MachineMaintenance

CNCmachinetoolsiselectronictechnology,measurementtechnology,automationtechnology,semiconductortechnology,computertechnologyandelectricaltechnology,andintegratedsetofautomationequipment,highprecision,highefficiencyandhighflexibility.CNCmachinetoolsisaprocesscontrolequipmentandaskedhiminreal-timecontroloftheaccuracyofeverymomentofwork,anypartofthefaultandfailure,sothatthemachinewillshutdown,resultinginproductionstoppages,whichseriouslyaffectedandrestrictedtheproductionefficiency.CNCmachinetoolsinmanyindustriestoworkthedeviceiscritical,ifnotafterafailureinitsmaintenanceandtroubleshootingtime,itwillcausegreatereconomiclosses.Therefore,theprinciplethatcomplexnumericalcontrolsystem,structure,maintenanceofsophisticatedequipmentisnecessary.CNCmachinetoolstoenhancefaultdiagnosisandmaintenanceofpower,canimprovethereliabilityofCNCmachinetools,CNCmachinetoolsisconducivetothepromotionanduse.

CNCmachinetoolsisamechanical,electrical,hydraulic,gascombinationofcomplexequipment,thoughthereasonsforfailurevary,butthefailureoccurred,thegeneralideaofthestepsarethesame.Fails,SpindlestartbelowtostopimmediatelyafterthefaultdiagnosisofCNCmachinetoolsasanexamplethegeneralprocess.

First,thefault-siteinvestigation.Thesurveycontentincludes1,2typesoffailure,thefailurefrequencyof3,4,externalconditions,theoperatingconditions5,6,machineconditions,thefunctioningof7,wiringbetweenmachinetoolsandsystems8,CNCequipmentvisualinspection.Afteraninvestigation,suchfailureisspindleclassfailure,onlyonce,outsideofallnormal,theoperatorofaboottoreflectthissituation.

Second,thefaultinformationcollation,analysis.Forsomesimplefault,becausenotalotoftime,themethodcanbeusedformoflogicalreasoning,analysis,identificationandtroubleshooting.Afterafailedon-siteinvestigationforseveralreasonswesuspectthatthesystemoutputpulse①②driveisnotenoughtimetomovethestatelinetocontrolthespindlecomponents③④damagetothespindlemotorshort-circuit,causingthespindlethermalrelayprotection⑤notwithself-controllooplockcircuits,andtheparameterissettopulsesignaloutput,sothatthespindlecannotoperatenormally.Identifypossiblereasonstoruleoutonebyone.

Third,conductfaultdiagnosisandtroubleshooting.

Diagnosisusuallyfollowsthefollowingprinciples:1,afterthefirstoutsideinside.ReliablelineofmodernCNCsystemincreasinglyhighfailurerateofCNCsystemitselflessandless,andmostarenon-occurrenceoffailurecausesthesystemitself.TheCNCmachineisamechanical,hydraulic,electricalasoneofthetools,theoccurrenceofthefaultwillbereflectedbythesethreecomprehensive,maintenancepersonnelshouldbefromoutsidetoinsideonebyoneinvestigationtoavoidarbitraryunsealed,demolition,otherwiseexpandthemalfunction,sothatthelossofprecisionmachinetools,slowperformance,outsidethesystemdetectedthefaultisduetoopenonebyone,hydrauliccomponents,pneumaticcomponents,electricalactuators,mechanicaldevicescausedproblems.2,thefirstaftertheelectricalmachinery.Ingeneral,themechanicalfailureeasiertofind,andnumericalcontrolsystemandelectricalfaultdiagnosismoredifficult,beforethetroubleshootingtoruleoutmechanicalfailureofthefirst3,afterthefirststaticdynamic.Poweroffthemachinefirst,quiescentstate,throughunderstanding,observation,testing,analysis,confirmthepowerfailurewillnotresultinexpansionoftheincidentonlyafterthepowertothemachine,runthestate,thedynamicofobservation,inspectionandtesting,tofindfault.Whileafterthedevastatingpowerfailure,youmustfirstruleoutthedanger,beforeelectricity.4,afterthefirstsimpleandcomplex.Whenmultiplefailuresareintertwined,andsometimesimpossibletostartwith,weshouldfirstsolvetheproblemeasily,thensolvethedifficultproblem,oftenasimpleproblemtosolve,thedifficultyoftheproblemmayalsobecomeeasier.

CNCmachinetoolsinthefaultdetectionprocess,shouldmakefulluseofnumericalcontrolsystemself-diagnosticfeaturestobejudged,butalsoflexibilityintheuseofsomecommontroubleshootingmethods.Troubleshootingcommonmethodsare:

1.Routineexaminationmethod

Routineexaminationmethodismainlyofhands,eyes,ears,noseandotherorgansofthefaultoccurrenceofvariouslight,sound,smellandabnormalobservationsandcarefullookateverysystem,followthe"firstpostoutsideof"theprincipleoffaultdiagnosisbylooking,listening,smelling,asking,moldandsoon,fromoutsidetoinsideonebyonecheck,thefaultcanoftenbenarroweddowntoamoduleoraprintedcircuitboard.Thisrequiresmaintenancepersonnelhaveawealthofpracticalexperience,tothewidermultidisciplinaryandcomprehensiveknowledgeoftheabilitytojudge.

