Technical information is a guide to repair it in the repair work plays a vital role. Through the use of technical information can greatly improve the efficiency of repair and maintenance of accurate wins. Generally speaking, for major repair of CNC machine tool failure. In an ideal state, should have the following technical data:
CNC machine tool instructions ⑴ use it by the machine tool manufacturers are well prepared to provide a random bed of random information. Machine instructions typically include the use and maintenance of F-related elements.
1) machine tool operations and the steps
2) machine tool main drive system and major mechanical components Schematic diagram of the structure.
3) Machine hydraulic, pneumatic, lubrication system diagram
4) machine to install and adjust the measures and steps
5) Machine Tool Electrical Control Schematic
6) machine using the special functions and descriptions.
Numerical control system operation, programming instructions (or use the manual), it is caused by the preparation of CNC system manufacturer CNC System User's Guide, usually including the contents of F:
1) CNC panel Description
2) CNC system specific steps (including manual, automatic, test run, such as steps. As well as procedural, parameters such as input, editing, set up and display methods).
3) processing procedures, as well as input formats, procedures for the preparation method, the basic format of the directive, as well as represent the meaning.
In some systems it may include system debugging, maintenance of substantial information, such as: "Machine parameters" note, warning of significantly less than treatment methods, and the system connection diagram and so on. It is the repair and operation of CNC machine tools must reference one of the technical information.
⑶ PLC list of procedures which are machine tool plant in accordance with the specific control requirements of machine tool design, the preparation of the machine tool control software, PLC program included the implementation of machine tool movements, as well as the conditions necessary for the implementation of action, it shows the command signal detection components and the implementation of components of all the logical relationship between. With PLC procedures, maintenance personnel can quickly find the reasons for failure, it is the repair process of CNC machine tools most frequently used, the most important information in some systems (such as FANUC system, SIEMENS802D, etc.), the use of numerical control system can be directly on the display PLC program for dynamic testing and observation, it provides a great deal of repair facilities, therefore, must be skilled in the repair skills of handling and use of the skills
⑷ list of machine parameters which are produced by the machine tool factory in accordance with the actual situation of the numerical control system and adjust the settings. Machine system and machine parameters are among the "bridge", it not only directly determines the system configuration and functions, but also related to machine tool dynamic and static performance and accuracy of repair is therefore an important basis for machine tool and reference. In the repair should be at any time reference system, "Machine parameters" clearance status of the settings to adjust, repair machine tools; particularly in the replacement of numerical control system module. Must set the original record of machine parameters for machine tool function.
CNC ⑸ connection description, functional description of the information from the CNC system manufacturer is usually available only to the preparation of machine tool manufacturers as a needle-based information. Maintenance personnel from the machine or system manufacturer production, marketing departments have been provided. Description of the connection system, the functional specification not only contains more than a more detailed electrical schematic diagram of the system to connect between the various parts of the requirements and description, but also includes the principle of ring signals are not reflected in the functional description are CNC repair, especially check the electrical wiring of an important reference.
⑹ servo drive system, the spindle drive system using the specification it is the servo system and the principles of the spindle drive system and connection instructions, including servo, spindle status display and alarm display, the drive debug, set points, signals, voltage, current test point, the drive set up the parameters and significance of such areas as content, for the servo drive system, the spindle drive system repair reference.
⑺ PLC and programming it using the machine are used in the external or built-in PLC use programming instructions. Through the PLC's instructions, maintenance personnel can function through the PLC and the instructions indicate. Analysis, understanding PLC procedures. And thus a detailed understanding and analysis of machine tool movements process, action condition, action-shun shore, as well as the logical relationship between the signal and, if necessary PLC can also revises part of the procedure.
⑻ Machine feature of major ancillary instructions and data in the machine tools often use more features such as digital turntable, automatic tool changing device, lubrication and cooling system, etc. Chip New Zealand. These features, and its manufacturers generally provide a more complete use instructions, machine tool manufacturers should be available to users with a hard feature event of the failure of reference. These are under ideal circumstances should be prepared by its technical information, but the actual repair is often difficult to do this. Therefore, when necessary, maintenance personnel should be through on-site mapping, accumulation, etc. End peacetime Pu, to sort out the relevant technical information.
⑼ This is a maintenance staff of the machine tool repair and maintenance records of the process of summing up the status of the best clearance are: to deal with their own maintenance staff to carry out each step are detailed repair records, regardless of whether the judge was correct. This will not only help to further repair, but also contribute to the maintenance personnel with experience levels.
Wednesday, February 25, 2009
CNC machine tool repair technology
With the electronic technology and automation technology, NC technology more widely. To microprocessor-based, large-scale integrated circuits marked CNC equipment, has been in our production, substantial introduction and popularization and application, they give the machine manufacturing industry created conditions for development, and bring great benefits. But at the same time, because of their advanced nature, complexity, and intelligent high, in the repair theory, technology and means to have taken place on changes in leaps and bounds.
CNC repair technology is not only a prerequisite for the protection of the normal operation of CNC technology development and improvement also has played an enormous role in promoting, Therefore, at present, it has become a specialized discipline.
In addition any CNC equipment is a process control equipment, which requires real-time control in every moment of the accuracy of work. Any part of the fault and failure, it will enable the machine tool downtime, resulting in the production of a standstill. Numerical control system and thus the complexity of such a principle, structural repair sophisticated devices it is very necessary. In particular, the introduction of CNC machine tools, most of them spent hundreds of thousands to tens of millions of dollars. In many industries, these devices are at a critical job, if not a timely manner after failure troubleshooting repair, will result in greater economic losses.
We repair the existing situation and the level of imported equipment and the design and manufacture of technical level there are still a large gap. Of the underlying reasons are: poor quality of personnel, lack of analysis of digital test instruments, the number of domain-domain and frequency domain and several aspects of the integrated test and analysis techniques to be improve and so on.
Here we have a modern CNC system constitutes the basic starting point to explore the numerical control system diagnosis and repair.
One numerical control system with the characteristics of the composition
The world a wide range of CNC system, the form of different structural components have their own characteristics. These structural characteristics of the system from the initial design of the basic requirements and engineering design ideas. Points such as control systems and continuous trajectory control system there is different requirements. The T system and the M system, also have vastly different, the former applied to Rotary Parts processing, which fit in the special-shaped non-rotating body parts processing. For different manufacturers is based on the historical development of factors and vary from place to place each of the complex of factors, may also be thinking in the design is different. For example, the United States Dynapath system uses a small plate structure, easy and flexible combination of the replacement board, while Japan FANUC system tended large panel structure to facilitate the work of the system reliability to the system MTBF rates rising. In either system, however, they constitute the basic principles and are very similar. In general the entire CNC system consists of three major components, namely, control system, servo system and position measuring system. Control system for processing workpieces by computing interpolation procedures, issued instructions to the servo drive control system; servo drive control system will command magnified, by the servo motor-driven machinery required to exercise; measurement system Detect mechanical position or velocity of the exercise, and feedback to the control system, to amend the control orders. Organic combination of the three-part form the complete closed-loop control of the CNC system.
Control system mainly by bus, CPU, power supply, memory, operating panels and displays, digital control unit, programmable logic controller control unit and data input / output interface and so on. The latest generation of CNC system also includes a communication unit, it can complete the CNC, PLC's internal data communications and external high network. Servo drive systems, including servo drives and motors. Position measurement system is mainly the use of long or round grating grating incremental displacement encoder.
The main features of numerical control system are: high reliability requirements: because once the CNC system failure, that is a tremendous economic loss; has a higher ability to adapt the environment, because the general numerical control system for industrial control machine, the working environment for the workshop environment, the requirements it has in the vibration, high temperature, humidity and various industrial sources of interference conditions and the ability to work under; interface circuit complexity, numerical control system with a variety of CNC equipment and peripherals to match, it is necessary to deal with the production process at any time in various situations, to adapt to a variety of process equipment requirements, and thus the complexity of the interface circuit, and frequent job.
2 Modern numerical control system of the basic conditions for repair job
2.1 Maintenance of the basic conditions for staff
Repair work was good or bad depends on the staff first of all conditions, the maintenance staff must possess the following requirements:
(1) a high degree of responsibility and good professional ethics;
(2) broad knowledge to master computer technology, basic analog and digital circuits, automatic control and electric drag, detection techniques and aspects of the machining process knowledge and a certain basic level of foreign language proficiency;
(3) After a good technical training, information on the CNC, drive and PLC's working principle, know how to CNC programming and programming languages;
(4) are familiar with the structure, with strong experimental skills and hands-capacity;
(5) have a variety of commonly used (especially the scene) of the test apparatus, instrumentation and various tools.
2.2 means in the repair should be the conditions
(1) ready to commonly used spare parts, accessories;
(2) micro-electronic components can be the actual support or supply;
(3) the necessary repair tools, instruments, meters, cables, computer. Have the best small-scale programming system or programmer to debug support equipment;
(4) complete information, manuals, circuit diagram, maintenance instructions (including the CNC operator instructions), and the interface, adjust with the diagnosis, specification-driven, PLC specification (including the PLC user program alone), components forms.
2.3 Preparation before the repair
Receiving the user's direct request, as far as possible direct contact with the user in order to access the site information as soon as possible, on-site conditions and fault information. Such as CNC machine tool spindle drive into the given model, the police instructions or failure phenomenon, the user site, such as the availability of spare parts. Accordingly pre-analysis of the cause of the malfunction that may arise with the site, then before the departure to the scene, ready-related technical information and repair service tool, apparatus, spare parts and so on, have prepared to do away.
3-site repair
Field repair of CNC machine tool breakdown (mainly NC part) for the diagnosis, identify the fault location to the corresponding normal parts replacement, so that machine to resume normal operation. This process are the key to diagnosis, that is, the system or the external line test to determine whether the fault, and fault location pointed out that the exact location of fault. From the machine to plug line positioning plate, and in some occasions even locate components. This is a major part of the repair job.
3.1 Numerical Control System Fault Diagnosis
(1) initial identification is usually a more full-time in the data through data analysis to determine where the fault, or interface signal law judge in accordance with the phenomenon of fault location fault may occur, and then in accordance with the fault with this part of the specific characteristics of each site inspection preliminary identification. In practical applications, it may be a way to find fault and to remove, and sometimes required a number of ways and used. Point of failure for a variety of ways to determine mastery of the extent of the malfunction of equipment depends primarily on the principle and structure of the depth of grasp.
(2) report to the police report to the police deal with the treatment ① system: CNC system failure, a general in the operation panel display or give fault signal and the corresponding information. Usually manual system or adjust the manual has detailed alarm number, alarm content and methods of treatment. Because of the alarm system set up a single, complete, tight, clear and repair may be based on the back of each alarm information and give way to deal with their own treatment. ② machine alarm information and operation of the treatment: Machine Tool Machine Tool factory in accordance with the electrical characteristics of the application of PLC program will be able to reflect some of the electrical machine control interface failure or operator specific information signs, displays give through and through specific keys, see a more detailed description of the alarm. This type of alarm can be provided in accordance with werkzeugmaschinenfabrik troubleshooting manual treatment, can also use the operation panel or the programmer circuit diagram and the PLC in accordance with procedures, to identify the corresponding signal state, according to the logical relationship to identify the point of failure to deal with.
(3) No alarm or alarm failure could not deal with the PLC when the system can not run, system downtime or system has not reported to the police but is not working correctly when required in accordance with pre-and post-fault system state information, the use of the available theoretical basis for analysis , make the right judgments. Elaborated the following fault diagnosis and rule out the possibility of such approaches.
Fault diagnosis method of conventional test
Visual visual fault plate, carefully check for blown fuses, components charred, smoked, cracking phenomenon, whether or not the phenomenon of foreign body circuit. As can be judged, and whether the board over-current, over voltage, short circuit and so on.
Hand touch and components, especially the resistance-capacitance, semiconductor devices sense whether or not loose as can check out some broken legs,and so on.
Electricity first used a multimeter to check whether the circuit between the various power, such as free access to the corresponding power supply, whether visual smoke, brand and other phenomena, whether or not abnormal hand components fever, this can be found in some of the more obvious failures, and to narrow the scope of overhaul.
For example: a factory in Harbin troubleshooting, the machine tool CNC system and the PLC is running normal, but the machine's hydraulic system will not boot, and check the PLC programmer process operating normally, the signal state are required to meet the conditions of the boot. Further inspection found, PLC signal state with the drawings and equipment marking inconsistencies, parking pull-out circuit board inspection and found that PLC 2 output boards addressing wrong, wrong location and another two by the exchange after the normal operation of machine tools. For this failure happen machine used in SIMATIC S5-150K programmable controller, as long as the addressing is correct, regardless of the location of the circuit board will be how to order, the system can be normal operation, but the implementation of the corresponding components and signal source must be correctly counterparts, once the corresponding fault error occurs, and even damage machine tools. In addition, according to users fault phenomenon, combined with their own on-site observation, the use of the system working principle can also quickly make the right judgments.
Instrument measurements when the system broke down after using conventional electrical testing instruments, tools, machine tool according to the system circuit diagrams and circuit diagrams of fault part of the voltage, power supply, such as pulse signal measured to determine where fault. Such as power supply input voltage overrun, causing power supply voltage meter measurements can be used to monitor the network voltage, or voltage tester with real-time monitoring to rule out other causes. Such as position control loop fault happened oscilloscope can be used to check the signal measurement circuit state, or oscilloscope to observe the signal output phase is missing, whether or not interference. For example, a factory in Shanghai in troubleshooting, system alarm, the location of ring hardware failure, using oscilloscopes have detected interference signal, we then used in circuit capacitance method to filter out the system working correctly. Emerging systems such as the reference point is unable to return to the situation that can be used to check whether the zero marker oscilloscope pulse, could be considered if there is no measurement system are damaged.
PLC controller with programmable interrupt state analysis: programmable logic controller failure, the reasons for their interruption of the way to break the stack memory. Programmer can use to stop in the system state, out of the stack and interrupt stack block, according to the instructions of their reasons for failure to identify the host. Programmable Logic Controller in the repair of this is the most common way to effectively and rapidly.
Interface signal examination: through the use of programmable logic controller to check machine tool control system interface signals and the correct manual and interface signals relative ratio, also found the corresponding point of failure.
