Y90端盖的加工工艺及夹具设计
毕业设计(论文)
类 型: 毕业设计说明书 □毕业论文 题 目: Y90端盖的加工工艺及夹具设计 学生姓名: 指导教师: 专 业: 时 间:
2013.03
摘 要
本课题的主要任务是端盖设计,包括零件图、毛坯图、装配图各一张。首先我们要熟悉零件和了解其作用。然后,根据零件的性质和零件图上各端面的粗糙度确定毛坯的尺寸和械加工余量。最后拟定端盖的工艺路线图,制定该工件的夹紧方案,画出夹具装配图。
关键词:端盖 夹具
Abstract
The abstract I this assignment design content is the end cover design, including detail drawing, semifinished materials chart, assembly drawing and jig detail drawing each,First we must be familiar with the components and understand its function.Th en, according to on components nature and detail drawing various end surfaces roughness determination semifinished materials size and weapon processing remainder.Finally draws up the end cover the craft road map, formulates this work piece clamp plan, draws the jig assembly drawing.
Key words: cover fixtures
目录
摘 要 ................................................................................. 1 ABSTRACT ....................................................................... 2 1. 端盖零件的用途、技术要求及工艺分析 .......................... 5
1.11.21.31.4
端盖的用途 ........................................................................... 5 端盖的技术要求(图见附图1) :............................................. 5 审查端盖的工艺性 . ................................................................ 6 确定端盖的生产类型 ............................................................. 6
2. 确定毛坯、绘制毛坯简图 ............................................... 7
2.1选择毛坯 . .............................................................................. 7
+0.025
φ2502.1.1 内圆加工余量的确定 ........................................... 7
2.1.2左端凸起端面的加工余量的确定 ..................................... 7
2.1.3右端面加工余量的确定 ................................................... 7 2.1.4左端环面加工余量的确定 . ............................................... 8 2.1.5左端凸起外圆面加工余量的确定 ..................................... 8 2.1.6其余尺寸的加工 . ............................................................. 8 2.2绘制毛坯图(图2-1)........................................................... 9
3. 拟定端盖工艺路线 ......................................................... 10
3.1定位基准的选择 ...................................................................10
3.1.1精基准的选择 ................................................................10 3.1.2精基准的选择 ................................................................10 3.2 表面加工方法的确定 ...........................................................10 3.3加工工序的安排 ...................................................................12 3.3.1主要加工工序 ................................................................12 3.3.2辅助加工工序 ................................................................12 3.4确定工艺路线 . ......................................................................12