2.Self-diagnosticfunctionmethod

ModernCNCsystemhasyettoachieveahighdegreeofintelligence.Butalreadyhasastrongself-diagnosticfunction.CNCreadytomonitorthehardwareandsoftwareisworking.Oncetheabnormal,immediatelydisplayedontheCRTalarmorfaultLEDsindicatetheapproximatecause.Usingself-diagnosisfunction,butalsoshowstheinterfacesignalsbetweenthesystemandthehoststate,inordertodeterminethefaultoccurredinthemechanicalpartorpartsofNCsystem,andindicatetheapproximatefaultlocation.Thismethodiscurrentlythemosteffectivemaintenancemethods.

3.Functionalprogramtestingmethod

So-calledfunctionalprogramtestingmethodiscommonlyusedinthenumericalcontrolsystemfunctionsandspecialfeatures,suchaslinearpositioning,circularinterpolation,helicalcut,fixedcycle,suchastheusermacroprogrammingbyhandorautomaticprogrammingmethods,thepreparationoftestproceduresintoafunctionalprogram,intothenumericalcontrolsystem,andthenstarttheCNCsystemtomakeitrun,tochecktheimtimethefirstbootofCNCwhetheraprogrammingerrororoperationalerrorormachine

4.Sparepartssubstitution

Sparepartsreplacementmethodisasimplemethodtodeterminethesceneisoneofthemostcommonlyused.Theso-calledsparesubstitutionisgenerallythecauseoffailureintheanalysisofthecase,maintenancepersonnelcanusethealternatePCB,templates,integratedcircuitchiporreplacethequestionablepartsofcomponents,whichnarrowedthefaulttoaprintedcircuitboardorchiplevel.Itisactuallyintheverificationanalysisiscorrect.However,beforeswitchingthestandbyboardshouldcarefullycheckthespareboardisintact,andshouldcheckthestatusofreserveboardshouldbefullyconsistentwiththeoriginalboardthestate.Thisincludescheckingwiththeboardselectionswitch,setthelocationandtheshortrodpotentiometerposition.Inshort,wemuststrictlyinaccordancewiththesystem'soperation,maintenancerequirementsmanualoperation.

Indeterminingthereplacementofapartto,shouldcarefullychecktherelevantconnectedtoelectricallinesandotherrelated,confirmingthatnofailureuptothenewreplacementtopreventfailurescausedbyexternaldamagetoreplacethepartsup.

5.TransferAct

Theso-calledtransfermethodistohavethesamenumericalcontrolsystemfeaturestwoprintedcircuitboards,templates,integratedcircuitchipsorcomponentstoexchange,observedfailurephenomenabetransferred.Inthisway,thesystemcanquicklydeterminethefaultposition.Thismethodisactuallyakindofsparepartssubstitution.Therefore,theconsiderationsdescribedinthesamesparepartssubstitution.

6.Parametercheckmethod

KnownparameterscandirectlyaffectthenumericalperformanceofCNCmachinetools.Parametersareusuallystoredinthemagneticbubblememory,orstoredinbatteriestobemaintainedbytheCMOSRAM,oncethebatteryisloworbecauseofoutsideinterferenceandotherfactors,someparameterswillbelostorchangeinchaos,sothatthemachinedoesnotwork.Atthispoint,throughtheproofreading,correctionparameters,willbeabletotroubleshoot.Whenthemachineidleforalongtimetoworkagainfornoreasonthatthereisnonormalorfailurewithoutwarning,itshouldbebasedonfaultcharacteristics,inspectionandproof-readingtherelevantparameters.

AfteralongrunofCNCmachinetools,wearandtearduetoitsmechanicaldrivecomponents,electricalcomponentperformancechangesandotherreasons,alsoneedtoadjusttheparametersofits.Somemachinetoolfailureisoftennottimelybecausetheparameterschangeduetosomenotmeet.Ofcourse,thesefailuresarethefaultoftheareasaresoft.

7.MeasurementofComparativeLaw

CNCsysteminthedesignofprintedcircuitboardmanufacturingplant,inordertoadjust,repairfacilities,intheprintedcircuitboarddesignedanumberoftestterminals.Userscanalsousenormalprintedcircuitboardterminalscomparingthemeasuredandthedifferencebetweentheprintedcircuitboardfailure.Theseterminalscandetectthevoltageandwaveformmeasurements,analyzethecausesoffailureandfailurelocation.Evenonanormalprintedcircuitboardcansometimesartificiallycreate"fault",suchasbrokenconnectionorshortcircuit,unplugthecomponents,inordertodeterminetherealcauseoffailure.Therefore,maintenancepersonnelshouldbeintheusualaccumulationofkeypartsoftheprintedcircuitboardorfailure-pronepartsoftherightinthenormalwaveformandvoltagevalues.BecausetheCNCsystemmanufactureroftendoesnotprovidetheinformationinthisregard.