Diagnosis of spare parts to replace Law: Most modern CNC system is modular design, divided according to different functions in different modules, with modern technology, the development of the integrated circuit the increasing scale of technology is also more complex, according to conventional methods, it is difficult to fault location to put a very small region, and when the system failure, in order to reduce downtime, we can according to the function module and fault phenomena, the initial judge the possible fault module, with the diagnosis of spare parts to replace it, so can quickly determine the The module has a fault. In the absence of diagnosed cases of spare parts can be used at the scene the same or compatible replacement module inspection, repair of the modern CNC, an increasing number of cases using this method of diagnosis, and then use the spare parts to replace damaged module, allowing the system to normal. The greatest extent possible to reduce downtime, use this method when they are in operation attention must be carried out in the blackout state, but also double-check the PCB version, model, a variety of markers, cross-access it the same as for the machine tool-related data and potentiometer position record should be prepared, should be well marked suture removal.
Use of system self-diagnostic function to determine: a modern CNC system in particular, are full-function NC has a strong ability to self-diagnosis, when the monitoring system through the implementation of the various parts of the job and promptly determine the failure, give the police information, and make corresponding action to avoid the accident. But sometimes when the hardware failure, will not be able to report to the police, and some numerical control system through the LED flashes different frequency or different combinations to make the corresponding instructions, these instructions can be used to help us accurately diagnose faults template. SINUMERIK 8 system such as MS100 CPU board in accordance with the four lights and operation panel FAULT bright lights out combinations can determine fault location.
The above diagnostic methods, in practical applications there is no strict time limits, may be able to use a method of troubleshooting may also require a number of ways at the same time. Its effect depends primarily on the principle of the system and structure of the depth of understanding and grasp, as well as the number of repair experience.
3.2 NC System Fault Analysis
Numerical control system in accordance with the composition, working principle and characteristics, combined with our experience in the repair will be a common phenomenon of fault location and fault analysis are as follows.
(1) This is the position loop control instructions issued by NC system, and position detection system compared to the value of the feedback to further complete the mission control of a key aspect. It has a very high frequency of job and peripherals connected, so prone to failure.
Common fault has: ① digital control loop warning: may be open loop measurements; measurement system damage, internal damage-bit ECU. ② instructions on the hair do not exercise, may be drifting too high, positive feedback, digital control unit breakdown; measurement component damage. ③ measurement component failure, the general performance without feedback value; machine can not return to reference point; high-speed pulse generator when the leak likely cause alarm or read the first grating are dirty; grating broken.
(2) Servo Drive System Servo drive system and power grid, and other associated mechanical systems, but also in the work has been in frequent start-up and running, so this is also part of larger failures.
Its main fault has: ① system damage. General because of the network voltage fluctuations or voltage shocks. Power quality in most areas of China's poor, will bring voltage transfinite machine, especially the moment overrun, such as non-specific voltage monitor, it will be difficult to detect, in the search when the cause of the malfunction, it is necessary to take note, there are Some reasons are because of special damage. Such as a factory in northern China because of lightning in the plant substation and caused many Power Units tools servo system damage. ② no control instructions, the electrical high-speed operation. This failure is due to the speed loop or open-loop positive feedback. Such as a factory in the northeast, the introduction of the Federal Republic of Germany Wotan rotor milling companies in debugging, the machine tool X-axis in the absence of instructions, the high-speed operation, by the analysis that we think are caused by positive feedback. Since the system zero drift, in the case of positive feedback, it will enable the rapid accumulation of motors at a high speed operation, and we check the line after the tag by completely correct, Machine Tool Plant technicians mistake then consider impossible in the full analysis and testing we will Reverse feedback line, the results of machine operating normally. Machine Tool Plant and technical personnel have to admit mistakes in the work of the German side. There is one example, we have a factory in Tianjin, training lectures should be the attitude of the management requirements of their Units from one plant into the plant have not been able to work properly after the repair of precision grinding machines for its failure are: 1 start motor on the machine running, but also a growing the sooner, until the maximum speed. Consider our analysis because of the speed loop are open, the system can not suppress drift caused. The reason is that after inspection line speed feedback received to the online result. ③ processing surface fail, go-for-axis circular interpolation to convex when Units, or electric low-speed crawling, or vibration, such failure is usually because of improper adjust servo system, the system does not gain the same axis or in connection with motor caused by inappropriate matching, the solution is optimized adjustment. ④ blown insurance, or motor overheated and burned, such failures are usually mechanical load is too large or the card die.
(3) part of the power supply system is to maintain a normal job to support the energy part of the failure or failures are caused by direct result of system downtime or damage to the entire system. General in Europe and the United States, relatively few of these questions, in the design considerations in this area much, but in China, because of volatile power supply, poor quality, but also to hide like a high-frequency pulse of this type of interference, plus man-made factors (such as sudden power outages, etc.). These reasons can cause power failure to monitor or damaged. In addition, the numerical control system to run some data, settings data and processing procedures stored in RAM memory in general, the system after power failure, battery backup power supply on or lithium batteries to maintain. Thus, a longer period of downtime, plug the power or memory can cause data loss, the system should not run.
(4) programmable logic controller interface numerical control system logic control,database management, hydraulic start and so on, mainly by the PLC to achieve, it is necessary to the completion of these controls must be collected on the status of the control point information, such as broken electrical , servo valves, lights and so on. Thus it with the outside world a wide range of variety of signal sources and the implementation of components linked to frequent changes, so the possibility of the failure of many more, but also the ever-changing fault type.
(5) other because of environmental conditions, such as interference, temperature, humidity exceed the scope of permit, improper operation, improper parameter settings, but also may result in downtime or failure. One factory has CNC equipment, the boot soon after the loss of NC ready signal, the system can not work, the examination revealed a very high body temperature because the ventilation filters have been blocked, causing the temperature sensor movements, replacement of filters, the system normal job. Not according to rules-swappable circuit boards, with or without protective measures, such as static electricity may cause malfunction or even destruction of system downtime.
General in the numerical control system design, use and repair, we must consider are frequently out of position to give alarm, alarm circuit after the job, on the one hand on the screen or operating panel give the police information, on the other hand the issue of interruption of the protective directive, allowing the system to stop working to identify and repair faults.
3.3 Troubleshooting Method
(1) initialization reset method under normal circumstances, because of the instantaneous system failure alarm, the available hardware reset or switch the system power in order to remove the fault, if the system is down because of storage areas, pluggable circuit board or battery voltage cause confusion, it must be cleared to initialize the system, removing the former should pay attention to make copies of data records, if initialization can not be ruled out after the fault is still, were carried out in hardware diagnosis.
(2) the parameters change, the program is more actual system parameters are determined based on system functions, parameter settings may cause errors on the system failure or a functional null and void. For example, a factory in Harbin rotor milling machine using a measurement of the circulatory system, the functional requirements have a background memory, debugging and found this feature can not be achieved. Examination revealed the background to determine the existence of memory data bit is not set, after setting the normal function. Sometimes, because of procedural errors can be caused by user downtime, which can be used search function block system to inspect and correct all errors, in order to ensure its normal operation.
(3) regulation, adjust the best method of regulation is one of the most simple solution. Potentiometer through regulation, to amend system failures. Such as a factory repair, the system displays the screen of their confusion, as adjusted to normal. A factory in Shandong, the spindle in the start-up and braking skid occurs when a belt because of its large spindle load torque, and drives the ramp-up time setting is too small, the adjusted normal.
Optimization are systematically adjust servo drive system and mechanical system was dragging achieve the best match of the integrated regulation of methods, their approach is very simple, with a multi-line recorder or dual trace storage oscilloscope, respectively, observation of instruction and speed feedback or current feedback response relationship. By regulating the speed regulator proportional coefficient and integral time, to make servo systems that have a higher dynamic response without oscillation of the best working condition. At the scene no oscilloscope or recorder of circumstances, based on experience, that is, adjust so that the electrical start-up, and then slowly adjust to the reverse, until you can eliminate the shock.
(4) replacement spare parts spare parts for the replacement of law with well diagnosed a bad circuit board, and make the corresponding initialization start, so that the normal operation of machine tools quickly, and then repair or rework bad board, which is currently ranked the most commonly used because approach.
(5) to improve the power quality of law is generally regulated power supply used to improve power supply fluctuations. For high-frequency interference filtering capacitor can be used by these preventive measures to reduce the power supply board failure.
(6) maintenance of information-tracking some of the large manufacturing company based on actual work because of design defects caused by accidental failure, have been revising and perfecting the system software or hardware. These changes to the form of constant repair information available to maintenance personnel. Used as the basis for troubleshooting can be completely correct troubleshooting.
3.4 repair should pay attention to matters
(1) removed from the machine on a piece of circuit board, the Record should be noted that their relative position should be to connect its cable for fixed installation of the circuit board, it should be removed before and after the press-fit parts and screws for record purpose. Demolition under the pressure parts and screws should be placed on a dedicated box, so as to avoid loss, the assembly, the box should be all things to use, otherwise the assembly is incomplete.
(2) electric soldering iron should be placed on the front easily, stay away from the circuit board repair. Jerdonii Dressing should be appropriate to meet the integrated circuit welding, and to avoid bumps when welding other components.
(3) measuring the resistance between lines should be broken power supply, measured resistance should be red and black table pen exchange measurements twice a year to a large value for the reference value.
(4) circuit board solder films have mostly brush, so measurements should be to find the corresponding point as the test spot, do not eradicate the solder film, and some board all the brush has the insulating layer, only in the solder joint Department with a blade and scratch - insulating layer.
(5) should not be arbitrarily cut off the printed circuit. Some maintenance personnel have some experience in home appliance repair, custom line check, but the numerical control devices are double-sided circuit board or metal plate of multi-hole plate, printing fine lines and dense, once cut off the hard welding, and easy to cut off tangent when the adjacent line, again some point, a cut off of a line, and should not make it and line out, required a few lines got cut off simultaneously.
(6) should not be components. Some maintenance personnel identifying fault components in the absence of circumstances that only the seat of your pants a component breaks down,immediately, so that a higher rate of miscarriage of justice, of the components removed artificially higher failure rate.
(7) should be used to demolish component suction device and suction tin tin rope, should not have the hardware check. The same heating pad should not be a long time and repeat the demolition to avoid damage to pad.
(8) replacement of the device, the pin should be an appropriate treatment, welding welding should not be used in acidic oil.
(9) Record lines switch, jumper position, it should not be changed. For more than polarization control inspection, or swap components on-board when the attention of all components tag in order to avoid disorder, with the result that a good board should not work also.
(10) investigated the power circuit board configurations and types, according to the required inspection can be powered separately or all of power. Should pay attention to high-pressure, and some direct access to high-voltage circuit board, or board has high-voltage generator, in need of appropriate insulation, should pay special attention to the operation.
4 CNC machine tools boot debugging
CNC machine tools is a high technology machinery and instruments of integration tools, the user to buy a CNC machine tool whether the correct safety boot, debugging is a crucial move. This step is the correct decision in large CNC machine tools that can exert Units normal economic efficiency and service life of its own, which is CNC machine tool manufacturers and users of the factory are very important issues. CNC machine tools boot, debugging the following steps should be carried out.
4.1 prior to the appearance of electricity inspection
(1) Open the machine tool inspection machine appliances electric control box, check the relays, contactors, fuses, servo motor speed control unit socket, the spindle motor speed control unit such as the availability of loose sockets, if loosening should be back to normal state, has locking institutions must be locking connector, adapter box has a machine must check the box on the socket adapter, the availability of loose wiring, has locking bodies must be locked.
(2) CNC electric box to check door open CNC electric box to check all types of socket interface, servo motor feedback line socket, the spindle pulse generator socket, hand pulse generator socket, CRT sockets, etc., if loose to re-plugged, Has locking bodies must be locked. Printed circuit board in accordance with the instructions to check all the settings for the situation of short-circuit terminals must be in line with the machine tool manufacturing plant set up a state, there are incorrect should be re-instated, under normal circumstances do not re-instated, but users must be on the short-circuit terminal settings do a good job in the state of original records.
(3) Quality Inspection inspect all wiring the terminal block. Including the strength of electric machine assembly plant on its own terminal and the electrical wiring of the power cord terminals, each terminal must be used with fastening rotating once, until the use of a rotary screw fixed date, all the electrical sockets must be tightened.
(4) solenoid valve solenoid valve check all hands must be promoted several times in order to prevent a long time is not caused by electricity adverse action, such as abnormal, should be prepared records, to prepare for power after the confirmation be repaired or replaced.
(5) check the check all limit switch limit switch moves the flexible and fixed it firmly and found that the adverse action is not solid or fixed should be addressed immediately.
(6) Operation panel buttons and switches for inspections of the operation panel buttons, switches, wiring lights and found that an error should be dealt with immediately, inspection unit on CRT socket and wiring.
(7) Ground inspection requirements have a good ground wire, ground wire measuring machine, grounding resistance should not greater than 1Ω.
(8) power supply phase sequence check sequence table used to check phase sequence of input power, input power to confirm the phase sequence and machine tool calibration throughout the power phase sequence should be absolutely consistent. Secondary Wiring has the equipment, such as power transformers, the secondary wiring must confirm the consistency of the phase sequence. To ensure that throughout the phase sequence is absolutely correct. Supply voltage to be measured at this time, do a good job records.
4.2 machine connected to the total voltage
(1) the total power supply connected to machine tools, inspection CNC electric box, spindle motor cooling fans, machine tool cooling fan electrical box steering is correct, lubrication, hydraulic oil, etc., as well as signs in the machine tool lighting and whether it is normal, the fuse has no damage, if any abnormal power failure should immediately overhaul, no abnormality can continue.
(2) measurement of the various parts of strong electric voltage, especially for the CNC and servo power unit used in the initial-level voltage transformer and to prepare themselves Record.
(3) to observe whether or not oil spills, especially for the turret to place cards tight, and the shift spindle chuck tight cards, etc. of the hydraulic cylinder and solenoid valve. If oil spills should be immediately repaired or replaced blackout.
Box 4.3 CNC electric power
(1) CNC electricity power button, power supply connected to CNC to observe the CRT display, until the normal screen. If the ALARM display, it should be looking for fault and ruled out at this time should be re-sent to check the electricity.
(2) Open CNC power, in accordance with the relevant information on the test terminal give the location of measurement at all levels of voltage, bias has to be adjusted to a given value, and to prepare themselves Record.