4. 机床设备及工艺设备的选用 . .......................................... 14
4.1机床设备的选用 ...................................................................14 4.2工艺装备的选用 ...................................................................14
5. 切削用量及工时定额的计算 . .......................................... 15
5.1工序1:粗镗、半精镗
Φ
25内圆 ..........................................15
5.1.1粗镗孔至φ24.82, . ......................................................15 5.1.2半精镗孔至φ25 ............................................................15 5.2工序2:粗车左端凸起端面...................................................16 5.3工序3:粗铣、半精铣右端面 ...............................................17 5.3.1粗铣至61.5-60.5mm . ......................................................17 5.3.2半精铣至60.5-60mm . ......................................................17 5.3.3倒角C1 ..........................................................................18 5.3.4钻4×φ9孔 ..................................................................18 5.3.5锪钻φ14孔 ..................................................................19 5.4工序4:粗铣左端环面及越程槽............................................20 5.4.1粗铣左端环面 ................................................................20 5.4.2粗铣越程槽 . ...................................................................20 5.5工序5:粗车,半精车凸台外圆............................................21 5.5.1粗车凸台 .......................................................................21 5.5.2半精车凸台 . ...................................................................22 5.6工序6:钻Φ14孔、及锪Φ10孔 ...........................................22 5.6.1钻φ4孔 ........................................................................22 5.6.2锪φ10孔 ......................................................................24
6. 夹具设计 ....................................................................... 25
6.1提出问题 . .............................................................................25 6.2设计思想 . .............................................................................25 6.3夹具设计 . .............................................................................25 6.3.1定位分析 .......................................................................25 6.3.2切削力及夹紧力的计算 ..................................................26 6.3.3夹具操作说明 ................................................................28 6.3.4确定导向装置 ................................................................28 6.3.5画出夹具装配图 . ............................................................28
7.设计体会 . ..................................................................... 29 8.参考文献 . ..................................................................... 30 附件:中英文互译 . ............................................................ 33