8.Percussionmethod

WhentheCNCsystemfailuresshowedRuoyouruowu,oftenusedmethodfordetectingthefaultstruckthesitelies.Thisisbecausethenumericalcontrolsystemiscomposedbythemulti-blockprintedcircuitboards,eachboardhasalotofsolderjoints,platesorbetweenmodulesandisconnectedthroughtheconnectorsandcables.Therefore,anycoldsolderjointorbad,maycauseamalfunction.WhenthetapwiththeinsulationandpoorcontactwithWelddoubtatfaultmustberepeatedreproduction.

9.Localheatingmethod

AfteralongrunningCNCsystemcomponentsaretobeaging,performancewilldeteriorate.Whentheyarenotfullydamaged,failureswillbecomefromtimetotime.Thenheatcanbeusedsuchasahairdryerorelectricironissuspectedtolocalheatingcomponents,acceleratingtheagingsothoroughlyexposedfaultcomponents.Ofcourse,usingthismethod,besuretopayattentiontocomponentsofthetemperatureparameters,donotroasttheoriginaldeviceisagoodorbad.

10.Principleofanalysis

Thecompositionaccordingtoprinciplesofnumericalcontrolsystemcanbeanalyzedfromvariouspointsoflogicallevelsandlogicalparameters(suchasvoltageorwaveform)andthenwithamultimeter,logicpen,onlytheoscilloscopeorlogicanalyzertomeasure,analyzeandcompare,andthusfailurepositioning.Usingthismethod,whichrequiresmaintenancepersonneltobeonthewholesystemortheprincipleofeachcircuithaveaclear,deepunderstanding.

Basedontheaboveprinciplesandmethods,wemaybeitemizedonthecheckitandeliminatethecauses.

Thefirstpossiblefailureforthesystemoutputpulsetimeisnotenough,weadjusttheM-codesystem,startthespindleoutputtime,foundtheproblemstillexists,andthenfindthenextpossiblecausemaybeinthedrivetomovethestate,refertothemanualdrive,setparametersstartthespindle,theproblemstillexistswesuspectedspindlemotorshort-circuit,resultinginthermalrelayprotection.Thenfindthecauseoftheshort,sothatthespindlethermalrelayresetthestartandfoundthatthenormaloperationofthespindle,theproblemsolved.

Fourth,doalessonslearnedandrecorded.Aftertroubleshooting,repairworkcannotbeconsideredcomplete,stillneedtechnicalandmanagementaspectsoftheunderlyingcausesoffailurehavetotakeappropriatemeasurestopreventfailuresfromhappeningagain.Underfieldconditionswhennecessaryuseofmaturetechnologiestotransformandimprovetheequipment.Finally,thefailureofthemaintenanceofthephenomenon,causeanalysis,resolutionprocess,thereplacementofcomponents,legacy,etc.tomakearecord.