(3) the state of switches placed in appropriate locations, such as Japan FANUC system should be placed in MDI, and choose to go to the page parameter. Bit-by-one by one to check the parameters, these parameters should be consistent with random brought in line with the parameter table. Such as are found inconsistent parameters, should understand the significance of various parameters and then decide whether or not to modify, such as backlash compensation value may be inconsistent with the parameter table, which in the actual processing can be modified at any time.
(4) the state of selector switch placed in the JOG position, will move the speed on the most low-grade, respectively positive and negative direction of the coordinates to move the operation, and simultaneously to move the hand according to the direction of the corresponding super-way protection switch, verify the reliability of its protective role, and then carry out the super-slow-way test, to verify the installation of ultra-way collision block is correct.
(5) will be placed in a state of switch back to zero position, the completion of the operation back to zero, the reference point return movements are not completed will not be able to carry out other operations. In such cases therefore should first carry out this operation, then we will proceed to item (4) operation.
(6) will be placed in a state of switch JOG position or MDI position, manually change file test will verify the minimum spindle speed control switch on the location of the file to the main axis of positive tests, observation of the spindle and the speed of operation show the correctness, and then gradually speed up to the highest speed, to observe the functioning of the stability of the spindle.
(7) manual rail lubrication test, so have a good rail lubrication.
(8) changes gradually shift ultra-fast transfer switch and the feed rate switch, to move the tool carrier at random to observe the correctness of the speed of change.
4.4 MDI test
(1) measuring the actual speed of the spindle lock switch on the machine connected to the location, using manual data entry instructions, carry out arbitrary variable spindle files, variable-speed test, measuring the actual spindle speed, spindle speed and observe the displayed value, adjust its error should be limited to within 5%.
(2) conducted or knife Block turret election knife test its purpose is to examine the knife block, or are, inversion and the correctness of positioning accuracy.
(3) function tests in accordance with the order situation is different, different functions can be made under the specific circumstances of each functional test. To prevent accidents from happening, the best first test machine is locked, and then open up a pilot machine.
(4) EDIT function tests will be placed in a state of EDIT selector switch position, to produce one easy process, as much as possible, including various functions and auxiliary functions of command instructions, mobile dimension to the largest machine tool stroke is limited, the procedure at the same time increase delete and modify.
(5) the state of the tests will be automatically locked machine, with the preparation of operating procedures and air test, to verify the correctness of the procedure, and then open up machine tools, feed rate, respectively, switches, ultra-fast transfer switch, spindle speed overshoot many switch kinds of changes in machine tool switches in the above circumstances a variety of changes in full operation, after the overshoot at switch 100% office to enable the full operation of machine tools to observe the work of the whole are normal.
At this point, a numerical control machine tool to be finished debugging boot.
5 After the repair debug technology deal
At the scene after the repair, maintenance records should be carefully filled out a list of essential spare parts list, set up user profiles for the failure time, the phenomenon of diagnostic methods, the use of scheduling methods so that if there should be a detailed record of the remaining issues, such not only for each fault are well documented, but also the accumulation of repair experience.
Above repair techniques for numerical control system as described in nearly a hundred years we are the number of control system debugging and maintenance experience. Although a wide range of numerical control system, fault is ever changing methods of repair are not the same, it is difficult to make a short reference, but we still wish to put some of the basic methods and ideas to write out, and everyone can communicate with a view to raise awareness of CNC system emphasis on repair techniques, repair techniques and results of the direct purpose is to enable the numerical control system to resume normal operation, thus ensuring the smooth progress of production. At present, numerical control technology in our country is rapidly infiltrate to the industrial sector, with the development of electronic technology, numerical control technology in the national economy also increases, then for an important component of the CNC Technology - CNC System repair techniques should also adapt quickly to the rapid development of numerical control technology requirements, as a numerical control system maintenance and technical personnel, they should be constantly learning and mastering new knowledge and technology, looking for a new diagnosis of repair methods and means to promote a few control system repair technology development and make due contributions.
CNC repair technology is not only a prerequisite for the protection of the normal operation of CNC technology development and improvement also has played an enormous role in promoting, Therefore, at present, it has become a specialized discipline.
In addition any CNC equipment is a process control equipment, which requires real-time control in every moment of the accuracy of work. Any part of the fault and failure, it will enable the machine tool downtime, resulting in the production of a standstill. Numerical control system and thus the complexity of such a principle, structural repair sophisticated devices it is very necessary. In particular, the introduction of CNC machine tools, most of them spent hundreds of thousands to tens of millions of dollars. In many industries, these devices are at a critical job, if not a timely manner after failure troubleshooting repair, will result in greater economic losses.
We repair the existing situation and the level of imported equipment and the design and manufacture of technical level there are still a large gap. Of the underlying reasons are: poor quality of personnel, lack of analysis of digital test instruments, the number of domain-domain and frequency domain and several aspects of the integrated test and analysis techniques to be improve and so on.
Here we have a modern CNC system constitutes the basic starting point to explore the numerical control system diagnosis and repair.
One numerical control system with the characteristics of the composition
The world a wide range of CNC system, the form of different structural components have their own characteristics. These structural characteristics of the system from the initial design of the basic requirements and engineering design ideas. Points such as control systems and continuous trajectory control system there is different requirements. The T system and the M system, also have vastly different, the former applied to Rotary Parts processing, which fit in the special-shaped non-rotating body parts processing. For different manufacturers is based on the historical development of factors and vary from place to place each of the complex of factors, may also be thinking in the design is different. For example, the United States Dynapath system uses a small plate structure, easy and flexible combination of the replacement board, while Japan FANUC system tended large panel structure to facilitate the work of the system reliability to the system MTBF rates rising. In either system, however, they constitute the basic principles and are very similar. In general the entire CNC system consists of three major components, namely, control system, servo system and position measuring system. Control system for processing workpieces by computing interpolation procedures, issued instructions to the servo drive control system; servo drive control system will command magnified, by the servo motor-driven machinery required to exercise; measurement system Detect mechanical position or velocity of the exercise, and feedback to the control system, to amend the control orders. Organic combination of the three-part form the complete closed-loop control of the CNC system.
Control system mainly by bus, CPU, power supply, memory, operating panels and displays, digital control unit, programmable logic controller control unit and data input / output interface and so on. The latest generation of CNC system also includes a communication unit, it can complete the CNC, PLC's internal data communications and external high network. Servo drive systems, including servo drives and motors. Position measurement system is mainly the use of long or round grating grating incremental displacement encoder.
The main features of numerical control system are: high reliability requirements: because once the CNC system failure, that is a tremendous economic loss; has a higher ability to adapt the environment, because the general numerical control system for industrial control machine, the working environment for the workshop environment, the requirements it has in the vibration, high temperature, humidity and various industrial sources of interference conditions and the ability to work under; interface circuit complexity, numerical control system with a variety of CNC equipment and peripherals to match, it is necessary to deal with the production process at any time in various situations, to adapt to a variety of process equipment requirements, and thus the complexity of the interface circuit, and frequent job.
2 Modern numerical control system of the basic conditions for repair job
2.1 Maintenance of the basic conditions for staff
Repair work was good or bad depends on the staff first of all conditions, the maintenance staff must possess the following requirements:
(1) a high degree of responsibility and good professional ethics;
(2) broad knowledge to master computer technology, basic analog and digital circuits, automatic control and electric drag, detection techniques and aspects of the machining process knowledge and a certain basic level of foreign language proficiency;
(3) After a good technical training, information on the CNC, drive and PLC's working principle, know how to CNC programming and programming languages;
(4) are familiar with the structure, with strong experimental skills and hands-capacity;
(5) have a variety of commonly used (especially the scene) of the test apparatus, instrumentation and various tools.
2.2 means in the repair should be the conditions
(1) ready to commonly used spare parts, accessories;
(2) micro-electronic components can be the actual support or supply;
(3) the necessary repair tools, instruments, meters, cables, computer. Have the best small-scale programming system or programmer to debug support equipment;
(4) complete information, manuals, circuit diagram, maintenance instructions (including the CNC operator instructions), and the interface, adjust with the diagnosis, specification-driven, PLC specification (including the PLC user program alone), components forms.
2.3 Preparation before the repair
Receiving the user's direct request, as far as possible direct contact with the user in order to access the site information as soon as possible, on-site conditions and fault information. Such as CNC machine tool spindle drive into the given model, the police instructions or failure phenomenon, the user site, such as the availability of spare parts. Accordingly pre-analysis of the cause of the malfunction that may arise with the site, then before the departure to the scene, ready-related technical information and repair service tool, apparatus, spare parts and so on, have prepared to do away.
3-site repair
Field repair of CNC machine tool breakdown (mainly NC part) for the diagnosis, identify the fault location to the corresponding normal parts replacement, so that machine to resume normal operation. This process are the key to diagnosis, that is, the system or the external line test to determine whether the fault, and fault location pointed out that the exact location of fault. From the machine to plug line positioning plate, and in some occasions even locate components. This is a major part of the repair job.
3.1 Numerical Control System Fault Diagnosis
(1) initial identification is usually a more full-time in the data through data analysis to determine where the fault, or interface signal law judge in accordance with the phenomenon of fault location fault may occur, and then in accordance with the fault with this part of the specific characteristics of each site inspection preliminary identification. In practical applications, it may be a way to find fault and to remove, and sometimes required a number of ways and used. Point of failure for a variety of ways to determine mastery of the extent of the malfunction of equipment depends primarily on the principle and structure of the depth of grasp.
(2) report to the police report to the police deal with the treatment ① system: CNC system failure, a general in the operation panel display or give fault signal and the corresponding information. Usually manual system or adjust the manual has detailed alarm number, alarm content and methods of treatment. Because of the alarm system set up a single, complete, tight, clear and repair may be based on the back of each alarm information and give way to deal with their own treatment. ② machine alarm information and operation of the treatment: Machine Tool Machine Tool factory in accordance with the electrical characteristics of the application of PLC program will be able to reflect some of the electrical machine control interface failure or operator specific information signs, displays give through and through specific keys, see a more detailed description of the alarm. This type of alarm can be provided in accordance with werkzeugmaschinenfabrik troubleshooting manual treatment, can also use the operation panel or the programmer circuit diagram and the PLC in accordance with procedures, to identify the corresponding signal state, according to the logical relationship to identify the point of failure to deal with.
(3) No alarm or alarm failure could not deal with the PLC when the system can not run, system downtime or system has not reported to the police but is not working correctly when required in accordance with pre-and post-fault system state information, the use of the available theoretical basis for analysis , make the right judgments. Elaborated the following fault diagnosis and rule out the possibility of such approaches.
Fault diagnosis method of conventional test
Visual visual fault plate, carefully check for blown fuses, components charred, smoked, cracking phenomenon, whether or not the phenomenon of foreign body circuit. As can be judged, and whether the board over-current, over voltage, short circuit and so on.
Hand touch and components, especially the resistance-capacitance, semiconductor devices sense whether or not loose as can check out some broken legs,and so on.
Electricity first used a multimeter to check whether the circuit between the various power, such as free access to the corresponding power supply, whether visual smoke, brand and other phenomena, whether or not abnormal hand components fever, this can be found in some of the more obvious failures, and to narrow the scope of overhaul.
For example: a factory in Harbin troubleshooting, the machine tool CNC system and the PLC is running normal, but the machine's hydraulic system will not boot, and check the PLC programmer process operating normally, the signal state are required to meet the conditions of the boot. Further inspection found, PLC signal state with the drawings and equipment marking inconsistencies, parking pull-out circuit board inspection and found that PLC 2 output boards addressing wrong, wrong location and another two by the exchange after the normal operation of machine tools. For this failure happen machine used in SIMATIC S5-150K programmable controller, as long as the addressing is correct, regardless of the location of the circuit board will be how to order, the system can be normal operation, but the implementation of the corresponding components and signal source must be correctly counterparts, once the corresponding fault error occurs, and even damage machine tools. In addition, according to users fault phenomenon, combined with their own on-site observation, the use of the system working principle can also quickly make the right judgments.
Instrument measurements when the system broke down after using conventional electrical testing instruments, tools, machine tool according to the system circuit diagrams and circuit diagrams of fault part of the voltage, power supply, such as pulse signal measured to determine where fault. Such as power supply input voltage overrun, causing power supply voltage meter measurements can be used to monitor the network voltage, or voltage tester with real-time monitoring to rule out other causes. Such as position control loop fault happened oscilloscope can be used to check the signal measurement circuit state, or oscilloscope to observe the signal output phase is missing, whether or not interference. For example, a factory in Shanghai in troubleshooting, system alarm, the location of ring hardware failure, using oscilloscopes have detected interference signal, we then used in circuit capacitance method to filter out the system working correctly. Emerging systems such as the reference point is unable to return to the situation that can be used to check whether the zero marker oscilloscope pulse, could be considered if there is no measurement system are damaged.
PLC controller with programmable interrupt state analysis: programmable logic controller failure, the reasons for their interruption of the way to break the stack memory. Programmer can use to stop in the system state, out of the stack and interrupt stack block, according to the instructions of their reasons for failure to identify the host. Programmable Logic Controller in the repair of this is the most common way to effectively and rapidly.
Interface signal examination: through the use of programmable logic controller to check machine tool control system interface signals and the correct manual and interface signals relative ratio, also found the corresponding point of failure.
Diagnosis of spare parts to replace Law: Most modern CNC system is modular design, divided according to different functions in different modules, with modern technology, the development of the integrated circuit the increasing scale of technology is also more complex, according to conventional methods, it is difficult to fault location to put a very small region, and when the system failure, in order to reduce downtime, we can according to the function module and fault phenomena, the initial judge the possible fault module, with the diagnosis of spare parts to replace it, so can quickly determine the The module has a fault. In the absence of diagnosed cases of spare parts can be used at the scene the same or compatible replacement module inspection, repair of the modern CNC, an increasing number of cases using this method of diagnosis, and then use the spare parts to replace damaged module, allowing the system to normal. The greatest extent possible to reduce downtime, use this method when they are in operation attention must be carried out in the blackout state, but also double-check the PCB version, model, a variety of markers, cross-access it the same as for the machine tool-related data and potentiometer position record should be prepared, should be well marked suture removal.