1. 端盖零件的用途、技术要求及工艺分析
1.1端盖的用途
端盖应用广泛,是非常重要的机械零件之一。端盖的一般作用是:(a )轴承外圈的轴向定位;(b )防尘和密封,除本身可以防尘和密封外,也常和密封件配合以达到密封的作用;(c )位于车床电动机和主轴箱之间的端盖,主要起传递扭矩和缓冲吸震的作用,使主轴箱的转动平稳。
因此该零件应具有足够的强度、钢度耐磨性和韧性,以适应端盖的工作条件。该零件的主要工作表面为左右端面以及左端面的外圆表面,在设计工艺规程时必须重点考虑。端盖加工工艺的可行性与合理性直接影响零件的质量、生产成本、使用性能和寿命等。
1.2端盖的技术要求(图见附图1) : 该端盖的各项技术要求如表1-1 表1-1
1.3审查端盖的工艺性
该端盖结构简单,形状普通,属一般的盘盖类零件。主要加工表面有端盖左、右端面,方形端面(见附图端盖技术参数图) ,要求其端面跳动度相对中心轴线满足0.03mm ,其次就是φ25孔及φ10孔,φ25孔的加工端面为平面,可以防止加工过程中钻头钻偏,以保证孔的加工精度;另外φ10孔的加工表面虽然在圆周上,但通过专用的夹具和钻套能够保证其加工工艺要求。该零件除主要加工表面外,其余的表面加工精度均较低,不需要高精度机床加工,通过铣削、钻床的粗加工就可以达到加工要求。由此可见,该零件的加工工艺性较好 1.4确定端盖的生产类型
依设计题目知:Q=5000件/年,m=1件/年,结合生产实际,备品率a%和废品率b%分别取3%和0.5%。代入公式得:
N=5000台/年×件/台×(1+3%)×(1+0.5%)=5175.75
端盖重量为0.5kg ,由表1-3知,端盖属轻型零件;由表1-4知,该端盖的生产类型为大批生产。(表查自参考文献8 P246页)
2. 确定毛坯、绘制毛坯简图
2.1选择毛坯
端盖在工作过程中不承受冲击载荷,也没有各种应力,毛坯选用铸件即可满足工作要求。该端盖的轮廓尺寸不大,形状亦不是很复杂,故采用砂型铸造。
+0.025φ2502.1.1 内圆加工余量的确定
2.1.2左端凸起端面的加工余量的确定
2.1.3右端面加工余量的确定
2.1.4左端环面加工余量的确定
2.1.5左端凸起外圆面加工余量的确定
2.1.6其余尺寸的加工
4×φ9孔可以直接钻出,再利用锪钻加工φ14孔,φ4孔也可直接钻出,再用锪钻加工φ10孔。
2.2绘制毛坯图(图2-1)
图2-1毛坯图
3. 拟定端盖工艺路线
3.1定位基准的选择 3.1.1精基准的选择
根据该端盖零件的技术要求,选择端盖右端面和φ25孔作为精基准,零件上的很多表面都可以采用它们作基准进行加工,即遵循“基准统一”原则。φ25孔的轴线是设计基准,选用其作竟基准定位端盖两端面,实现了设计基准和工艺基准的重合,保证了被加工表面的端面跳动度要求。选用端盖右端面作为精基准同样是遵循了“基准重合”原则,因为该端盖在轴向方向上的尺寸多以该端面作设计基准。
3.1.2精基准的选择
考虑要保证零件的加工精度和装夹准确方便,依据“基准重合”原则和“基准统一”原则,以精加工后的 25孔中心轴线为主要的定位精基准。 3.2 表面加工方法的确定
根据端盖零件图上的各加工表面的尺寸精度和表面粗糙度,确定加工件各表面的加工方法,如表3-2 表3-2
(表查自参考文献7 P65)
3.3加工工序的安排 3.3.1主要加工工序
(1)遵循“先基准后其他”原则,首先加工基准 25内圆中心轴线。 (2)遵循“先粗后精”原则,先安排粗加工工序,后安排精加工工序。 (3)遵循“先主后次”原则,先加工端盖右端面,后加工端盖左端环面。 (4)遵循“先面后孔”原则,先加工端盖端面,再加工端盖的各孔。 3.3.2辅助加工工序
由于加工零件为端盖,材料为HT150,主要面进行热处理工序,当加工完主要平面后,可安排一次中检。加工完后,需去除毛刺,在安排清洗和终检工序。 3.4确定工艺路线
在综合考虑上述工序顺序安排原则的基础上,列出端盖的工艺路线。 表3-4工艺路线及设备、工装的选用
表3-4
4. 机床设备及工艺设备的选用
4.1机床设备的选用
考虑到本文的端盖零件精度要求不是很高,本文采用的机床主要有:卧式镗床、车床CA6140、铣床X51、钻床Z525等。 4.2工艺装备的选用
根据以上机床设备进行加工时,要选用的工艺装备有车刀、钻头、锪钻、百分表、游标卡尺等。
5. 切削用量及工时定额的计算
5.1工序1:粗镗、半精镗φ25内圆 5.1.1粗镗孔至φ24.82,
2Z=0.82mm则 Z=0.41mm
t =
l 1+l 2+l 20+2+0
==82.5s n w f 80⨯0.2
查参考,确定镗床的切削速度为v=40m/min,f=0.3mm/min由于卧式镗床主轴转数为无级调数,故以上转数可以作为加工时使用的转数。
l =58mm ,l =2mm ,l =4mm
则:
t m =
l 1+l 2+l
×i 58+2+4⨯2=50s n w f =509⨯0. 3
t α=0.15s t m =7.5s
(t b +t x ) 1=6%⨯(t m +t α) =3.45s
5.1.2半精镗孔至φ25
2Z=0.18mm,Z=0.09mm
f=0.2mm/r v=40m/min
n w =
1000v 1000⨯40i =⨯1=509r /min πd 25π
计算切削工时
l =58mm ,l 1=2mm ,l 2=4mm
则:
t m =
l 1+l 2+l 58+2+4
×i =⨯1=38s
509⨯0. 2n w f
t a =0.15s t m =5.7s
(t b +t x ) 1=6%(t m +t α) =2.62s
5.2工序2:粗车左端凸起端面
工件材料:HT150,铸造。
加工要求:粗车φ75端面及表面粗糙度值R a 为12.5。 机床:卧式车床CA6140。 刀具:刀片材料为YG6
确定端面最大加工余量:已知毛坯长度方向单边余量为加工等级取IT12级,取,
v=20m/min d=75mm
a p =0.7mm
f =0. 4mm
则,
n =
1000v πd =1000⨯2075π