數(shù)控技術(shù)的發(fā)展與維修數(shù)控技術(shù)及裝備是發(fā)展新興高新技術(shù)產(chǎn)業(yè)和尖端工業(yè)的使能技術(shù)和最基本的裝備。世界各國(guó)信息產(chǎn)業(yè)、生物產(chǎn)業(yè)、航空、航天等國(guó)防工業(yè)廣泛采用數(shù)控技術(shù)，以提高制造能力和水平，提高對(duì)市場(chǎng)的適應(yīng)能力和競(jìng)爭(zhēng)能力。工業(yè)發(fā)達(dá)國(guó)家還將數(shù)控技術(shù)及數(shù)控裝備列為國(guó)家的戰(zhàn)略物資，不僅大力發(fā)展自己的數(shù)控技術(shù)及其產(chǎn)業(yè)，而且在"高精尖"數(shù)控關(guān)鍵技術(shù)和裝備方面對(duì)我國(guó)實(shí)行封鎖和限制政策。因此大力發(fā)展以數(shù)控技術(shù)為核心的先進(jìn)制造技術(shù)已成為世界各發(fā)達(dá)國(guó)家加速經(jīng)濟(jì)發(fā)展、提高綜合國(guó)力和國(guó)家地位的重要途徑。第一部分：數(shù)控機(jī)床個(gè)性化的發(fā)展趨勢(shì)1.高速化、高精度化、高可靠性高速化：提高進(jìn)給速度與提高主軸轉(zhuǎn)速。高精度化：其精度從微米級(jí)到亞微米級(jí)，乃至納米級(jí)(高可靠性：一般數(shù)控系統(tǒng)的可靠性要高于數(shù)控設(shè)備的可靠性在一個(gè)數(shù)量級(jí)以上，但也不是可靠性越高越好，因?yàn)樯唐肥苄阅軆r(jià)格比的約束。2.復(fù)合化數(shù)控機(jī)床的功能復(fù)合化的發(fā)展，其核心是在一臺(tái)機(jī)床上要完成車、銑、鉆、攻絲、絞孔和擴(kuò)孔等多種操作工序，從而提高了機(jī)床的效率和加工精度，提高生產(chǎn)的柔性。3.智能化智能化的內(nèi)容包括在數(shù)控系統(tǒng)中的各個(gè)方面：為追求加工效率和加工質(zhì)量方面的智能化；為提高驅(qū)動(dòng)性能及使用連接方便等方面的智能化；簡(jiǎn)化編程、簡(jiǎn)化操作方面的智能化；還有如智能化的自動(dòng)編程、智能化的人機(jī)界面等，以及智能診斷、智能監(jiān)控等方面的內(nèi)容，方便系統(tǒng)的診斷及維修。4.柔性化、集成化當(dāng)今世界上的數(shù)控機(jī)床向柔性自動(dòng)化系統(tǒng)發(fā)展的趨勢(shì)是：從點(diǎn)(數(shù)控單機(jī)、加工中心和數(shù)控復(fù)合加工機(jī)床)、線（FMC、FMS、FTL、FML）向面(工段車間獨(dú)立制造島FA)、體（CIMS、分布式網(wǎng)絡(luò)集成制造系統(tǒng)）的方向發(fā)展，另一方面向注重應(yīng)用性和經(jīng)濟(jì)性方向發(fā)展。柔性自動(dòng)化技術(shù)是制造業(yè)適應(yīng)動(dòng)態(tài)市場(chǎng)需求及產(chǎn)品迅速更新的主要手段，是各國(guó)制造業(yè)發(fā)展的主流趨勢(shì)，是先進(jìn)制造領(lǐng)域的基礎(chǔ)技術(shù)。二、個(gè)性化是市場(chǎng)適應(yīng)性發(fā)展趨勢(shì)當(dāng)今的市場(chǎng)，國(guó)際合作的格局逐漸形成，產(chǎn)品競(jìng)爭(zhēng)日趨激烈，高效率、高精度加工手段的需求在不斷升級(jí)，用戶的個(gè)性化要求日趨強(qiáng)烈，專業(yè)化、專用化、高科技的機(jī)床越來(lái)越得到用戶的青睞。三、開(kāi)放性是體系結(jié)構(gòu)的發(fā)展趨勢(shì)新一代數(shù)控系統(tǒng)的開(kāi)發(fā)核心是開(kāi)放性。開(kāi)放性有軟件平臺(tái)和硬件平臺(tái)的開(kāi)放式系統(tǒng)，采用模塊化，層次化的結(jié)構(gòu)，并通過(guò)形式向外提供統(tǒng)一的應(yīng)用程序接口。為解決傳統(tǒng)的數(shù)控系統(tǒng)封閉性和數(shù)控應(yīng)用軟件的產(chǎn)業(yè)化生產(chǎn)存在的問(wèn)題。目前許多國(guó)家對(duì)開(kāi)放式數(shù)控系統(tǒng)進(jìn)行研究，數(shù)控系統(tǒng)開(kāi)放化已經(jīng)成為數(shù)控系統(tǒng)的未來(lái)之路。目前開(kāi)放式數(shù)控系統(tǒng)的體系結(jié)構(gòu)規(guī)范、通信規(guī)范、配置規(guī)范、運(yùn)行平臺(tái)、數(shù)控系統(tǒng)功能庫(kù)以及數(shù)控系統(tǒng)功能軟件開(kāi)發(fā)工具等是當(dāng)前研究的核心。網(wǎng)絡(luò)化數(shù)控裝備是近兩年的一個(gè)新的焦點(diǎn)。數(shù)控裝備的網(wǎng)絡(luò)化將極大地滿足生產(chǎn)線、制造系統(tǒng)、制造企業(yè)對(duì)信息集成的需求，也是實(shí)現(xiàn)新的制造模式如敏捷制造、虛擬企業(yè)、全球制造的基礎(chǔ)單元。國(guó)內(nèi)外一些著名數(shù)控機(jī)床和數(shù)控系統(tǒng)制造公司都在