Use of system self-diagnostic function to determine: a modern CNC system in particular, are full-function NC has a strong ability to self-diagnosis, when the monitoring system through the implementation of the various parts of the job and promptly determine the failure, give the police information, and make corresponding action to avoid the accident. But sometimes when the hardware failure, will not be able to report to the police, and some numerical control system through the LED flashes different frequency or different combinations to make the corresponding instructions, these instructions can be used to help us accurately diagnose faults template. SINUMERIK 8 system such as MS100 CPU board in accordance with the four lights and operation panel FAULT bright lights out combinations can determine fault location.
The above diagnostic methods, in practical applications there is no strict time limits, may be able to use a method of troubleshooting may also require a number of ways at the same time. Its effect depends primarily on the principle of the system and structure of the depth of understanding and grasp, as well as the number of repair experience.
3.2 NC System Fault Analysis
Numerical control system in accordance with the composition, working principle and characteristics, combined with our experience in the repair will be a common phenomenon of fault location and fault analysis are as follows.
(1) This is the position loop control instructions issued by NC system, and position detection system compared to the value of the feedback to further complete the mission control of a key aspect. It has a very high frequency of job and peripherals connected, so prone to failure.
Common fault has: ① digital control loop warning: may be open loop measurements; measurement system damage, internal damage-bit ECU. ② instructions on the hair do not exercise, may be drifting too high, positive feedback, digital control unit breakdown; measurement component damage. ③ measurement component failure, the general performance without feedback value; machine can not return to reference point; high-speed pulse generator when the leak likely cause alarm or read the first grating are dirty; grating broken.
(2) Servo Drive System Servo drive system and power grid, and other associated mechanical systems, but also in the work has been in frequent start-up and running, so this is also part of larger failures.
Its main fault has: ① system damage. General because of the network voltage fluctuations or voltage shocks. Power quality in most areas of China's poor, will bring voltage transfinite machine, especially the moment overrun, such as non-specific voltage monitor, it will be difficult to detect, in the search when the cause of the malfunction, it is necessary to take note, there are Some reasons are because of special damage. Such as a factory in northern China because of lightning in the plant substation and caused many Power Units tools servo system damage. ② no control instructions, the electrical high-speed operation. This failure is due to the speed loop or open-loop positive feedback. Such as a factory in the northeast, the introduction of the Federal Republic of Germany Wotan rotor milling companies in debugging, the machine tool X-axis in the absence of instructions, the high-speed operation, by the analysis that we think are caused by positive feedback. Since the system zero drift, in the case of positive feedback, it will enable the rapid accumulation of motors at a high speed operation, and we check the line after the tag by completely correct, Machine Tool Plant technicians mistake then consider impossible in the full analysis and testing we will Reverse feedback line, the results of machine operating normally. Machine Tool Plant and technical personnel have to admit mistakes in the work of the German side. There is one example, we have a factory in Tianjin, training lectures should be the attitude of the management requirements of their Units from one plant into the plant have not been able to work properly after the repair of precision grinding machines for its failure are: 1 start motor on the machine running, but also a growing the sooner, until the maximum speed. Consider our analysis because of the speed loop are open, the system can not suppress drift caused. The reason is that after inspection line speed feedback received to the online result. ③ processing surface fail, go-for-axis circular interpolation to convex when Units, or electric low-speed crawling, or vibration, such failure is usually because of improper adjust servo system, the system does not gain the same axis or in connection with motor caused by inappropriate matching, the solution is optimized adjustment. ④ blown insurance, or motor overheated and burned, such failures are usually mechanical load is too large or the card die.
(3) part of the power supply system is to maintain a normal job to support the energy part of the failure or failures are caused by direct result of system downtime or damage to the entire system. General in Europe and the United States, relatively few of these questions, in the design considerations in this area much, but in China, because of volatile power supply, poor quality, but also to hide like a high-frequency pulse of this type of interference, plus man-made factors (such as sudden power outages, etc.). These reasons can cause power failure to monitor or damaged. In addition, the numerical control system to run some data, settings data and processing procedures stored in RAM memory in general, the system after power failure, battery backup power supply on or lithium batteries to maintain. Thus, a longer period of downtime, plug the power or memory can cause data loss, the system should not run.
(4) programmable logic controller interface numerical control system logic control,database management, hydraulic start and so on, mainly by the PLC to achieve, it is necessary to the completion of these controls must be collected on the status of the control point information, such as broken electrical , servo valves, lights and so on. Thus it with the outside world a wide range of variety of signal sources and the implementation of components linked to frequent changes, so the possibility of the failure of many more, but also the ever-changing fault type.
(5) other because of environmental conditions, such as interference, temperature, humidity exceed the scope of permit, improper operation, improper parameter settings, but also may result in downtime or failure. One factory has CNC equipment, the boot soon after the loss of NC ready signal, the system can not work, the examination revealed a very high body temperature because the ventilation filters have been blocked, causing the temperature sensor movements, replacement of filters, the system normal job. Not according to rules-swappable circuit boards, with or without protective measures, such as static electricity may cause malfunction or even destruction of system downtime.
General in the numerical control system design, use and repair, we must consider are frequently out of position to give alarm, alarm circuit after the job, on the one hand on the screen or operating panel give the police information, on the other hand the issue of interruption of the protective directive, allowing the system to stop working to identify and repair faults.
3.3 Troubleshooting Method
(1) initialization reset method under normal circumstances, because of the instantaneous system failure alarm, the available hardware reset or switch the system power in order to remove the fault, if the system is down because of storage areas, pluggable circuit board or battery voltage cause confusion, it must be cleared to initialize the system, removing the former should pay attention to make copies of data records, if initialization can not be ruled out after the fault is still, were carried out in hardware diagnosis.
(2) the parameters change, the program is more actual system parameters are determined based on system functions, parameter settings may cause errors on the system failure or a functional null and void. For example, a factory in Harbin rotor milling machine using a measurement of the circulatory system, the functional requirements have a background memory, debugging and found this feature can not be achieved. Examination revealed the background to determine the existence of memory data bit is not set, after setting the normal function. Sometimes, because of procedural errors can be caused by user downtime, which can be used search function block system to inspect and correct all errors, in order to ensure its normal operation.
(3) regulation, adjust the best method of regulation is one of the most simple solution. Potentiometer through regulation, to amend system failures. Such as a factory repair, the system displays the screen of their confusion, as adjusted to normal. A factory in Shandong, the spindle in the start-up and braking skid occurs when a belt because of its large spindle load torque, and drives the ramp-up time setting is too small, the adjusted normal.
Optimization are systematically adjust servo drive system and mechanical system was dragging achieve the best match of the integrated regulation of methods, their approach is very simple, with a multi-line recorder or dual trace storage oscilloscope, respectively, observation of instruction and speed feedback or current feedback response relationship. By regulating the speed regulator proportional coefficient and integral time, to make servo systems that have a higher dynamic response without oscillation of the best working condition. At the scene no oscilloscope or recorder of circumstances, based on experience, that is, adjust so that the electrical start-up, and then slowly adjust to the reverse, until you can eliminate the shock.
(4) replacement spare parts spare parts for the replacement of law with well diagnosed a bad circuit board, and make the corresponding initialization start, so that the normal operation of machine tools quickly, and then repair or rework bad board, which is currently ranked the most commonly used because approach.
(5) to improve the power quality of law is generally regulated power supply used to improve power supply fluctuations. For high-frequency interference filtering capacitor can be used by these preventive measures to reduce the power supply board failure.
(6) maintenance of information-tracking some of the large manufacturing company based on actual work because of design defects caused by accidental failure, have been revising and perfecting the system software or hardware. These changes to the form of constant repair information available to maintenance personnel. Used as the basis for troubleshooting can be completely correct troubleshooting.
3.4 repair should pay attention to matters
(1) removed from the machine on a piece of circuit board, the Record should be noted that their relative position should be to connect its cable for fixed installation of the circuit board, it should be removed before and after the press-fit parts and screws for record purpose. Demolition under the pressure parts and screws should be placed on a dedicated box, so as to avoid loss, the assembly, the box should be all things to use, otherwise the assembly is incomplete.
(2) electric soldering iron should be placed on the front easily, stay away from the circuit board repair. Jerdonii Dressing should be appropriate to meet the integrated circuit welding, and to avoid bumps when welding other components.
(3) measuring the resistance between lines should be broken power supply, measured resistance should be red and black table pen exchange measurements twice a year to a large value for the reference value.
(4) circuit board solder films have mostly brush, so measurements should be to find the corresponding point as the test spot, do not eradicate the solder film, and some board all the brush has the insulating layer, only in the solder joint Department with a blade and scratch - insulating layer.
(5) should not be arbitrarily cut off the printed circuit. Some maintenance personnel have some experience in home appliance repair, custom line check, but the numerical control devices are double-sided circuit board or metal plate of multi-hole plate, printing fine lines and dense, once cut off the hard welding, and easy to cut off tangent when the adjacent line, again some point, a cut off of a line, and should not make it and line out, required a few lines got cut off simultaneously.
(6) should not be components. Some maintenance personnel identifying fault components in the absence of circumstances that only the seat of your pants a component breaks down,immediately, so that a higher rate of miscarriage of justice, of the components removed artificially higher failure rate.
(7) should be used to demolish component suction device and suction tin tin rope, should not have the hardware check. The same heating pad should not be a long time and repeat the demolition to avoid damage to pad.
(8) replacement of the device, the pin should be an appropriate treatment, welding welding should not be used in acidic oil.
(9) Record lines switch, jumper position, it should not be changed. For more than polarization control inspection, or swap components on-board when the attention of all components tag in order to avoid disorder, with the result that a good board should not work also.
(10) investigated the power circuit board configurations and types, according to the required inspection can be powered separately or all of power. Should pay attention to high-pressure, and some direct access to high-voltage circuit board, or board has high-voltage generator, in need of appropriate insulation, should pay special attention to the operation.
4 CNC machine tools boot debugging
CNC machine tools is a high technology machinery and instruments of integration tools, the user to buy a CNC machine tool whether the correct safety boot, debugging is a crucial move. This step is the correct decision in large CNC machine tools that can exert Units normal economic efficiency and service life of its own, which is CNC machine tool manufacturers and users of the factory are very important issues. CNC machine tools boot, debugging the following steps should be carried out.
4.1 prior to the appearance of electricity inspection
(1) Open the machine tool inspection machine appliances electric control box, check the relays, contactors, fuses, servo motor speed control unit socket, the spindle motor speed control unit such as the availability of loose sockets, if loosening should be back to normal state, has locking institutions must be locking connector, adapter box has a machine must check the box on the socket adapter, the availability of loose wiring, has locking bodies must be locked.
(2) CNC electric box to check door open CNC electric box to check all types of socket interface, servo motor feedback line socket, the spindle pulse generator socket, hand pulse generator socket, CRT sockets, etc., if loose to re-plugged, Has locking bodies must be locked. Printed circuit board in accordance with the instructions to check all the settings for the situation of short-circuit terminals must be in line with the machine tool manufacturing plant set up a state, there are incorrect should be re-instated, under normal circumstances do not re-instated, but users must be on the short-circuit terminal settings do a good job in the state of original records.
(3) Quality Inspection inspect all wiring the terminal block. Including the strength of electric machine assembly plant on its own terminal and the electrical wiring of the power cord terminals, each terminal must be used with fastening rotating once, until the use of a rotary screw fixed date, all the electrical sockets must be tightened.
(4) solenoid valve solenoid valve check all hands must be promoted several times in order to prevent a long time is not caused by electricity adverse action, such as abnormal, should be prepared records, to prepare for power after the confirmation be repaired or replaced.
(5) check the check all limit switch limit switch moves the flexible and fixed it firmly and found that the adverse action is not solid or fixed should be addressed immediately.
(6) Operation panel buttons and switches for inspections of the operation panel buttons, switches, wiring lights and found that an error should be dealt with immediately, inspection unit on CRT socket and wiring.
(7) Ground inspection requirements have a good ground wire, ground wire measuring machine, grounding resistance should not greater than 1Ω.
(8) power supply phase sequence check sequence table used to check phase sequence of input power, input power to confirm the phase sequence and machine tool calibration throughout the power phase sequence should be absolutely consistent. Secondary Wiring has the equipment, such as power transformers, the secondary wiring must confirm the consistency of the phase sequence. To ensure that throughout the phase sequence is absolutely correct. Supply voltage to be measured at this time, do a good job records.
4.2 machine connected to the total voltage
(1) the total power supply connected to machine tools, inspection CNC electric box, spindle motor cooling fans, machine tool cooling fan electrical box steering is correct, lubrication, hydraulic oil, etc., as well as signs in the machine tool lighting and whether it is normal, the fuse has no damage, if any abnormal power failure should immediately overhaul, no abnormality can continue.
(2) measurement of the various parts of strong electric voltage, especially for the CNC and servo power unit used in the initial-level voltage transformer and to prepare themselves Record.
(3) to observe whether or not oil spills, especially for the turret to place cards tight, and the shift spindle chuck tight cards, etc. of the hydraulic cylinder and solenoid valve. If oil spills should be immediately repaired or replaced blackout.
Box 4.3 CNC electric power
(1) CNC electricity power button, power supply connected to CNC to observe the CRT display, until the normal screen. If the ALARM display, it should be looking for fault and ruled out at this time should be re-sent to check the electricity.
(2) Open CNC power, in accordance with the relevant information on the test terminal give the location of measurement at all levels of voltage, bias has to be adjusted to a given value, and to prepare themselves Record.
(3) the state of switches placed in appropriate locations, such as Japan FANUC system should be placed in MDI, and choose to go to the page parameter. Bit-by-one by one to check the parameters, these parameters should be consistent with random brought in line with the parameter table. Such as are found inconsistent parameters, should understand the significance of various parameters and then decide whether or not to modify, such as backlash compensation value may be inconsistent with the parameter table, which in the actual processing can be modified at any time.
(4) the state of selector switch placed in the JOG position, will move the speed on the most low-grade, respectively positive and negative direction of the coordinates to move the operation, and simultaneously to move the hand according to the direction of the corresponding super-way protection switch, verify the reliability of its protective role, and then carry out the super-slow-way test, to verify the installation of ultra-way collision block is correct.
(5) will be placed in a state of switch back to zero position, the completion of the operation back to zero, the reference point return movements are not completed will not be able to carry out other operations. In such cases therefore should first carry out this operation, then we will proceed to item (4) operation.
(6) will be placed in a state of switch JOG position or MDI position, manually change file test will verify the minimum spindle speed control switch on the location of the file to the main axis of positive tests, observation of the spindle and the speed of operation show the correctness, and then gradually speed up to the highest speed, to observe the functioning of the stability of the spindle.