=85r /min 卧式车床CA6140为无级调整,可取,
v =85r /min 。
计算切削工时l =37. 5mm ,则:
t m =
l nf =37.5
84⨯0.4
=66s 0.7mm ,
t α=0.15t m =9.9s
(t b +t α) 1=6%⨯(t m +t α) =4.55s
5.3工序3:粗铣、半精铣右端面
铣床:X51
铣刀:选用立铣刀d=16mm、齿数Z=5 5.3.1粗铣至61.5-60.5mm
参照机械零件加工工艺手册,确定切削速度:
v=19m/min f=0.2mm/r,
n =
1000v 1000⨯19
==378r /min πd 16π
采用X51立式铣床,根据机床使用说明书,取
n w =380r /min
故实际切削速度为:
V =
πd w n w
1000
=
16π⨯380
=19.1r /min
1000
当n w =380r /min 时,工作台的每分钟进给量f m 应为
f m =f z zn w =0.2⨯5⨯380=380mm /min
L=18mm
t m =
L 18=⨯5=23.7s f m 380
t α=0.15s t m =3.56s
t m =7.16s
5.3.2半精铣至60.5-60mm
参照机械零件加工工艺手册,确定切削速度:
v=19m/min f=0.1mm/r
n =
1000v 1000⨯19
==378r /min πd 16π
采用X51立式铣床,根据机床使用说明书,取
n w =380r /min
故实际切削速度为:
V =
πd w n w
1000
=
16π⨯380
=19.1r /min
1000
当n w =380r /min 时,工作台的每分钟进给量f m 应为
f m =f z zn w =0.1⨯5⨯380=190mm /min
L=18mm
t m =
L 18=⨯5=47.4s f m 190
t α=0.15s t m =7.16s
(t b +t α) 1=6%⨯(t m +t α) =3.27s
5.3.3倒角C1
采用锪钻。 5.3.4钻4×φ9孔
参照机械零件加工工艺手册确定
f=0.1mm/r V=16mm/min
所以,
n =
1000v
=1273r /min 4π
根据机床说明书,取;
n w =1225r /min
所以实际切削速度为:
V =
πd w n w
1000
=
14π⨯1225
=15.4r /min
1000
切削工时,
l 1=2.44mm ,l 2=0mm ,l =15mm
则:
t m =
l 1+l 2+l 2. 44+0+15
×i ==8. 5s n w f 1225⨯0. 1
t α=0.15s t m =12.38s
(t b +t α) 1=6%⨯(t m +t α) =0.59s
5.3.5锪钻φ14孔
参照机械零件加工工艺手册,确定:
f=0.1mm/r v=4m/min
所以,n =
根据机床说明书,取;
1000v
=91r /min 14π
n w =100r /min
则实际切削削工时
l =9mm ,l 1=1mm ,l 2=0mm
则:
t =
l 1+l 2+l 9+1
==60s n w f 100⨯0.1
t α=0.15s t m =9s
(t b +t α) 1=6%⨯(t m +t α) =4.14s
5.4工序4:粗铣左端环面及越程槽
5.4.1粗铣左端环面
粗铣左端环面至51.7-51mm
参照机械零件加工工艺手册,确定:
a p =0.7mm
f=2mm/r
v=28.8m/min
d=115mm
取,
n=80
机床可直接选取
n w =80r /min
则计算工时,
l =15mm ,l 1=2mm ,l 2=0mm
则:
t =l 1+l 2+l 20+2+0==82.5s n w f 80⨯0.2
t α=0.15s
(t b +t α) 1=6%⨯(t m +t α) =17.33s
5.4.2粗铣越程槽
参照机械零件加工工艺手册,确定:
a p =1.4mm
f=0.4mm/r
V=25m/min
d=75mm
所以,
n =1000v =106r /min 75π
根据机床说明书,取:
n w =100r /min
则,
V =πd w n w
1000=75π⨯100=23.55r /min 1000
l =1.4mm ,l 1=2mm ,l 2=4mm
则:
t =l 1+l 2+l 1.4+2+4==11.1s n w f 100⨯0.4
t α=0.15s t m =1.67s
(t b +t α) 1=6%⨯(t m +t α) =0.77s
5.5工序5:粗车,半精车凸台外圆
5.5.1粗车凸台
粗车凸台外圆至77mm
参照机械零件加工工艺手册,确定:
f=0.3mm/r
v=24 d=75mm
n s =1000v 1000⨯24==102r /min πd w 750π
计算切削工时
l =4mm ,l 1=3mm ,l 2=0mm
则:
t =l 1+l 2+l 3+0+4⨯i =⨯3=41.2s n w f 102⨯0.3
t α=0.15s t m =6.18s
(t b +t α) 1=6%⨯(t m +t α) =2.84s
5.5.2半精车凸台
半精车凸台外圆至76.0-75mm
参照机械零件加工工艺手册,确定:
f=0.25mm/r
v=25m/min d=75mm
n s =1000v 1000⨯25==106r /min πd w 75π
计算切削工时
l =4mm ,l 1=3mm ,l 2=0mm
则:
t =l 1+l 2+l 3+0+4⨯i =⨯3=31.7s n w f 106⨯0.25
t α=0.15s t m =4.76s
(t b +t α) 1=6%⨯(t m +t α) =2.2s
5.6工序6:钻φ14孔、及锪φ10孔
5.6.1钻φ4孔
参照机械零件加工工艺手册,确定:
f=0.2mm/r
v=12.25m/min
n s =1000v 1000⨯12.25 ==398r /min πd w 4π
n w =400r/min所以实际切削速度
V =πd w n w
1000=4π⨯400=5.02r /min 1000
切削工时计算:
l =15mm ,l 1=2.5mm ,l 2=0mm
t =l 1+l 2+l 15+0
n ⨯i =+2.5=13.13s
w f 400⨯0.2
t α=0.15s t m =1.97s
(t b +t α) 1=6%⨯(t m +t α) =0.9s
5.6.2锪φ10孔
根据参考文献9,锪孔时进给量及切削速度约为钻孔时的1/2-1/3,故 d=10mm
f =11f 钻=⨯0.6=0.1mm/r 33
v =12m /min
n s =1000v 1000⨯12==255r /min πd w 10π
按机床选取:
n w =275r /min
所以实际切削速度为:
V =πd w n w
1000=10π⨯275=8.6r /min 1000
切削工时计算:
l 1=2.5mm ,l 2=0mm ,l =12mm
t =l 1+l 2+l 12+0+2.5⨯i ==31.6min n w f 275⨯0.1
t α=0.15s t m =4.74s
(t b +t α) 1=6%⨯(t m +t α) =2.18s
6. 夹具设计
夹具是一种能够使工件按一定的技术要求准确定位和牢固夹紧的工艺装备,它广泛地运用于机械加工,检测和装配等整个工艺过程中。在现代化的机械和仪器的制造业中,提高加工精度和生产率,降低制造成本,一直都是生产厂家所追求的目标。正确地设计并合理的使用夹具,是保证加工质量和提高生产率,从而降低生产成本的重要技术环节之一。同时也扩大各种机床使用范围必不可少重要手段。
6.1提出问题
(1)怎样限制零件的自由度;一个面限制3个自由度,长圆柱销限制2个自由度,定位销限制1个自由度。
(2)怎样夹紧;设计夹具由螺旋夹紧工件。
(3)设计的夹具怎样排削;此次加工利用麻花钻和铰刀,排削通过钻模板与工件之间的间隙排削。
(4)怎样使夹具使用合理,便于装卸。
6.2设计思想
设计必须保证零件的加工精度,保证夹具的操作方便,夹紧可靠,使用安全,有合理的装卸空间,还要注意机构密封和防尘作用,使设计的夹具完全符合要求。
本夹具主要用来对φ14孔进行加工,这个孔尺寸精度要求为IT9,表面粗糙度Ra3.2,钻、粗铰、精铰以可满足其精度。所以设计时要在满足精度的前提下提高劳动生产效率,降低劳动强度。
6.3夹具设计
6.3.1定位分析
(1)定位基准的选择
据《夹具手册》知定位基准应尽可能与工序基准重合,在同一工件的各道工序中,应尽量采用同一定位基准进行加工。故加工φ14孔
时,采用端盖右端面和φ25孔内圆柱面作为定位基准。
(2)定位误差的分析
定位元件尺寸及公差的确定。夹具的主要定位元件为一个面与两个孔定位,因为该定位元件的定位基准为孔的轴线,所以基准重合△b=0,由于存在间隙,定位基准会发生相对位置的变化即存在基准位移误差。
△j=(T D +T d +△S )/2
T D =0.050mm
T d =0.011mm
△S=0.010mm
△j=0.0355mm
6.3.2切削力及夹紧力的计算
刀具:φ13. 8的麻花钻,φ14铰刀。
①钻孔切削力:查《机床夹具设计手册》P 70表3-6,
公式:
P =70.6D 0.9S HB 0.6
式中 P ───钻削力
t ───钻削深度,12mm
S ───每转进给量, 0.1mm
D ───麻花钻直径, Φ13.8mm
HB ───布氏硬度,140HBS
所以
P =70. 6D 0. 9S HB 0. 6
=762(N )
钻孔的扭矩:
M =0. 014D 2S 0. 94HB 0. 6
式中 S ───每转进给量, 0.1mm
D ───麻花钻直径, Φ13.8mm
得钻削力计算
HB ───布氏硬度,140HBS
M =0.014D 2S 0.94HB 0.6
=8200(N·M)
②铰孔时的切削力:查《机床夹具设计手册》P 70表3-6,得钻削力计算公式:
P =9.1t 12S 0.4HB 0.6
式中 P ───切削力
t ───钻削深度, 12mm
S ───每转进给量, 0.4mm
D ───铰孔钻直径, Φ14mm
HB ───布氏硬度,140HBS
所以
P =9. 1t 12S 0. 4H B 0 .
= 73(N )
铰孔的扭矩:
P =0. 031t 0. 75S 0. 6HB 0. 4D
式中 t ───钻削深度, 12mm
S ───每转进给量, 0.4mm
D ───铰刀直径, Φ14mm
HB ───布氏硬度,140HBS
P =0.031t 0.75S 0.6HB 0.4D
=600(N ·M )
③钻孔夹紧力:查《机床夹具设计手册》P70表3-6,
个面和两个孔定位时所需夹紧力计算公式:
W =2Q L
d (α+φ) +z t g 3f d 1
式中 φ───螺纹摩擦角
查得工件以一
d 1───平头螺杆端的直径
───工件与夹紧元件之间的摩擦系数,0.16 f
d z ───螺杆直径
α ───螺纹升角
Q ───手柄作用力
L ───手柄长度
则所需夹紧力
W =2Q L
2d z t g (α+φ) +f d 13
=766(N )
根据手册查得该夹紧力满足要求,故此夹具可以安全工作。
6.3.3夹具操作说明
此次设计的夹具夹紧原理为:通过φ25孔和侧面为定位基准,在圆柱销、平面和定位销实现完全定位,以钻模板引导刀具进行加工。采用手动螺旋快速夹紧机构夹紧工件。
定位元件:
定位元件是用以确定正确位置的元件。用工件定位基准或定位基面与夹具定位元件接触或配合来实现工件定位。该设计用可换定位销
6.3.4确定导向装置
本工序要求对被加工的孔依次进行钻、铰的加工,最终达到工序简图上规定的加工要求,故选用快换钻套作为刀具的导向元件,查9-13(参考文献1)
6.3.5画出夹具装配图
(见附图2)
7.设计体会
通过这次课程设计,我更加熟练的掌握了使用机械制图的方法,加深了对机械制造技术基础课程知识的理解。由于时间仓促,设计还有很多不足之处,如:夹具部分不够全面,效率不高等等,都是对工艺基础不熟练,对相关认识缺乏造成的。在实践过程中施老师给了我很大的帮助和鼓励,在今后的学习中我会加强理论与实践的结合,通过不断的摸索来弥补自己在机械制作方面的差距。
8.参考文献
[1].王启平主编 机床夹具设计(第二版)[M]哈尔滨工业大学出版社 2000.