第二部分：機(jī)床的維修數(shù)控機(jī)床是將電子技術(shù)、測(cè)量技術(shù)、自動(dòng)化技術(shù)、電子半導(dǎo)體技術(shù)、計(jì)算機(jī)技術(shù)及電機(jī)技術(shù)等集與一體的自動(dòng)化設(shè)備，具有高精度、高效率和高柔性的特點(diǎn)。數(shù)控機(jī)床是一種過(guò)程控制設(shè)備，要求他在實(shí)時(shí)控制的每一時(shí)刻都準(zhǔn)確無(wú)誤地工作，任何部分的故障與失效，都會(huì)使機(jī)床停機(jī)，從而造成生產(chǎn)停頓，嚴(yán)重地影響和制約生產(chǎn)效率的提高。在很多行業(yè)中數(shù)控機(jī)床設(shè)備處于關(guān)鍵的工作崗位，若在其出現(xiàn)故障后不及時(shí)維修及排除故障，就會(huì)造成較大的經(jīng)濟(jì)損失。因此，對(duì)于數(shù)控系統(tǒng)這樣原理復(fù)雜、結(jié)構(gòu)精密的裝置進(jìn)行維修很有必要。加強(qiáng)數(shù)控機(jī)床的故障診斷與維修的力量，可以提高數(shù)控機(jī)床的可靠性，有利于數(shù)控機(jī)床的推廣和使用。數(shù)控機(jī)床是機(jī)、電、液、氣相結(jié)合的復(fù)雜設(shè)備，盡管故障原因各不相同，但在故障發(fā)生后，大體的思路步驟是相同的。發(fā)生故障后，下面以數(shù)控車床主軸啟動(dòng)后立即停止為例說(shuō)明數(shù)控機(jī)床故障診斷的一般過(guò)程。一、進(jìn)行故障現(xiàn)場(chǎng)調(diào)查。調(diào)查的內(nèi)容包括1、故障的種類2、故障的頻繁程度3、外界狀況4、有關(guān)操作情況5、機(jī)床情況6、運(yùn)轉(zhuǎn)情況7、機(jī)床和系統(tǒng)之間接線情況8、CNC裝置的外觀檢查。經(jīng)過(guò)調(diào)查，該類故障屬于主軸類故障，只出現(xiàn)過(guò)一次，外界一切正常，操作人員反映一開(kāi)機(jī)就出現(xiàn)這種情況。二、進(jìn)行故障信息整理、分析。對(duì)于一些簡(jiǎn)單的故障，原因不是很多時(shí)，可采用形式邏輯推理的方法，分析、確定和排除故障。經(jīng)過(guò)故障現(xiàn)場(chǎng)調(diào)查我們懷疑有以下幾種原因①系統(tǒng)輸出的脈沖時(shí)間不夠②變頻器處于點(diǎn)動(dòng)狀態(tài)③主軸線路的控制元器件損壞④主軸電機(jī)短路，造成熱繼電器保護(hù)⑤主軸控制回路沒(méi)有帶自鎖電路，而把參數(shù)設(shè)置為脈沖信號(hào)輸出，使主軸不能正常運(yùn)轉(zhuǎn)。找出可能出現(xiàn)的原因，就逐項(xiàng)排除。三、進(jìn)行故障診斷與排除。故障診斷一般遵循以下幾個(gè)原則：1、先外部后內(nèi)部?，F(xiàn)代數(shù)控系統(tǒng)的可靠行越來(lái)越高，數(shù)控系統(tǒng)本身的故障率越來(lái)越低，而大部分故障的發(fā)生都是非系統(tǒng)本身原因引起的。由于數(shù)控機(jī)床是集機(jī)械、液壓、電氣為一體的機(jī)床，其故障的發(fā)生也會(huì)由這三種綜合反映出來(lái)，維修人員應(yīng)該先由外向內(nèi)逐一進(jìn)行排查，盡量避免隨意的啟封、拆卸，否則會(huì)擴(kuò)大故障，使機(jī)床喪失精度、降低性能，系統(tǒng)外部的故障逐一是由于檢測(cè)開(kāi)個(gè)、液壓元件、氣動(dòng)元件、電氣執(zhí)行元件、機(jī)械裝置等出現(xiàn)問(wèn)題而引起的。2、先機(jī)械后電氣。一般來(lái)說(shuō)，機(jī)械故障較易發(fā)覺(jué)，而數(shù)控系統(tǒng)及電氣故障的診斷難度較大，在故障檢修之前首先注意排除機(jī)械的故障3、先靜態(tài)后動(dòng)態(tài)。先在機(jī)床斷電斷電靜止?fàn)顟B(tài)，通過(guò)了解、觀察、測(cè)試、分析，確認(rèn)通電后不會(huì)造成故障擴(kuò)大，發(fā)生事故后，方可給機(jī)床通電，在運(yùn)行狀態(tài)下，進(jìn)行動(dòng)態(tài)的觀察、檢驗(yàn)和測(cè)試，查找故障。而對(duì)通電后發(fā)生破壞性故障的，必須先排除危險(xiǎn)后，方可通電。4、先簡(jiǎn)單后復(fù)雜。當(dāng)出現(xiàn)多種故障互相交織，一時(shí)無(wú)從下手時(shí)，應(yīng)先解決容易的問(wèn)題，后解決難度較大的問(wèn)題，往往簡(jiǎn)單問(wèn)題解決后，難度大的問(wèn)題也可能變的容易。 數(shù)控機(jī)床在故障檢測(cè)過(guò)程中，應(yīng)充分利用數(shù)控系統(tǒng)的自診斷功能來(lái)進(jìn)行判斷，同時(shí)還要靈活運(yùn)用故障檢查的一些常用方法。常見(jiàn)的故障檢查方法有：1.常規(guī)檢查法常規(guī)檢查法主要是利用人的手、眼、耳、鼻等器官對(duì)故障發(fā)生時(shí)的各種光、聲、味等異?，F(xiàn)象的觀察以及認(rèn)真察看系統(tǒng)的每一處，遵循“先外后內(nèi)”的原則，診斷故障采用望、聽(tīng)、嗅、問(wèn)、模等方法，由外向內(nèi)逐一檢查，往往可將故障范圍縮小到一個(gè)模塊或一塊印刷線路板。