(7) manual rail lubrication test, so have a good rail lubrication.
(8) changes gradually shift ultra-fast transfer switch and the feed rate switch, to move the tool carrier at random to observe the correctness of the speed of change.
4.4 MDI test
(1) measuring the actual speed of the spindle lock switch on the machine connected to the location, using manual data entry instructions, carry out arbitrary variable spindle files, variable-speed test, measuring the actual spindle speed, spindle speed and observe the displayed value, adjust its error should be limited to within 5%.
(2) conducted or knife Block turret election knife test its purpose is to examine the knife block, or are, inversion and the correctness of positioning accuracy.
(3) function tests in accordance with the order situation is different, different functions can be made under the specific circumstances of each functional test. To prevent accidents from happening, the best first test machine is locked, and then open up a pilot machine.
(4) EDIT function tests will be placed in a state of EDIT selector switch position, to produce one easy process, as much as possible, including various functions and auxiliary functions of command instructions, mobile dimension to the largest machine tool stroke is limited, the procedure at the same time increase delete and modify.
(5) the state of the tests will be automatically locked machine, with the preparation of operating procedures and air test, to verify the correctness of the procedure, and then open up machine tools, feed rate, respectively, switches, ultra-fast transfer switch, spindle speed overshoot many switch kinds of changes in machine tool switches in the above circumstances a variety of changes in full operation, after the overshoot at switch 100% office to enable the full operation of machine tools to observe the work of the whole are normal.
At this point, a numerical control machine tool to be finished debugging boot.
5 After the repair debug technology deal
At the scene after the repair, maintenance records should be carefully filled out a list of essential spare parts list, set up user profiles for the failure time, the phenomenon of diagnostic methods, the use of scheduling methods so that if there should be a detailed record of the remaining issues, such not only for each fault are well documented, but also the accumulation of repair experience.
Above repair techniques for numerical control system as described in nearly a hundred years we are the number of control system debugging and maintenance experience. Although a wide range of numerical control system, fault is ever changing methods of repair are not the same, it is difficult to make a short reference, but we still wish to put some of the basic methods and ideas to write out, and everyone can communicate with a view to raise awareness of CNC system emphasis on repair techniques, repair techniques and results of the direct purpose is to enable the numerical control system to resume normal operation, thus ensuring the smooth progress of production. At present, numerical control technology in our country is rapidly infiltrate to the industrial sector, with the development of electronic technology, numerical control technology in the national economy also increases, then for an important component of the CNC Technology - CNC System repair techniques should also adapt quickly to the rapid development of numerical control technology requirements, as a numerical control system maintenance and technical personnel, they should be constantly learning and mastering new knowledge and technology, looking for a new diagnosis of repair methods and means to promote a few control system repair technology development and make due contributions.
How to fix CNC machine tools, CNC repair experience
CNC machine tools are well-known contemporary high-tech machines, electricity, light, gas integration of the crystallization of complex electrical, pipe cross-proliferation of all kinds of NC system, products from the 70's to 90's, are not interchangeable, fault is the strange phenomenon, different, especially for large, heavy-duty CNC machine tools, which is very expensive, about several million dollars each, the installation time to adjust length (l a few months to over a year). Large-scale NC machine tools, there are hundreds of thousands of components, if one of has has a component failure will cause the abnormal phenomenon of machine tools, as well as wire connections, the pipe coupling with each other, it will neglect the problem, In addition, large, heavy-duty CNC machine tools are huge in size and in the absence of plants under conditions of constant temperature use, environmental impact can easily lead to failure. To this end, the NC machine tool, "difficult to repair" the problem on the U.S. before.
The introduction and manufacturing of our country for so many of CNC machine tools, how to quickly identify the failures, dangers, and promptly ruled out of? How can repair these expensive equipment? First of all, in my opinion to have a high degree of responsibility and the spirit of fearing no difficulties; Second, we must strive to master digital technology, contact my CNC machine tool repair for more than a decade of practice, in my opinion to watch many, many ask, many in mind that many thought practicing (over 5), and gradually improve their own technical standards and repair capabilities, to adapt to a variety of more complex situation, to solve difficult problems, repair of CNC machine tools.
First, it is necessary to watch many
1. To watch many of NC data
Many look to, to understand a variety of numerical control system and PLC programmable logic controller of features and functions; To learn more about CNC system alarm and troubleshooting; To learn more about NC, PLC machine parameter settings meaning; To learn more about PLC's programming language; To learn more about NC programming methods; to understand control panel operation and the contents of the menu; to understand and take the knife spindle motor drive performance and characteristics and so on, often a lot of numerical control information, look how? In my opinion we should give prominence to the main focus, to understand the origin and development, focusing on a thorough grasp of numerical control system are the basic composition and structure, master block diagram. The rest can "tour" and read, but every part of the contents must be focused on understanding, grasp. Because of numerical control system is a complex internal circuit diagram, and manufacturers do not provide. Therefore there is no need to find out in detail. Such as NX 1 154 five axis machine tools even the rotor blades using A 1 B10 system, we should focus on understanding the role of each part, the board's function, the destination interface, LED lights, such as the meaning. Now many models of CNC system, faster updates, different factories, different models often vary widely. To learn more about their similarities and individuality (uniqueness). Generally familiar with the CNC system SIEMENS repair person will not necessarily rule out the A-B skilled system failure, therefore, it is necessary to watch many, and constantly learning, updating our knowledge.
2. To watch many electrical diagram, electrical diagram digestion
For each electrical component, such as: contactors, relays, time relays, etc., as well as PLC input and output, to indicate electrical diagram 11. Let me give a simple example, such as 1A1 start for hydraulic pump motor contactor 1M generally in Fig bet its normally open, normally closed contacts of the future. Therefore, its corresponding page in a normally open or normally closed contacts 1A1, specify the content for the hydraulic pump motor to open for large-scale NC machine tool has dozens of electrical map pages, or even hundreds of pages. To understand that the function of each component should be of a very long time. Sometimes, one, the second look may also not sure the role of the components, it is necessary to watch and so many after the digestion and then write. Therefore, the startup has also mentioned that the hydraulic pump motor 1M, should also be clearly marked PLC of which are outside the output contactor Driven 1A1 action, to do the whole story, clearly. Electrical circuit diagram of some of the block diagram, such as the drive for each axis, only a block diagram, as long as the understanding of a certain control conditions (on-off situation), for detailed time and other things such as further study and consider. Individual countries are not the same as electrical symbols, they must first clearly understand. Factory prepared for the thick layer of several PLC STL, but also many look to master its programming language, in the read on the basis of Chinese Notes. This can be reduced substantially after the troubleshooting time, and if such failure happened again to become familiar with the electrical diagram, PLC STL, it is bound to cost a lot of time and often lead to wrong judgments.
3. To watch many hydraulic, pneumatic diagram, and depth of digestion
CNC machine tools for mechanical milling machine, hydraulic, pneumatic diagram, it is necessary to clarify its role and context. And 11 in the drawings indicate, such as Germany COBURG CNC gantry milling attachment, tool installation more complex, it is necessary to break down their plans, such as locking tool which moves the solenoid valve? Corresponding PLC exports, imports which are? Stated in the chart, so that the electrical to the mechanical action from the one pole in the end, while particular machines, electric part relatively close to the focus of understanding, such as Italian INNSE CNC Boring Milling Machine using electro-hydraulic proportional valve technology, we should focus on understanding its role and function, in particular, to understand and adjust adjust its data, static and dynamic when the proportional valve current and the corresponding equilibrium pressure pump, knows also understand electric machines, mechanical and electrical integration, have a variety of skills, such problem-solving skills on larger.
4. To watch many foreign languages, it is necessary to improve their professional ability of foreign language reading
Do not know foreign languages, especially English. Will not be able to read a large number of foreign technical information, simply relying on the translation, often are not very satisfactory. Watch foreign-language version of the technical information, the beginning of relatively difficult vocabulary many, many more look in mind, the commonly used word professional is the only way many future looks smooth, and a competent maintenance personnel to the basic tools to master the language.
Second, it is necessary to ask many
1. To ask many foreign experts
If you have training opportunities abroad or foreign experts to come to your factory installation and debugging tools, you'd better have the opportunity to participate. This is a best opportunity to study, because a large number of first-hand access to information and method of debugging tools and techniques. Such as in laser precision determination of the axis, the electric how to approach such an amendment. To many question, do not have to find out. Through this period of time will be of great benefit, be able to get a lot of internal information and manual (the user is confidential). When the machine into formal production, should also be frequent contacts with foreign experts maintain close ties. Through FAX, E-MALL, asked whether the problems were resolved Machine Fault further solutions and related information, can also be a special, special spare parts, which are very useful, while the CNC system agents, such as SIEMENS, FANUC, etc. Companies should also maintain good relations, many asked, could also be timely step in the numerical control system of deep information and related spare parts, also have the opportunity to participate in the NC system thematic study classes.
2. Malfunction, the master asked the operator to the failure of the entire process, and will not question, or just look like a question, so often fail to get the correct information at the scene will cause wrong judgments, so that complicating the issue, Therefore, in order to ask many, that question in detail and understand the entire process of fault occurred (beginning, middle, end), resulting in what the police number, then what components to operate, come across what to turn over what and how the external environment? To fully investigate the scene gain first-hand material on the basis of questions put fault correctly listed, in fact has solved half the problem, then analyze the solution for the experienced and skilled master operator, they are familiar with machine operator and processing procedures are familiar with, machine tools is very common understanding, close cooperation with them, for rapid troubleshooting very favorable.
3. To ask many other maintenance staff
When the other maintenance staff in the maintenance of machine tools, and you do not go when they came back, many should also ask, just what happened wrong? Is how to exclude him? Asked him to rule out the introduction of its methods. This is also a good learning opportunities. Others studying the correct troubleshooting skills and methods, in particular, to repair the old, experienced staff study,put their skills to improve their knowledge and standards.
Three, it is necessary to remember many
1. To record the various parameters)
Record machine adjust the focus after a good variety of parameters, such as NC machine tool parameters, PLC machine parameter, PLC program (more than the existence of disks), as well as the spindle and the tool motor current, voltage, speed and other data. Would also like to note the electric cabinet relays, contactors, such as in processing power and formal status (pull-in or disconnected) and the PLC for all input and output state of light-emitting diode LED (light dark, shining) or record the screen PLC state of IB (input bit), QB (output bit) is 0 or 1, such as IB1 =: 00000001, that is, I1.0 = 1, I1.1-1.7 = 0. This record for later analysis to determine the benefits of a great fault. Such as Germany SCHIESS happen CNC Vertical Lathe Z axis motor current relay action, we check the Z-axis motor normal working hours of the PLC state (0,1) and non-normal compared to the situation quickly find the cause of the malfunction, because one has Comparing the state of not only the relay, through adjustment, failure to immediately rule out the possibility.
2. To Record hydraulic, pneumatic state
Record same hydraulic, pneumatic or not in the formal processing of processing all kinds of pressure gauge, barometer pressure, the suction solenoid valve fault state, which adjust to judge is also a great help. Such as the United States keep out INGERSOLL OPENsIDE MASTERHEAD CNC milling machine hydrostatic dual-film technology, has more than 100 pressure measurement points, its high and low pressure machine features a direct impact on the normal action or not, the record of static and dynamic pressure is very important.
3. Carry a notebook, put the failures happen every day, how to exclude the process of record each and every human brain has been a long time easy to forget that "good memory, it is better written rotten," the benefits of a great record. CNC machine tools we have found some fault will often repeated, but always a few failures, as long as the check was how to resolve, and a few minutes troubleshooting, fast and good. Our company has a "running diary of CNC machine tools" and a "CNC machine tools ranked it the Record" to record information on these two, this is a CNC machine tools complete archives.
Fourth, it is necessary to think of many
1. To think of many, it is necessary to broaden our horizons
Often sometimes repair is not calm, not a good analysis, go to a dead end. COBURG remember that Y-axis gantry milling in the processing of a sudden shutdown, the screen on several occasions appeared dirty 1361Y-axis grating alarm, when we clean things Grating and grating the first 2 times and the results or downtime. Of a few days yet to be resolved, and finally found the real reason is because the Y-axis grating head to the wire between the amplifier EXE have questions, because Y-axis movement of long-term snakeskin tube bending, one of a position feedback lines well, to a certain location of the fracture caused by machine downtime. At that time, we only pay attention to static, neglecting the dynamics of 1321, there were once open-loop control police, but did not cause us enough attention. Therefore, we should put what happened alarm, fault conditions list them all, through, judge and integrated screening, prediction of the greatest possibility of failure, and then take actions to remove. "Exhausted suspect a blind alley and prospect", many think, give you a clear direction.
2. To think of many, it is necessary to know
Often when we are troubleshooting, and sometimes not find the real reasons for failure, after the failures continued to occur. Ingersoll remember to cotyledon root groove milling machine, spindle Sl happened 2 hours after the operation of "automatic stop" the failure of foreign experts at the time the order for a piece of board, seems to solve the problems, but after more than a month after they committed In other words, the order of a prepared plate or board, but did not find out the reasons for its damage. We have carefully inspected through the use of oscilloscopes and found that the "start" command the corresponding optocoupler particularly high anti-peak voltage, the addition of a separate grounding line, and its anti-optocoupler greatly reduced peak voltage, Since then, there have been no "automatic stop" failures, the reasons are because of the anti-peak voltage is too high, after a long time to optocoupler due to the gradual failure.
3. To think of many consider to be one step ahead
According to the frequency of failures happen, repeatability, life expectancy of electrical machinery, spare parts do a good job seriously. This is the machine to ensure continuous, the normal operation of an important job, non-do not. At the same time, some devices, as time delayed, eliminated, the market has been unable to buy tickets or buy very expensive, how do? Prior considerations, such as have a early 80's CNC machine tools used in photoelectric readers read with LOOP way into the processing procedures, may also use the opt-SPOOL way the original tapes (machine settings data), the event does not get sent, then the entire machines will become "dead" machine, with very serious consequences, because we are one step ahead to consider, in cooperation with relevant units, after numerous tests, using a floppy disk processor solves this problem to ensure that the machines can use so far. Many think, it is necessary to consider in advance, give leadership to rationalize the proposals, efforts to improve the external environment for CNC machine tools, from the temperature, dust, humidity, etc. want to approach several aspects, the use of retro-power voltage regulator, the installation of electric air-conditioning cabinets small house and other measures to enable the machine tool failure greatly reduced.