[2].秦国华、张卫红主编 机床夹具的现代设计方法[M]航空工业出版社 2006.
[3].杨俊峰主编 机床及夹具[M] 清华大学出版社 2005.
[4].秦宝荣主编 机床夹具设计[M] 中国建材工业出版社 1998.
[5].崇凯主编 机械制造技术基础课程设计指南[M]化学工业出版社 2007.
[6].陈国香主编 机械制造与模具制造工艺学[M]情话大学出版社 2006.
[7].李彩霞主编 机械精度设计与检测技术[M]上海交通大学出版社 2006.
[8].韩秀琴主编 机械加工工艺学[M]东南大学出版社 2002.4
[9].韩秀琴等主编 机械加工工艺基础[M]哈尔滨工业大学出版社2005.
[10].孙丽媛 机械制造工艺及专用夹具设计指导[M]冶金工业出版社 2002.
[11].邹青主编 机械制造技术基础课程设计指导教程[M]机械工业出版社 2004.
附
图
附图1
附图
2
附图2
附件:中英文互译
Hoist Crane
Use modularization to design the complete machine design procedures replace tradition, the identical with upper crane function basic component , component and part are made from having various use, have the identical linkup key element to compose in reply a standard module interchangeable, mutuality by being unlike a module constitutes, form the crane being unlike the type and specification. Be in progress to the crane improvement, need specifically for some several modules. The module designing the new model crane, needing selecting and using diversity carries out combination again. The module changing Cheng having batches suitable produces the crane may make a stick mass-produce for a short time, high efficiency specialization of different parts of production, the enterprise childbirth organize realization also may become module administration from management of product. Reach the improvement complete machine function , reduce cost of manufacture , improve be applied or used universally degree, uses be composed of many breeds , many specification series of products of less specification numbers component and part, to satisfy the consumer need sufficiently.
The batches cranes are that usage, the job are not very strenuous in the occasion being applied or used universally. This kind of crane batches big , are widely used, think that the heddle agrees well with beneficial result considerably , require that the crane reduces external form to the full facilitating structure highly, diminish the self-respect and wheel-pressure , also, may make the entire building come down highly , build structure light , reduce cost of construction. The therefore electric bottle gourd bridge crane and the dyadic beam lifting chance have quicker development, small tonnage in major part being replaced together sort use bridge crane. The Germany Damage company several tens years of exploitation and FOAK passes, series having already formed a light
dyadic combination standard crane. Get weight for the rank working 1-63 tons, is A1-A7, pair of beams wait for the entire series to be breed composition more by I-shaped and box type Shan , suspension box shape Shan , angle-type handcart box shape Shan and box shape. The main beam and the end beam connect with as well as lifting handcart arrangement has the various pattern, may be suitable to the request being unlike a building and being unlike sling height. According to consumer need, every kind of specification crane has three kinds Shan speed and provides the speed regulation choosing arbitrarily, being able to select and use frequency conversion three kinds of pair quickly. Control way having floor door proper motion displacement, door to follow handcart displacement, door fixed, wireless remote control, driver's cage fixation , driver's cage to follow seven kinds such as handcart displacement , driver's cage proper motion displacement to choose. The cart and the handcart current supply have the cable handcart to conduct electricity, DVS system grows way. Choosing an item much like this, may arrange hundreds and thousands of kind of crane in groups, satisfy different need of consumer sufficiently by different combination. This crane another maximal merit is light, the self-respect is light, wheel-pressure is light, external form the dimension is highly small , may reduce workshop building construction cost greatly , may diminish the crane operation power and run cost at the same time also. Start to compare, weight with the general goods being 10 t , spans 22.5 ms, the pair of dyadic beam bridge cranes self-respect being applied or used universally is 24 t, above crane track face highly 1876 mms , crane width 5980 mms; Damage crane self-respect has only had 8.7 t , weight has made light of 176%, the crane has reduced 104% highly above track face for 920 mms, crane has been 2980 mms in width, external form the dimension decreases by 100%.