這要求維修人員具有豐富的實(shí)際經(jīng)驗(yàn)，要有多學(xué)科的較寬的知識(shí)和綜合判斷的能力。2.自診斷功能法現(xiàn)代的數(shù)控系統(tǒng)雖然尚未達(dá)到智能化很高的程度.但已經(jīng)具備了較強(qiáng)的自診斷功能。能隨時(shí)監(jiān)視數(shù)控系統(tǒng)的硬件和軟件的工作狀況。一旦發(fā)現(xiàn)異常，立即在CRT上顯示報(bào)警信息或用發(fā)光二極管指示出故障的大致起因。利用自診斷功能，也能顯示出系統(tǒng)與主機(jī)之間接口信號(hào)的狀態(tài)，從而判斷出故障發(fā)生在機(jī)械部分還是數(shù)控系統(tǒng)部分，并指示出故障的大致部位。這個(gè)方法是當(dāng)前維修工作最有效的一種方法。3.功能程序測(cè)試法所謂功能程序測(cè)試法就是將數(shù)控系統(tǒng)的常用功能和特殊功能，如直線定位、圓弧插補(bǔ)、螺旋切削、固定循環(huán)、用戶宏程序等用手工編程或自動(dòng)編程方法，編制成一個(gè)功能程序測(cè)試程序，送入數(shù)控系統(tǒng)中，然后啟動(dòng)數(shù)控系統(tǒng)使之運(yùn)行，借以檢查機(jī)床執(zhí)行這些功能的淮確性和可靠性，進(jìn)而判斷出故障發(fā)生的可能起因。本方法對(duì)于長(zhǎng)期閑置的數(shù)控機(jī)床第一次開(kāi)機(jī)時(shí)的檢查以及機(jī)床加工造成廢品但又無(wú)報(bào)警的情況下，一時(shí)難以確定是編程錯(cuò)誤或是操作錯(cuò)誤，還是機(jī)床故障的原因是一個(gè)較好的判斷方法。4.備件替換法備件替換法是一種簡(jiǎn)單易行的方法，也是現(xiàn)場(chǎng)判斷時(shí)最常用的方法之一。所謂備件替換法就是在分析故障大致起因的情況下，維修人員可以利用備用的印刷線路板、模板，集成電路芯片或元器件替換有疑點(diǎn)的部分，從而把故障范圍縮小到印刷線路板或芯片一級(jí)。它實(shí)際上也是在驗(yàn)證分析的正確性。但在備用板交換之前，應(yīng)仔細(xì)檢查備用板是否完好，并應(yīng)檢查備用板的狀態(tài)應(yīng)與原板狀態(tài)完全一致。這包括檢查用板上的選擇開(kāi)關(guān)，短路棒的設(shè)定位置以及電位器的位置?？傊欢ㄒ獓?yán)格地按照有關(guān)系統(tǒng)的操作、維修說(shuō)明書的要求進(jìn)行操作。在確定對(duì)某部分要進(jìn)行替換前，應(yīng)認(rèn)真檢查與其連接的有關(guān)線路和其他相關(guān)的電器，確認(rèn)無(wú)故障后才能將新的替換上去，防止外部故障引起替換上去的部件損壞。5.轉(zhuǎn)移法所謂轉(zhuǎn)移法就是將數(shù)控系統(tǒng)中具有相同功能的兩塊印刷線路板、模板、集成電路芯片或元器件互相交換，觀察故障現(xiàn)象是否隨之轉(zhuǎn)移。借此，可迅速確定系統(tǒng)的故障部位。這個(gè)方法實(shí)際上就是備件替換法的一種。因此，有關(guān)注意事項(xiàng)同備件替換法所述。6.參數(shù)檢查法眾所周知，數(shù)控參數(shù)能直接影響數(shù)控機(jī)床的性能。參數(shù)通常是存放在磁泡存儲(chǔ)器或存放在需由電池保持的CMOSRAM中，一旦電池不足或由于外界的干擾等因素，會(huì)使個(gè)別參數(shù)丟失或變化，發(fā)生混亂，使機(jī)床無(wú)法正常工作。此時(shí)，通過(guò)校對(duì)、修正參數(shù)，就能將故障排除。當(dāng)機(jī)床長(zhǎng)期閑置重新工作時(shí)無(wú)緣無(wú)故地出現(xiàn)不正?，F(xiàn)象或有故障而無(wú)報(bào)警時(shí)，就應(yīng)根據(jù)故障特征，檢查和校對(duì)有關(guān)參數(shù)。經(jīng)過(guò)長(zhǎng)期運(yùn)行的數(shù)控機(jī)床，由于其機(jī)械傳動(dòng)部件磨損，電氣元件性能變化等原因，也需對(duì)其有關(guān)參數(shù)進(jìn)行調(diào)整。有些機(jī)床的故障往往就是由于未及時(shí)修改某些不適應(yīng)的參數(shù)所致。當(dāng)然這些故障都是屬于軟故障的范疇。7.測(cè)量比較法數(shù)控系統(tǒng)生產(chǎn)廠在設(shè)計(jì)印刷線路板時(shí)，為了調(diào)整、維修的便利，在印刷線路板上設(shè)計(jì)了多個(gè)檢測(cè)端子。用戶也可利用這些端子比較測(cè)量正常的印刷線路板和有故障的印刷線路板之間的差異?？梢詸z測(cè)這些測(cè)量端子的電壓和波形，分析故障的起因和故障的所在位置。甚至，有時(shí)還可對(duì)正常的印刷線路板人為地制造“故障”，如斷開(kāi)連線或短路、拔去組件等，以判斷真實(shí)故障的起因。為此，維修人員應(yīng)在平時(shí)積累印刷線路板上關(guān)鍵部位或易出故障部位在正常時(shí)的正確波形和電壓值。因?yàn)閿?shù)控系統(tǒng)生產(chǎn)廠往往不提供有關(guān)這方面的資料。8.敲擊法當(dāng)數(shù)控系統(tǒng)出現(xiàn)的故障表現(xiàn)為若有若無(wú)時(shí)，往往可用敲擊法檢查出故障的部位所在。這是由于數(shù)控系統(tǒng)是由多塊印刷線路板組成，每塊板上有許多焊點(diǎn)，板間或模塊間又通過(guò)插接件及電線相連。