Friday, it is necessary to train many, that is, the practice of many:
1. To the practice of many, should have the courage to do, good hands
For maintenance personnel who will have to bold but cautious, we must dare to do, it will only talk about, not his fists, not CNC machine tool repair. However, the situation should be cooked no longer do, do not blindly, or else they will expand the fault, resulting in accidents, the consequences would be unthinkable. At the same time we still have good hands, first of all to familiar with the machine tool on the machine operation panel and the contents of the menu and do a good job operating ease, because the various models and system operation are the same. At the same time must also take full advantage of self-diagnosis of CNC machine tool technology to quickly solve the fault treatment. CNC technology is now more developed, it has since more and more consultation capacity. 1 A system such as B10, have special diagnostic software, Internet diagnostics.
2. To many practices, develop their own practical ability and mastery of experimental skills
Fault sometimes seem very vague, are hard to mechanical failure or electrical fault, such as gantry milling COBURG such a fault happened, which means that the Z-axis, whether to increase or to decrease, Z-axis ram always down and alarm. We have adopted a "separation of law", the electrical part of the control and completely separated from the original circuit, the Z-axis DC motor terminals on the line removed, and the other pass DC (220V power supply can communicate through the regulator, after four rectifier diodes give) received the electrical two-terminal and found that motor in accordance with the polarity of the DC transform change the rotation direction, remove the electrical fault, re-examination revealed that films are playing because of mechanical friction caused by ptosis pillow. There are a lot of other methods, such as "isolation method", "displacement method", "contrast", "percussion Act" and other methods can be used as an effective means to help us find and remove faults.
3. To many practice and learn the use of the device
Such as oscilloscope, multimeter, on-line detector circuit, short circuit tester, computer, programming, etc. can help us determine the specific circuit, inspection, in particular the PLC programmer, computer, it is necessary to skillfully use, be free to import, export machine parameters online test on the state, such as system initialization. This analysis of failures, especially for complex fault, has a lot to help solve the problem.
4. To many practices, the "small改小reforming"
Often happen in the normal work of a particular component damage (such as choice of switches, buttons, relays, etc.) and no spare parts, they do as far as possible, stick with the legitimate use of such means as the repair or temporary special ways in which machine tools can continue to work , to wait until after the restoration of spare parts. VDF CNC carts such as Germany's No. 2 in the Blade has five clamping pressure with micro-switch, one of two micro-switches accidentally damaged, no spare parts, we have adopted a "short connection" so that the touch pressure switch point in line with the PLC input conditions for the machine tool is not the normal work of the police can go on. Sometimes long after the use of machinery, worse positioning accuracy, positioning alarms generated in the machine tool can not re-adjust the circumstances under which a temporary amendment to machine parameters, to increase "tolerance" zone, so that it can work properly, in a word, such an approach also much.
5. To the practice of many, it is necessary to do-it-yourself repair board
CNC machine tools in general the reliability of the circuit board, and the failure rate is extremely low, go check the CNC machine tools in general, do not question the board first suspected. Such as the Siemens 850 system, sometimes 41NC-CPU alarm or 43PLC-CPU alarm, not the board has in fact a fault can be removed Stubbs Law, NC initialization methods such as hot and cold start the PLC can generally be excluded from trial and error. If indeed proved to be circuit board problem, it is necessary to make repairs. These plates (usually without the drawings) is expensive, there are generally a few thousand dollars ─ few million, for each enterprise "hard parts", the price too expensive, preparedness can not afford, so CNC machine tools is extremely good or bad circuit board important, once the circuit board without damage to spare parts, at other times, they repair bad shutdown is bound to seriously affect production. Sometimes only a very small circuit board failures, as long as careful inspection, it is not difficult to discover problems, we have repeatedly found that individual capacitor leakage, board, short-circuit fault, etc., some more complex circuit board failure, but as long as time, through inspection instruments, or be able to repaired; but there are some circuit boards in serious condition, especially the large-scale integrated circuits, maintenance difficulties, coupled with the original device no spare parts, can only be prepared in advance to buy board or send out repair. Do-It-Yourself repair board, has a great advantage, on the one hand, enterprises can reduce costs and solve the immediate needs, on the other hand, "Anatomy of Sparrows" familiar with the electronic circuit, develop their own analysis and practical ability is very useful.
Through the repair more than a decade of practice, we are foreigners designed CNC machine tools, especially large-scale NC machine tools are not perfect, there are also many problems and shortcomings. Through our study of NC machine tools, and deepen, to find out where the problem is one of boldly to improve on some issues, and achieved good results. VDF CNC carts such as Germany, the original design of two hydrostatic power bracket on one job, hydrostatic pump continuous operation, so that also charges electric pump also shortens the life span of imports. We modified PLC, an increase of two switches, only dozens of yuan, so that hydrostatic two brackets can be arbitrarily open or stopped, so that imports of extended pump life, a full year saving more than 20,000 degrees. Ingersoll Milling impeller shafts are the original design, the main head and deputy head only reverse milling, milling in the same direction without. High and medium pressure in the processing section 20 impeller rotor, the impeller because of the distance between the small and should not reverse milling, it can only be a first for processing. Through our research, subtly altering the limit two-way connection, an increase of PLC program, the result of almost no money, to achieve the same milling. 2 heads are now available at the same time processing, improve efficiency doubled, advanced 3 ─ 4 days processing rotor task. Therefore, we should further tap the potential of CNC machine tools, and better exert its power for the production of services.
Despite the numerical control machine tool fault complex, ever-changing, as long as we take seriously and cultivate a high-quality repair of mechanical and electrical integration team, look through the many, many ask, many thought, many training and accumulated experience and repair techniques, together, we must be able to rely mainly on their own strength, the CNC machine tool repair and make good use of, possession of a good.
The introduction and manufacturing of our country for so many of CNC machine tools, how to quickly identify the failures, dangers, and promptly ruled out of? How can repair these expensive equipment? First of all, in my opinion to have a high degree of responsibility and the spirit of fearing no difficulties; Second, we must strive to master digital technology, contact my CNC machine tool repair for more than a decade of practice, in my opinion to watch many, many ask, many in mind that many thought practicing (over 5), and gradually improve their own technical standards and repair capabilities, to adapt to a variety of more complex situation, to solve difficult problems, repair of CNC machine tools.
First, it is necessary to watch many
1. To watch many of NC data
Many look to, to understand a variety of numerical control system and PLC programmable logic controller of features and functions; To learn more about CNC system alarm and troubleshooting; To learn more about NC, PLC machine parameter settings meaning; To learn more about PLC's programming language; To learn more about NC programming methods; to understand control panel operation and the contents of the menu; to understand and take the knife spindle motor drive performance and characteristics and so on, often a lot of numerical control information, look how? In my opinion we should give prominence to the main focus, to understand the origin and development, focusing on a thorough grasp of numerical control system are the basic composition and structure, master block diagram. The rest can "tour" and read, but every part of the contents must be focused on understanding, grasp. Because of numerical control system is a complex internal circuit diagram, and manufacturers do not provide. Therefore there is no need to find out in detail. Such as NX 1 154 five axis machine tools even the rotor blades using A 1 B10 system, we should focus on understanding the role of each part, the board's function, the destination interface, LED lights, such as the meaning. Now many models of CNC system, faster updates, different factories, different models often vary widely. To learn more about their similarities and individuality (uniqueness). Generally familiar with the CNC system SIEMENS repair person will not necessarily rule out the A-B skilled system failure, therefore, it is necessary to watch many, and constantly learning, updating our knowledge.
2. To watch many electrical diagram, electrical diagram digestion
For each electrical component, such as: contactors, relays, time relays, etc., as well as PLC input and output, to indicate electrical diagram 11. Let me give a simple example, such as 1A1 start for hydraulic pump motor contactor 1M generally in Fig bet its normally open, normally closed contacts of the future. Therefore, its corresponding page in a normally open or normally closed contacts 1A1, specify the content for the hydraulic pump motor to open for large-scale NC machine tool has dozens of electrical map pages, or even hundreds of pages. To understand that the function of each component should be of a very long time. Sometimes, one, the second look may also not sure the role of the components, it is necessary to watch and so many after the digestion and then write. Therefore, the startup has also mentioned that the hydraulic pump motor 1M, should also be clearly marked PLC of which are outside the output contactor Driven 1A1 action, to do the whole story, clearly. Electrical circuit diagram of some of the block diagram, such as the drive for each axis, only a block diagram, as long as the understanding of a certain control conditions (on-off situation), for detailed time and other things such as further study and consider. Individual countries are not the same as electrical symbols, they must first clearly understand. Factory prepared for the thick layer of several PLC STL, but also many look to master its programming language, in the read on the basis of Chinese Notes. This can be reduced substantially after the troubleshooting time, and if such failure happened again to become familiar with the electrical diagram, PLC STL, it is bound to cost a lot of time and often lead to wrong judgments.
3. To watch many hydraulic, pneumatic diagram, and depth of digestion
CNC machine tools for mechanical milling machine, hydraulic, pneumatic diagram, it is necessary to clarify its role and context. And 11 in the drawings indicate, such as Germany COBURG CNC gantry milling attachment, tool installation more complex, it is necessary to break down their plans, such as locking tool which moves the solenoid valve? Corresponding PLC exports, imports which are? Stated in the chart, so that the electrical to the mechanical action from the one pole in the end, while particular machines, electric part relatively close to the focus of understanding, such as Italian INNSE CNC Boring Milling Machine using electro-hydraulic proportional valve technology, we should focus on understanding its role and function, in particular, to understand and adjust adjust its data, static and dynamic when the proportional valve current and the corresponding equilibrium pressure pump, knows also understand electric machines, mechanical and electrical integration, have a variety of skills, such problem-solving skills on larger.
4. To watch many foreign languages, it is necessary to improve their professional ability of foreign language reading
Do not know foreign languages, especially English. Will not be able to read a large number of foreign technical information, simply relying on the translation, often are not very satisfactory. Watch foreign-language version of the technical information, the beginning of relatively difficult vocabulary many, many more look in mind, the commonly used word professional is the only way many future looks smooth, and a competent maintenance personnel to the basic tools to master the language.
Second, it is necessary to ask many
1. To ask many foreign experts
If you have training opportunities abroad or foreign experts to come to your factory installation and debugging tools, you'd better have the opportunity to participate. This is a best opportunity to study, because a large number of first-hand access to information and method of debugging tools and techniques. Such as in laser precision determination of the axis, the electric how to approach such an amendment. To many question, do not have to find out. Through this period of time will be of great benefit, be able to get a lot of internal information and manual (the user is confidential). When the machine into formal production, should also be frequent contacts with foreign experts maintain close ties. Through FAX, E-MALL, asked whether the problems were resolved Machine Fault further solutions and related information, can also be a special, special spare parts, which are very useful, while the CNC system agents, such as SIEMENS, FANUC, etc. Companies should also maintain good relations, many asked, could also be timely step in the numerical control system of deep information and related spare parts, also have the opportunity to participate in the NC system thematic study classes.
2. Malfunction, the master asked the operator to the failure of the entire process, and will not question, or just look like a question, so often fail to get the correct information at the scene will cause wrong judgments, so that complicating the issue, Therefore, in order to ask many, that question in detail and understand the entire process of fault occurred (beginning, middle, end), resulting in what the police number, then what components to operate, come across what to turn over what and how the external environment? To fully investigate the scene gain first-hand material on the basis of questions put fault correctly listed, in fact has solved half the problem, then analyze the solution for the experienced and skilled master operator, they are familiar with machine operator and processing procedures are familiar with, machine tools is very common understanding, close cooperation with them, for rapid troubleshooting very favorable.
3. To ask many other maintenance staff
When the other maintenance staff in the maintenance of machine tools, and you do not go when they came back, many should also ask, just what happened wrong? Is how to exclude him? Asked him to rule out the introduction of its methods. This is also a good learning opportunities. Others studying the correct troubleshooting skills and methods, in particular, to repair the old, experienced staff study,put their skills to improve their knowledge and standards.
Three, it is necessary to remember many
1. To record the various parameters)
Record machine adjust the focus after a good variety of parameters, such as NC machine tool parameters, PLC machine parameter, PLC program (more than the existence of disks), as well as the spindle and the tool motor current, voltage, speed and other data. Would also like to note the electric cabinet relays, contactors, such as in processing power and formal status (pull-in or disconnected) and the PLC for all input and output state of light-emitting diode LED (light dark, shining) or record the screen PLC state of IB (input bit), QB (output bit) is 0 or 1, such as IB1 =: 00000001, that is, I1.0 = 1, I1.1-1.7 = 0. This record for later analysis to determine the benefits of a great fault. Such as Germany SCHIESS happen CNC Vertical Lathe Z axis motor current relay action, we check the Z-axis motor normal working hours of the PLC state (0,1) and non-normal compared to the situation quickly find the cause of the malfunction, because one has Comparing the state of not only the relay, through adjustment, failure to immediately rule out the possibility.
2. To Record hydraulic, pneumatic state
Record same hydraulic, pneumatic or not in the formal processing of processing all kinds of pressure gauge, barometer pressure, the suction solenoid valve fault state, which adjust to judge is also a great help. Such as the United States keep out INGERSOLL OPENsIDE MASTERHEAD CNC milling machine hydrostatic dual-film technology, has more than 100 pressure measurement points, its high and low pressure machine features a direct impact on the normal action or not, the record of static and dynamic pressure is very important.
3. Carry a notebook, put the failures happen every day, how to exclude the process of record each and every human brain has been a long time easy to forget that "good memory, it is better written rotten," the benefits of a great record. CNC machine tools we have found some fault will often repeated, but always a few failures, as long as the check was how to resolve, and a few minutes troubleshooting, fast and good. Our company has a "running diary of CNC machine tools" and a "CNC machine tools ranked it the Record" to record information on these two, this is a CNC machine tools complete archives.