Crane renewal and development, depend on electric drive and the improvement controlling to a great extent. The machinery technology and the electron technology is looked at and appraised being tied in wedlock, drive and applying advanced computer art , microelectronics technology , electric power electron technology , optical cable technology , hydraulic pressure technology , blurred control technique to machinery, realize the
crane automation and intellectualized. The new la rge-scale high-effect crane generation electric control device already develops for entire electron digitization. Be composed of entire digitization equipment such as controlling a driving device, may weave the program controller , malfunction diagnose and data management system , digitize controlling given detecting mainly. Data communication , the malfunction control varying voltage frequency conversion speed regulation , radio frequency from examining supervisory control , slings for lifting loads guardi ng against mixing up swaying , laser seeks the centre of gravity craning a thing , near field induction guards against the collision technology , the scene highway , carrier wave communication and controlling , there being no the contact current supply and three-dimensional bar code technology and so on will be applied broadly. Make a crane have higher flexibility, level producing a pattern , improving the automation of single with the flexibility being suitable to much little batch batches. Priority develops the high-performance centering on microprocessor electric drive device , make a crane have good speed regulation county moving characteristic property , may carry out auto control , automation display and precis writer handling, working crane automation protection and automation detecting, remote peculiar occasion remote control waits, to adapt to the automatic production need.
Adopt laser aid to seek the centre-of-gravity position craning a thing's for instance, the device jacket has an ultrasonic sensor to lead to fetch the thing device grabbing a goods voluntarily in fetching a thing. The automation guards against slings for lifting loads swaying system can 200 m /min , acceleration make the thing craning sway amplitude cutting till several millimeters very quickly in running speed under condition. The crane may fix position by the fact that the magnetic field converter or laser reaches high-accuracy. Assemble near field induced system on the crane, mutuality between may avoid a crane crashes. Have assembled certainly diagnose PC supervisory control system on the crane , have been system's turn to be able to provide most routine defending examination content, if gear case paints the temperature , oil level , the carriage wheel axle bearing temperature, an d crane loading ,
strain shaking condition, arrester friction lining life -span and temperature situation etc.
Machinery is composed of a material on basis automating in crane single, by the fact that the computer transports various lifting carrying integrated system, controlling by the central control room, production facility is organically combined and , the childbirth system harmonizes and composition. This kind of crane automation degree high , has the information processing function, the various information may a sensor be checked coming out puts memory , arithmetic, logic treatment treating such as judging , varying into practice , issue a control command then to actuating mechanism. This kind of crane has the fairly good information entering, output interface, realizes all, accurate , reliable transmission in carrying integrated system in entire material of information. The crane passes system integration, can form the best match and combination that be unlike machine grows, adopt strong points while o vercoming one's weak points , bring the best efficacy into play. Priority develops at present have a factory to give birth to a child carrying automatic system, flexibility processes fabrication system , the commerce goods distribution collects and distributes system , the container loads and unloads doing the automation sorting wrapping up a goods and carrying system and so on carrying system , traffic and post and telecommunications branch.System the automation producing the engineering machinery USA Carter Pile company metal structures plant for instance having bought a material giving first place to the bridge crane is carried, gushing being used for steel plate handles, cutting and the automation being put in storage load and unload the availability carrying school assignment, adopt single operation than former to have improved 65%. The Japan small river Kawasaki factory uses the material that the full-automatic bridge crane is composed of to transport the working procedure or storehouse coming to carry flexibility processing upper line clamp and work piece system , being that the machine tool conveys a blank or the good with treating part delivers to time as soon as. That the system these crane moving in space is carried has replace the automatic guide be put into use generally in the past to carry vehicle,
makes workshop's floor area be fully utilized.