因此，任何虛焊或接觸不良，都可能引起故障。當(dāng)用絕緣物輕輕敲打有虛焊及接觸不良的疑點(diǎn)處，故障肯定會(huì)重復(fù)再現(xiàn)。9.局部升溫法數(shù)控系統(tǒng)經(jīng)過(guò)長(zhǎng)期運(yùn)行后元器件均要老化，性能會(huì)變壞。當(dāng)它們尚未完全損壞時(shí)，出現(xiàn)的故障會(huì)變得時(shí)有時(shí)無(wú)。這時(shí)可用熱吹風(fēng)機(jī)或電烙鐵等來(lái)局部升溫被懷疑的元器件，加速其老化，以便徹底暴露故障部件。當(dāng)然，采用此法時(shí)，一定要注意元器件的溫度參數(shù)，不要將原來(lái)是好的器件烤壞。10.原理分析法根據(jù)數(shù)控系統(tǒng)的組成原理，可從邏輯上分析各點(diǎn)的邏輯電平和特征參數(shù)（如電壓值或波形），然后用萬(wàn)用表、邏輯筆、示波器或邏輯分析僅進(jìn)行測(cè)量、分析和比較，從而對(duì)故障定位。運(yùn)用這種方法，要求維修人員必須對(duì)整個(gè)系統(tǒng)或每個(gè)電路的原理有清楚的、較深的了解。根據(jù)上面的原則和方法，我們逐項(xiàng)對(duì)可能出現(xiàn)的原因進(jìn)行查探并排除。第一個(gè)可能故障為系統(tǒng)輸出的脈沖時(shí)間不夠，我們調(diào)整系統(tǒng)的M代碼輸出時(shí)間后啟動(dòng)主軸，發(fā)現(xiàn)問(wèn)題仍然存在，接著查找下一可能原因，變頻器可能處于點(diǎn)動(dòng)狀態(tài)，參閱變頻器的使用說(shuō)明書，設(shè)置好參數(shù)后啟動(dòng)主軸，問(wèn)題仍然存在我們懷疑是主軸電機(jī)短路，造成熱繼電器保護(hù)。于是查找短路原因，使熱繼電器復(fù)位后啟動(dòng)主軸，發(fā)現(xiàn)主軸正常運(yùn)轉(zhuǎn)，問(wèn)題解決。要做一個(gè)經(jīng)驗(yàn)總結(jié)和記錄。故障排除以后，維修工作還不能算完成，尚需從技術(shù)與管理兩方面分析故障產(chǎn)生的深層原因，采取適當(dāng)措施避免故障再次發(fā)生。必要時(shí)可根據(jù)現(xiàn)場(chǎng)條件使用成熟技術(shù)對(duì)設(shè)備進(jìn)行改造與改進(jìn)。最后，對(duì)此次維修的故障現(xiàn)象、原因分析、解決過(guò)程、更換元件、遺留問(wèn)題等要做好記錄。TheDIL/NetPCsDNP/1110–UsingtheEmbeddedLinuxWebServerforEmbeddedSystemsAfterthe“everybody-in-the-Internet-wave”nowobviouslyfollowsthe“everything-in-the-Internet-wave”.Theostcoffee,vendingandwashingachinesarestillnotavailableabouttheworldwidenet.HowevertheebeddedInternetintegrationforreteaintenanceanddiagnosticaswellastheso-calledM2Mcounicationisgrowingwithaconsiderablespeedrate.JustthereoteaintenanceanddiagnosticofcoponentsandsystesbyebbrowsersviatheInternet,oralocalItranethasaveryhighweightforanydevelopentprojects.Innuerousdevelopentdepartentspeopleworkoncoletelyebbasedconfigurationsndservicesforebeddedsystes.ThereainingdaysoftheclassicuserinteraceadebyasallLC-displaywithfrontpanelandafewfunctionkeysareover.ThroughfutureevolutionsinthefieldoftheobileInternet,Bluetooth-baseds(PersonalAreaNetworks)andtherapidlygrowingM2Mcounication(M2M=Machine-to-Machine)afurtherinnovatingadvanceistobeexpected.Thecentralfunctionunittogetaccessonanebeddedsysteviaebbrowseristheebserver.SuchebserversbringthedesiredHTMLpages(HTML=HyperTextMarkupLanguage)andpicturesovertheworldwideInternetoralocalnetworktotheebbrowser.Thishappens-based(HyperTextTransferProtocol).ATCP/IPprotocolstack–thateansitisbasedonsophisticatedandestablishedstandards–anagestheentirecounication.ebserver(server)andbrowser(client)builTCP/IP-applications.achievedaphenoenaldistributioninthelastyeas.Meanwhileillionsofuseraroundtheworldsurf-basedintheWorldWideWeb.Todayalosteverypersonalcoputeroffersthenecessaryassistanceforthisprotocol.Thisstatusisvalidreandreforebeddedsystesalso.Thespreadsupwithafastratetoo.TheDIL/NetPCsDNP/1110–UsingtheEmbeddedLinux1.TCP/IP-basedasCommunicationPlatformisasileprotocolthatisbasedonaTCP/IPprotocolstack(picture1.A).usesTCP(TransissionControlProtocol).TCPisarelativecoplexandhigh-qualityprotocoltotransferdatabythesubordinateIPprotocol.TCPitselfalwaysguaranteesasafeguardedconnetionbetweentwocounicationpartnersbasedonanextensivethree-way-handshakeprocedure.Asaresultthedatatransferviaisalwaysprotectd.DuetotheextensiveTCPprotocolechanissoffersonlyalow-gradeperforance.Figure1:TCP/IPstackandprograingodelisbasedonasipleclient/server-concept.serverandclientcounicateviaaTCPconnection.AsdfaultTCPportvaluetheportnuber80willbeused.Theserverworkscopletelypassive.Hewaitsorarequest(order)oaclient.ThisrequestnorallyreerstothetransitionospeciicHTMLdocuents.ThisHTMLdocuentpossiblyhavetobegenerateddynaicallybyCGI.Asresultoftherequsts,theserverwillanswerwitharesponsethatusuallycontainsthedesiredHTMLdocuentsaongothers(picture1.B).Listing1.A:GET-requestTheDIL/NetPCsDNP/1110–UsingtheEmbeddedLinuxListing1.B:responseasresultoftheGET-requestfrolisting1.Arequestsnorallyconsistoseveraltextlines,whicharetransittedtotheserverbyTCP.Thelisting1.Ashowsaneaple.Thefirstlinecharacterizestherequesttype(GET),therequestedobject(/test1.ht)andtheusedversion(/1.1).Inthesecondrequestlinetheclienttellstheserver,whichkindoffilesitisabletoevaluate.Thethirdlineincludesinforationabouttheclient-software.Thefourthandlastlineoftherquestfrolisting1.AisusedtoinformtheserverabouttheIPaddressofthelient.Inaccordingtothetypeofrequestandtheusedclientsoftwaretherecouldfollowsoefurtherlines.Asanendoftherequestablanklineisexpected.Theresponsesasrequestanswerotlyconsistoftwoparts.Atfirstthereisaheaderofindividuallinesoftext.Thenfollowsacontentobject(optional).Thiscontentobjectaybeconsistsofsotextlines–incaseofaHTMLfile–orabinaryfilewhenaGIFoJPEGiageshouldbetransferred.Thefirstlineoftheheaderisespeciallyiportant.Itworksasstatusorerroressage.Ifanerroroccurs,onlytheheaderorapartoitwillbetransittedasanswer.2.FunctionalprincipleofaWebServerSiplifiedaebservercanbeiaginelikeaspecialkindofafileserver.Picture2.Ashowsanoverview.ThebserverreceivesaGET-requestfrotheebbrowser.Bythisrequest,aspecificfileisrequiredasanswer(seestep1intopicture2.A).Afterthat,the