Fourth, it is necessary to think of many
1. To think of many, it is necessary to broaden our horizons
Often sometimes repair is not calm, not a good analysis, go to a dead end. COBURG remember that Y-axis gantry milling in the processing of a sudden shutdown, the screen on several occasions appeared dirty 1361Y-axis grating alarm, when we clean things Grating and grating the first 2 times and the results or downtime. Of a few days yet to be resolved, and finally found the real reason is because the Y-axis grating head to the wire between the amplifier EXE have questions, because Y-axis movement of long-term snakeskin tube bending, one of a position feedback lines well, to a certain location of the fracture caused by machine downtime. At that time, we only pay attention to static, neglecting the dynamics of 1321, there were once open-loop control police, but did not cause us enough attention. Therefore, we should put what happened alarm, fault conditions list them all, through, judge and integrated screening, prediction of the greatest possibility of failure, and then take actions to remove. "Exhausted suspect a blind alley and prospect", many think, give you a clear direction.
2. To think of many, it is necessary to know
Often when we are troubleshooting, and sometimes not find the real reasons for failure, after the failures continued to occur. Ingersoll remember to cotyledon root groove milling machine, spindle Sl happened 2 hours after the operation of "automatic stop" the failure of foreign experts at the time the order for a piece of board, seems to solve the problems, but after more than a month after they committed In other words, the order of a prepared plate or board, but did not find out the reasons for its damage. We have carefully inspected through the use of oscilloscopes and found that the "start" command the corresponding optocoupler particularly high anti-peak voltage, the addition of a separate grounding line, and its anti-optocoupler greatly reduced peak voltage, Since then, there have been no "automatic stop" failures, the reasons are because of the anti-peak voltage is too high, after a long time to optocoupler due to the gradual failure.
3. To think of many consider to be one step ahead
According to the frequency of failures happen, repeatability, life expectancy of electrical machinery, spare parts do a good job seriously. This is the machine to ensure continuous, the normal operation of an important job, non-do not. At the same time, some devices, as time delayed, eliminated, the market has been unable to buy tickets or buy very expensive, how do? Prior considerations, such as have a early 80's CNC machine tools used in photoelectric readers read with LOOP way into the processing procedures, may also use the opt-SPOOL way the original tapes (machine settings data), the event does not get sent, then the entire machines will become "dead" machine, with very serious consequences, because we are one step ahead to consider, in cooperation with relevant units, after numerous tests, using a floppy disk processor solves this problem to ensure that the machines can use so far. Many think, it is necessary to consider in advance, give leadership to rationalize the proposals, efforts to improve the external environment for CNC machine tools, from the temperature, dust, humidity, etc. want to approach several aspects, the use of retro-power voltage regulator, the installation of electric air-conditioning cabinets small house and other measures to enable the machine tool failure greatly reduced.
Friday, it is necessary to train many, that is, the practice of many:
1. To the practice of many, should have the courage to do, good hands
For maintenance personnel who will have to bold but cautious, we must dare to do, it will only talk about, not his fists, not CNC machine tool repair. However, the situation should be cooked no longer do, do not blindly, or else they will expand the fault, resulting in accidents, the consequences would be unthinkable. At the same time we still have good hands, first of all to familiar with the machine tool on the machine operation panel and the contents of the menu and do a good job operating ease, because the various models and system operation are the same. At the same time must also take full advantage of self-diagnosis of CNC machine tool technology to quickly solve the fault treatment. CNC technology is now more developed, it has since more and more consultation capacity. 1 A system such as B10, have special diagnostic software, Internet diagnostics.
2. To many practices, develop their own practical ability and mastery of experimental skills
Fault sometimes seem very vague, are hard to mechanical failure or electrical fault, such as gantry milling COBURG such a fault happened, which means that the Z-axis, whether to increase or to decrease, Z-axis ram always down and alarm. We have adopted a "separation of law", the electrical part of the control and completely separated from the original circuit, the Z-axis DC motor terminals on the line removed, and the other pass DC (220V power supply can communicate through the regulator, after four rectifier diodes give) received the electrical two-terminal and found that motor in accordance with the polarity of the DC transform change the rotation direction, remove the electrical fault, re-examination revealed that films are playing because of mechanical friction caused by ptosis pillow. There are a lot of other methods, such as "isolation method", "displacement method", "contrast", "percussion Act" and other methods can be used as an effective means to help us find and remove faults.
3. To many practice and learn the use of the device
Such as oscilloscope, multimeter, on-line detector circuit, short circuit tester, computer, programming, etc. can help us determine the specific circuit, inspection, in particular the PLC programmer, computer, it is necessary to skillfully use, be free to import, export machine parameters online test on the state, such as system initialization. This analysis of failures, especially for complex fault, has a lot to help solve the problem.
4. To many practices, the "small改小reforming"
Often happen in the normal work of a particular component damage (such as choice of switches, buttons, relays, etc.) and no spare parts, they do as far as possible, stick with the legitimate use of such means as the repair or temporary special ways in which machine tools can continue to work , to wait until after the restoration of spare parts. VDF CNC carts such as Germany's No. 2 in the Blade has five clamping pressure with micro-switch, one of two micro-switches accidentally damaged, no spare parts, we have adopted a "short connection" so that the touch pressure switch point in line with the PLC input conditions for the machine tool is not the normal work of the police can go on. Sometimes long after the use of machinery, worse positioning accuracy, positioning alarms generated in the machine tool can not re-adjust the circumstances under which a temporary amendment to machine parameters, to increase "tolerance" zone, so that it can work properly, in a word, such an approach also much.
5. To the practice of many, it is necessary to do-it-yourself repair board
CNC machine tools in general the reliability of the circuit board, and the failure rate is extremely low, go check the CNC machine tools in general, do not question the board first suspected. Such as the Siemens 850 system, sometimes 41NC-CPU alarm or 43PLC-CPU alarm, not the board has in fact a fault can be removed Stubbs Law, NC initialization methods such as hot and cold start the PLC can generally be excluded from trial and error. If indeed proved to be circuit board problem, it is necessary to make repairs. These plates (usually without the drawings) is expensive, there are generally a few thousand dollars ─ few million, for each enterprise "hard parts", the price too expensive, preparedness can not afford, so CNC machine tools is extremely good or bad circuit board important, once the circuit board without damage to spare parts, at other times, they repair bad shutdown is bound to seriously affect production. Sometimes only a very small circuit board failures, as long as careful inspection, it is not difficult to discover problems, we have repeatedly found that individual capacitor leakage, board, short-circuit fault, etc., some more complex circuit board failure, but as long as time, through inspection instruments, or be able to repaired; but there are some circuit boards in serious condition, especially the large-scale integrated circuits, maintenance difficulties, coupled with the original device no spare parts, can only be prepared in advance to buy board or send out repair. Do-It-Yourself repair board, has a great advantage, on the one hand, enterprises can reduce costs and solve the immediate needs, on the other hand, "Anatomy of Sparrows" familiar with the electronic circuit, develop their own analysis and practical ability is very useful.
Through the repair more than a decade of practice, we are foreigners designed CNC machine tools, especially large-scale NC machine tools are not perfect, there are also many problems and shortcomings. Through our study of NC machine tools, and deepen, to find out where the problem is one of boldly to improve on some issues, and achieved good results. VDF CNC carts such as Germany, the original design of two hydrostatic power bracket on one job, hydrostatic pump continuous operation, so that also charges electric pump also shortens the life span of imports. We modified PLC, an increase of two switches, only dozens of yuan, so that hydrostatic two brackets can be arbitrarily open or stopped, so that imports of extended pump life, a full year saving more than 20,000 degrees. Ingersoll Milling impeller shafts are the original design, the main head and deputy head only reverse milling, milling in the same direction without. High and medium pressure in the processing section 20 impeller rotor, the impeller because of the distance between the small and should not reverse milling, it can only be a first for processing. Through our research, subtly altering the limit two-way connection, an increase of PLC program, the result of almost no money, to achieve the same milling. 2 heads are now available at the same time processing, improve efficiency doubled, advanced 3 ─ 4 days processing rotor task. Therefore, we should further tap the potential of CNC machine tools, and better exert its power for the production of services.
Despite the numerical control machine tool fault complex, ever-changing, as long as we take seriously and cultivate a high-quality repair of mechanical and electrical integration team, look through the many, many ask, many thought, many training and accumulated experience and repair techniques, together, we must be able to rely mainly on their own strength, the CNC machine tool repair and make good use of, possession of a good.
CNC repair three-step method
1, power supply circuit
In the maintenance of power supply circuit should first check whether it is normal, and then check the other parts. Power failure has the following forms:
(1) No supply voltage or supply voltage low
CNC system often used ± 5V, ± 12V, ± 15V, ± 24V, using a small number of +3.3 V. The supply voltage is not normal, that is, the system will cause abnormal job. Of emergency equipment, causing equipment and personnel injury, must pay great attention to. Machining center, after boot without any CRT display. Detection system using a multimeter power board A14B - 0067 - B002 - 01, found +5 V power supply voltage of 3.75V, remove the load detection, +5 V power supply for the +4.95 V. Note the low power supply with load capacity or load short-circuit has existence. After checking the normal load. Note decline in power supply with load capacity. After inspection the replacement filter capacitor C36, the system work properly. Tool-free action. Turn off the power supply, power back on, machine tools can work in a period of time. Check all the normal power supply. Fault may be in the system's motherboard. After overhaul motherboard A16B-1000-0220/04A, found two crystal an internal crystal oscillator 16.3840MHz bad, have not replaced the use of the recurrence of similar failures.
(2) power supply voltage detection voltage meter to normal, but Oscillograph detected large ripple voltage waveform. Power supply filter capacitor is normally open circuit, rectifier diode caused by bad or, and sometimes are a component breakdown caused by damage to power overload.
(3) when the system just drive normal, after a period of job decline in the supply voltage. This is usually the voltage regulator circuit or high-power triode bad. In temperature caused by power supply voltage drop, or it may be a component defect, temperature after bad.
No supply voltage or supply voltage severely reduced, the system will cause the disruption or cessation of work, which was easy to detect and find fault. When the power supply capacity with load decrease or filter circuit failure, it is difficult to judge. System it will suddenly stop working, causing
If Units composed by FANUC 3MA
2, the clock circuit
The main clock circuit in the system are the motherboard, it is the large-scale integrated circuits which work in basic conditions. It is crystal oscillator (commonly known as crystal oscillator) for the foundation, in the circuit produce a constant square wave signal. Crystalloid vibration, just like people, like the cardiac arrest, allowing the system to in a paralyzed state. Crystal normal job, the system circuit can be under the command of the CPU clock by crystal beat job. Quantity and frequency of the oscillator with the CNC system vary, but generally at least one, and the remaining requirements of the different circuit clock frequency by dividing frequency of the crystal oscillator circuit or another to solve.
The higher the failure rate of crystal, and its common fault has the following categories:
(1) crystal leakage damage. Multimeter available P × 10K block measurement, if the resistance is infinite, compared with normal; if compared with leakage resistance.
(2) the internal open-circuit crystal. Measuring its resistance with a multimeter though infinite, but in the circuit should not have a pulse oscillation.
(3) crystal metamorphic change its parameters. Only by oscilloscope and frequency meter can detect. Crystal are able to oscillation, but the clock frequency from its nominal value, although the oscillation pulse at this time, but because of the number of error pulses, the system can not work the circuit. At this point only by frequency meter can be accurately measured their deviation.
(4) in the actual clock circuit, the crystal at both ends to have access to have a few to dozens of Paper Paper Act law tiles capacitance, the capacitor leakage, deterioration caused by the clock circuit fault is also more common. Detection of mixed crystal is best to use oscilloscopes and frequency of measurement, it is difficult to assess its quality multimeter.
If FANUC 6M Control Units from the machining center, working for some time, a sudden black screen CRT,
3, reset circuit
Reset circuit is also exist in the system circuit board, which is unique to large-scale digital integrated circuits circuit. Microprocessors, interface circuit and others have reset terminal.
Reset circuit reset pulse generated by the program counter cleared, so that CPU out from the memory initialization file for the control port to initialize the chip. If the reset circuit bad, the system will happen disorders, such as fault crash.
Oscilloscope observation generally reset pulse should be repeated on-off power supply, the switch connected to the instantaneous observation of each reset pulse. Reset pulse should be rectangular ideal square wave. If no reset pulse should be checked in the reset circuit resistors, capacitors, transistors and so on. IC reset the rules of client should be low or high, otherwise, should be reset circuit failure or damage to integrated circuits.
Units like the use of large-scale PLASMA CNC machining center, the system could not be activated, CRT showed no alarm. After inspection ± 5V, ± 12V, ± 24V supply voltage normal, normal clock circuit. Suspected to be the system's motherboard problem, reset circuit in the inspection, it was found that no client CPU reset reset pulse. Further examination revealed a reset terminal 3.3k/0.5W open resistance, the replacement of normal after the system restart.
In the maintenance of power supply circuit should first check whether it is normal, and then check the other parts. Power failure has the following forms:
(1) No supply voltage or supply voltage low
CNC system often used ± 5V, ± 12V, ± 15V, ± 24V, using a small number of +3.3 V. The supply voltage is not normal, that is, the system will cause abnormal job. Of emergency equipment, causing equipment and personnel injury, must pay great attention to. Machining center, after boot without any CRT display. Detection system using a multimeter power board A14B - 0067 - B002 - 01, found +5 V power supply voltage of 3.75V, remove the load detection, +5 V power supply for the +4.95 V. Note the low power supply with load capacity or load short-circuit has existence. After checking the normal load. Note decline in power supply with load capacity. After inspection the replacement filter capacitor C36, the system work properly. Tool-free action. Turn off the power supply, power back on, machine tools can work in a period of time. Check all the normal power supply. Fault may be in the system's motherboard. After overhaul motherboard A16B-1000-0220/04A, found two crystal an internal crystal oscillator 16.3840MHz bad, have not replaced the use of the recurrence of similar failures.
(2) power supply voltage detection voltage meter to normal, but Oscillograph detected large ripple voltage waveform. Power supply filter capacitor is normally open circuit, rectifier diode caused by bad or, and sometimes are a component breakdown caused by damage to power overload.
(3) when the system just drive normal, after a period of job decline in the supply voltage. This is usually the voltage regulator circuit or high-power triode bad. In temperature caused by power supply voltage drop, or it may be a component defect, temperature after bad.