起重机
用模块化设计代替传统的整机设计方法,将起重机上功能基本相同的构件、部件和零件制成有多种用途,有相同联接要素和可互换的标准模块,通过不同模块的相互组合,形成不同类型和规格的起重机。对起重机进行改进,只需针对某几个模块。设计新型起重机,只需选用不同模块重新进行组合。可使单件小批量生产的起重机改换成具有相当批量的模块生产,实现高效率的专业化生产,企业的生产组织也可由产品管理变为模块管理。达到改善整机性能,降低制造成本,提高通用化程度,用较少规格数的零部件组成多品种、多规格的系列产品,充分满足用户需求。
批量的起重机是在通用的场合使用,工作并不很繁重。这类起重机批量大、用途广,考虑综合效益,要求起重机尽量降低外形高度,简化结构,减小自重和轮压,也可使整个建筑物高度下降,建筑结构轻型化,降低造价。因此电动葫芦桥式起重机和梁式起重机会有更快的发展,并将大部分取代中小吨位的一般用途桥式起重机。德国德马格公司经过几十年的开发和创新,已形成了一个轻型组合式的标准起重机系列。起重量为1-63吨,工作级别为A1-A7,整个系列由工字形和箱型单梁、悬挂箱形单梁、角形小车箱形单梁和箱形双梁等多个品种组成。主梁与端梁相接以及起重小车的布置有多种型式,可适合不同建筑物及不同起吊高度的要求。根据用户需要每种规格起重机都有三种单速及三种双速供任意选择,还可以选用变频调速。操纵方式有地面手电门自行移动、手电门随小车移动、手电门固定、无线遥控、司机室固定、司机室随小车移动、司机室自行移动等七种选择。大车及小车的供电有电缆小车导电、DVS 系统两种方式。如此多的选择项,通过不同的组合,可搭配成百上千种起重机,充分满足用户不同的需求。这种起重机的另一最大优点是轻型化,自重轻、轮压轻、外形尺寸高度小,可大大降低厂房建筑物的建造成本,同时也可减小起重机的运行功率和运行成本。与通用产品相比较,起重量为10t ,跨度22.5m ,通用双梁桥式起重机自重是24t ,起重机轨面以上高度1876mm ,起重机宽度5980mm; 德马格起重机的自重只有8.7t ,重量轻了176%,起重机轨面以上高度为920mm ,降低了104%,起重机宽度为2980mm ,外形尺寸减少了100%。
起重机的更新和发展,在很大程度上取决于电气传动与控制的改
进。将机械技术和电子技术相结合,将先进的计算机技术、微电子技术、电力电子技术、光缆技术、液压技术、模糊控制技术应用到机械的驱动和控制系统,实现起重机的自动化和智能化。大型高效起重机的新一代电气控制装置已发展为全电子数字化控制系统。主要由全数字化控制驱动装置、可编程序控制器、故障诊断及数据管理系统、数字化操纵给定检测等设备组成。变压变频调速、射频数据通讯、故障自诊监控、吊具防摇的模糊控制、激光查找起吊物重心、近场感应防碰撞技术、现场总线、载波通讯及控制、无接触供电及三维条形码技术等将广泛得到应用。使起重机具有更高的柔性,以适合多批次少批量的柔性生产模式,提高单机综合自动化水平。重点开发以微处理机为核心的高性能电气传动装置,使起重机具有优良的调速和静动特性,可进行操作的自动控制、自动显示与记录,起重机运行的自动保护与自动检测,特殊场合的远距离遥控等,以适应自动化生产的需要。
例如采用激光装置查找起吊物的重心位置,在取物装置上装有超声波传感器引导取物装置自动抓取货物。吊具自动防摇系统能在运行速度200m /min 、加速度0.5m/s2的情况下很快使起吊物摇摆振幅减至几个毫米。起重机可通过磁场变换器或激光达到高精度定位。起重机上安装近场感应系统,可避免起重机之间的互相碰撞。起重机上还安装了微机自诊断监控系统,该系统能提供大部分常规维护检查内容,如齿轮箱油温、油位,车轮轴承温度,起重机的载荷、应力和振动情况,制动器摩擦衬片的寿命及温度状况等。
在起重机单机自动化的基础上,通过计算机把各种起重运输机械组成一个物料搬运集成系统,通过中央控制室的控制,与生产设备有机结合,与生产系统协调配合。这类起重机自动化程度高,具有信息处理功能,可将传感器检测出来的各种信息实施存储、运算、逻辑判断、变换等处理加工,进而向执行机构发出控制指令。这类起重机还具有较好的信息输入、输出接口,实现信息全部、准确、可靠地在整个物料搬运集成系统中的传输。起重机通过系统集成,能形成不同机种的最佳匹配和组合,取长补短,发挥最佳效用。目前重点发展的有工厂生产搬运自动化系统,柔性加工制造系统,商业货物配送集散系统,集装箱装卸搬运系统,交通运输和邮电部门行包货物的自动分拣与搬运系统等。
例如生产工程机械的美国卡特皮勒公司金属结构厂购置了一条以桥式起重机为主的物料自动搬运系统,用于钢板的喷丸处理、切割和
入库的自动装卸搬运作业,比原先采用单机操作工作效率提高了65%。日本东芝浜川崎工厂用全自动桥式起重机组成的物料输送系统来搬运柔性加工线上的夹具和工件,为机床运送毛坯或将加工好的零件送到下一工序或仓库。这些在空间移动的起重机搬运系统代替了过去通常使用的自动导向搬运车,使车间的地面面积得到充分利用。
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