No supply voltage or supply voltage severely reduced, the system will cause the disruption or cessation of work, which was easy to detect and find fault. When the power supply capacity with load decrease or filter circuit failure, it is difficult to judge. System it will suddenly stop working, causing
If Units composed by FANUC 3MA
2, the clock circuit
The main clock circuit in the system are the motherboard, it is the large-scale integrated circuits which work in basic conditions. It is crystal oscillator (commonly known as crystal oscillator) for the foundation, in the circuit produce a constant square wave signal. Crystalloid vibration, just like people, like the cardiac arrest, allowing the system to in a paralyzed state. Crystal normal job, the system circuit can be under the command of the CPU clock by crystal beat job. Quantity and frequency of the oscillator with the CNC system vary, but generally at least one, and the remaining requirements of the different circuit clock frequency by dividing frequency of the crystal oscillator circuit or another to solve.
The higher the failure rate of crystal, and its common fault has the following categories:
(1) crystal leakage damage. Multimeter available P × 10K block measurement, if the resistance is infinite, compared with normal; if compared with leakage resistance.
(2) the internal open-circuit crystal. Measuring its resistance with a multimeter though infinite, but in the circuit should not have a pulse oscillation.
(3) crystal metamorphic change its parameters. Only by oscilloscope and frequency meter can detect. Crystal are able to oscillation, but the clock frequency from its nominal value, although the oscillation pulse at this time, but because of the number of error pulses, the system can not work the circuit. At this point only by frequency meter can be accurately measured their deviation.
(4) in the actual clock circuit, the crystal at both ends to have access to have a few to dozens of Paper Paper Act law tiles capacitance, the capacitor leakage, deterioration caused by the clock circuit fault is also more common. Detection of mixed crystal is best to use oscilloscopes and frequency of measurement, it is difficult to assess its quality multimeter.
If FANUC 6M Control Units from the machining center, working for some time, a sudden black screen CRT,
3, reset circuit
Reset circuit is also exist in the system circuit board, which is unique to large-scale digital integrated circuits circuit. Microprocessors, interface circuit and others have reset terminal.
Reset circuit reset pulse generated by the program counter cleared, so that CPU out from the memory initialization file for the control port to initialize the chip. If the reset circuit bad, the system will happen disorders, such as fault crash.
Oscilloscope observation generally reset pulse should be repeated on-off power supply, the switch connected to the instantaneous observation of each reset pulse. Reset pulse should be rectangular ideal square wave. If no reset pulse should be checked in the reset circuit resistors, capacitors, transistors and so on. IC reset the rules of client should be low or high, otherwise, should be reset circuit failure or damage to integrated circuits.
Units like the use of large-scale PLASMA CNC machining center, the system could not be activated, CRT showed no alarm. After inspection ± 5V, ± 12V, ± 24V supply voltage normal, normal clock circuit. Suspected to be the system's motherboard problem, reset circuit in the inspection, it was found that no client CPU reset reset pulse. Further examination revealed a reset terminal 3.3k/0.5W open resistance, the replacement of normal after the system restart.
Saturday, February 21, 2009
FANUC System PC program conversion
FANUC System PC program conversion
All know: FANUC control system for a lot of models, PLC types more. Different types of systems may have to configure different types of PC, the same type of system may also be configured for different types of PC. In this way, for the FANUC control system has long been engaged in the application of people, how to realize under the DOS version of the same ladder in different PC types of conversion, how to realize under the Windows version of the same ladder in different PC types of conversion, how to realize a different PC development environment prepared ladder (DOS version / Windows version) has become really important for the conversion, only a very good solution to these problems, old and new systems in order to shorten the replacement cycle of the application in order to promote the new system FANUC promotion and use. The above are three kinds of conversion through the use of FANUC "FAPT LADDER_ Ⅲ" software programming, the programming software operating environment is Windows.
In order to facilitate the introduction and understanding of, first the definition of several terms: the current ladder - the existing ladder; current PC types - existing ladder diagram of the PC types; target ladder - wishing to change the ladder diagram can be generated; target PC types - hope that after the conversion of the PC can generate the type of ladder; DOS version of the ladder - in the DOS version of software tools prepared under the ladder; Windows version of the ladder - in the Windows version of software tools prepared under trapezoidal map; between documents - in the ladder generated by the conversion process a document, also known as Mnemonic document.
1 DOS version of the ladder with the Windows version of the ladder between the conversion
1.1DOS version of the ladder into a Windows version of the ladder
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Select Toolbar [Tool] in the data conversion of [Data Conversion].
(3) in the drop-down menu, select [Data File → LAD File] item, it shows [Conversion into LAD Format File] page. Among them, the program name (Program Name) field select the current DOS version of the ladder, and with ladder storage path, by [File] select.
DOS version of the ladder file in general different from the file name plus the extension of the composition, a total of 10 documents. For example: If the ladder called the KT13, the KT13 of Ladder 10 from the following files: KT13. # C1, KT13. # C2, KT13. # TA, KT13. # CN, KT13. # EX, KT13. # IO , KT13. # LA, KT13. # ME, KT13. # PA, KT13. # SY. The current DOS version of the ladder were 10 for the above-mentioned document any. LAD type document (LAD Format File) column to be a new target Windows version of the ladder (or folder), including Ladder Diagram (or folder) storage path.
(4) the completion of the above options, click [OK] to confirm, and then there appears the choice of procedure (Program Select) page option, click the [OK], and finally prompted [Succeed Change Data], marks the success of data conversion, click [OK ] can be.
This will complete the DOS version of the ladder to the Windows version of the ladder diagram of the conversion, the "target Windows version of the ladder name" is the conversion of the Windows version of Ladder Diagram Generation.
1.2Windows version of the ladder diagram is converted to DOS version of the ladder.
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Select Toolbar [Tool] in the data conversion of [Data Conversion].
(3) in the drop-down menu, select [Data File ← LAD File] item, it shows [Conversion into Program Data File] page. Which, LAD-type documents (LAD Format File) column must select the current Windows version of the ladder, and with ladder storage path, by [File] select. Name (Program Name) field goal to be the new DOS version of the ladder, and with ladder storage path. Program format (Program Format) column select Format A or C. If they choose to Format A, is generated by the 10 documents consisting of DOS version of Ladder Diagram; if you choose Format C, are generated folder ladder forms of DOS version.
(4) the completion of the above options, click [OK] to confirm, after the prompt [Succeed Change Data], marks the success of data conversion, click [OK] you.
This will complete the Windows version of the ladder to the DOS version of the ladder diagram of the conversion, the "target DOS version of the ladder name" is the conversion of the DOS version of Ladder Diagram Generation.
2 Windows version of PC under the same ladder of different types of conversion between
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Click [File] field, select [Open Program] key, to open a PC want to change the Windows version of the type of ladder documents.
(3) Select Toolbar [Tool] Mnemonic of the conversion of [Mnemonic Convert], showed [Mnemonic Conversion] page. Among them, the Mnemonic document (Mnemonic File) column to be between the new file name, including file storage path. Conversion of data types (Convert Data Kind) need to choose to convert the column data, but generally they ALL.
(4) the completion of the above options, click [OK] to confirm and then display the data conversion information, no other error information after the turn off this page, and then turn off [Mnemonic Conversion] page.
(5) Click [File] field, select [New Program] key, create a new Windows version of the target ladder, at the same time targeting Windows version of the PC type of ladder.
(6) Select Toolbar [Tool] in the conversion of source code [Source Program Convert], showed [Source Program Conversion] page. Of these, between documents (Mnemonic File) column just need to choose between the generated file name, including file storage path.
(7) completion of the above options, click [OK] to confirm and then display the data conversion information, "All the content of the source program is going to be lost. Do you replace it?", Click [Yes] to confirm, no error after turn off this information page, and then turn off [Source Program Conversion] page. This will complete the Windows version under the same ladder of different types of conversion between PC, such as Ladder Diagram KT13.LAD of PMC_SA1 converted to PMC_SA3 of MM.LAD ladder, and after conversion of MM.LAD ladder and KT13 . LAD same ladder logic.
3 DOS version of PC under the same ladder of different types of conversion between
This conversion can be divided into three steps: (1) The first DOS version of the ladder into the next Windows version under the ladder. (2) In the Windows version under the same ladder between different types of PC conversion. (3) Finally, the PC has completed the conversion of the Windows version of the type of ladder and then converted to the ladder under the DOS version.
This will complete the DOS version of PC under the same ladder of different types of conversion between.
4 PC program to follow the principle of conversion
(1) high-low version PC version to PC conversion; (2) functional command of the PC to function less directive and more PC conversion. Instead, you may convert error.
FANUC "FAPT LADDER_ Ⅲ" programming software can be prepared a lot of PC types and can meet FANUC16/18/160/180/21/16i/18i/21i/0i such as the PC control system programming, debugging use. PC conversion process for the PC design, laid the foundation for the rapid reorganization
All know: FANUC control system for a lot of models, PLC types more. Different types of systems may have to configure different types of PC, the same type of system may also be configured for different types of PC. In this way, for the FANUC control system has long been engaged in the application of people, how to realize under the DOS version of the same ladder in different PC types of conversion, how to realize under the Windows version of the same ladder in different PC types of conversion, how to realize a different PC development environment prepared ladder (DOS version / Windows version) has become really important for the conversion, only a very good solution to these problems, old and new systems in order to shorten the replacement cycle of the application in order to promote the new system FANUC promotion and use. The above are three kinds of conversion through the use of FANUC "FAPT LADDER_ Ⅲ" software programming, the programming software operating environment is Windows.
In order to facilitate the introduction and understanding of, first the definition of several terms: the current ladder - the existing ladder; current PC types - existing ladder diagram of the PC types; target ladder - wishing to change the ladder diagram can be generated; target PC types - hope that after the conversion of the PC can generate the type of ladder; DOS version of the ladder - in the DOS version of software tools prepared under the ladder; Windows version of the ladder - in the Windows version of software tools prepared under trapezoidal map; between documents - in the ladder generated by the conversion process a document, also known as Mnemonic document.
1 DOS version of the ladder with the Windows version of the ladder between the conversion
1.1DOS version of the ladder into a Windows version of the ladder
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Select Toolbar [Tool] in the data conversion of [Data Conversion].
(3) in the drop-down menu, select [Data File → LAD File] item, it shows [Conversion into LAD Format File] page. Among them, the program name (Program Name) field select the current DOS version of the ladder, and with ladder storage path, by [File] select.
DOS version of the ladder file in general different from the file name plus the extension of the composition, a total of 10 documents. For example: If the ladder called the KT13, the KT13 of Ladder 10 from the following files: KT13. # C1, KT13. # C2, KT13. # TA, KT13. # CN, KT13. # EX, KT13. # IO , KT13. # LA, KT13. # ME, KT13. # PA, KT13. # SY. The current DOS version of the ladder were 10 for the above-mentioned document any. LAD type document (LAD Format File) column to be a new target Windows version of the ladder (or folder), including Ladder Diagram (or folder) storage path.
(4) the completion of the above options, click [OK] to confirm, and then there appears the choice of procedure (Program Select) page option, click the [OK], and finally prompted [Succeed Change Data], marks the success of data conversion, click [OK ] can be.
This will complete the DOS version of the ladder to the Windows version of the ladder diagram of the conversion, the "target Windows version of the ladder name" is the conversion of the Windows version of Ladder Diagram Generation.
1.2Windows version of the ladder diagram is converted to DOS version of the ladder.
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Select Toolbar [Tool] in the data conversion of [Data Conversion].
(3) in the drop-down menu, select [Data File ← LAD File] item, it shows [Conversion into Program Data File] page. Which, LAD-type documents (LAD Format File) column must select the current Windows version of the ladder, and with ladder storage path, by [File] select. Name (Program Name) field goal to be the new DOS version of the ladder, and with ladder storage path. Program format (Program Format) column select Format A or C. If they choose to Format A, is generated by the 10 documents consisting of DOS version of Ladder Diagram; if you choose Format C, are generated folder ladder forms of DOS version.
(4) the completion of the above options, click [OK] to confirm, after the prompt [Succeed Change Data], marks the success of data conversion, click [OK] you.
This will complete the Windows version of the ladder to the DOS version of the ladder diagram of the conversion, the "target DOS version of the ladder name" is the conversion of the DOS version of Ladder Diagram Generation.
2 Windows version of PC under the same ladder of different types of conversion between
(1) run FANUC "FAPT LADDER_ Ⅲ" programming software.
(2) Click [File] field, select [Open Program] key, to open a PC want to change the Windows version of the type of ladder documents.
(3) Select Toolbar [Tool] Mnemonic of the conversion of [Mnemonic Convert], showed [Mnemonic Conversion] page. Among them, the Mnemonic document (Mnemonic File) column to be between the new file name, including file storage path. Conversion of data types (Convert Data Kind) need to choose to convert the column data, but generally they ALL.
(4) the completion of the above options, click [OK] to confirm and then display the data conversion information, no other error information after the turn off this page, and then turn off [Mnemonic Conversion] page.
(5) Click [File] field, select [New Program] key, create a new Windows version of the target ladder, at the same time targeting Windows version of the PC type of ladder.
(6) Select Toolbar [Tool] in the conversion of source code [Source Program Convert], showed [Source Program Conversion] page. Of these, between documents (Mnemonic File) column just need to choose between the generated file name, including file storage path.
(7) completion of the above options, click [OK] to confirm and then display the data conversion information, "All the content of the source program is going to be lost. Do you replace it?", Click [Yes] to confirm, no error after turn off this information page, and then turn off [Source Program Conversion] page. This will complete the Windows version under the same ladder of different types of conversion between PC, such as Ladder Diagram KT13.LAD of PMC_SA1 converted to PMC_SA3 of MM.LAD ladder, and after conversion of MM.LAD ladder and KT13 . LAD same ladder logic.
3 DOS version of PC under the same ladder of different types of conversion between
This conversion can be divided into three steps: (1) The first DOS version of the ladder into the next Windows version under the ladder. (2) In the Windows version under the same ladder between different types of PC conversion. (3) Finally, the PC has completed the conversion of the Windows version of the type of ladder and then converted to the ladder under the DOS version.
This will complete the DOS version of PC under the same ladder of different types of conversion between.
4 PC program to follow the principle of conversion
(1) high-low version PC version to PC conversion; (2) functional command of the PC to function less directive and more PC conversion. Instead, you may convert error.
FANUC "FAPT LADDER_ Ⅲ" programming software can be prepared a lot of PC types and can meet FANUC16/18/160/180/21/16i/18i/21i/0i such as the PC control system programming, debugging use. PC conversion process for the PC design, laid the foundation for the rapid reorganization
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