First, the specific steps
Mechanical repair combined with electrical transformation
In general, mechanical repairs are required for machines that require electrical modifications. It is necessary to determine the requirements, scope and content of the repair; also to determine the requirements and contents of the mechanical structural transformation required for electrical transformation; and to determine the interleaving time requirements between electrical renovation and mechanical repair and transformation. The good mechanical properties are the basis for the successful electrical transformation.
First easy and then difficult, first partial after the global
When determining the transformation steps, the whole electrical part transformation should be divided into several subsystems, such as numerical control system, measuring system, main shaft, feed system, panel control and high-voltage part, etc., after the basic forming of each system, the interconnection is completed. jobs. This can make the renovation work less omissions and errors. In each subsystem work, you should first do a less technical, high-volume work, and then do technically high-level, demanding work, so that people's attention can be concentrated in key areas.
Select the system according to the conditions of use
For a certain machine or a certain number of machine tools, determine its environment, temperature, humidity, dust, power, light, and even external conditions such as rat damage, which is the protection performance, anti-interference performance, self-cooling performance of the selected electrical system. Air filtration performance, etc. can provide the correct basis, so that the modified electrical system has a feasible use guarantee. Of course, the choice of electrical system must consider mature products, reasonable performance, practical, spare parts and maintenance support, functions to meet the current and future development requirements in the next few years.
Implement the personnel and responsibilities of participating in the transformation
Reconstruction is a systematic project, and staffing is very important. In addition to the quality of personnel, depending on the size of the project, a reasonable determination of the number of people and division of labor is the key. Too few people are not conducive to carrying out work, too many people are also likely to cause confusion. According to each divided subsystem, the responsibilities of the personnel are determined, and there are times for the owner to facilitate organization and coordination. If the project adopts the form of external cooperation, it is necessary to define the division of labor and determine the technical coordinator under the premise of clear objectives.
Determination of the scope and cycle of the transformation
Sometimes the transformation of the CNC machine electrical system does not necessarily include all the electrical systems of the machine. The scope of the transformation should be determined according to scientific measurement and analysis. The cycle of shutdown reconstruction is determined according to the actual situation of each enterprise. The factors of consideration include production tension, personnel technical level, sufficient preparation work, new system size and complexity, and even weather conditions. Don't be too happy, be eager for success, and rush into battle, but also make reasonable arrangements to prevent dragging.
Second, technical preparation for transformation
The adequacy of technical preparation before the transformation determines to a large extent whether the transformation can be successful. Technical preparations include:
Mechanical part preparation
The measurement, calculation, design, drawing, and part making of the mechanical modification required to cope with the electrical transformation shall be completed in advance. At the same time, the parts that need to be dismantled, modified and processed after the shutdown should be planned in advance, and clear requirements should be put forward, and the whole transformation work should be properly connected.
New system electrical data digestion
The new system has many new functions, new requirements, and new technologies. Therefore, you should be familiar with the technical materials before the transformation, including system principle description, circuit diagram, PLC ladder diagram and text, installation and debugging instructions, user manual, programming manual, etc. It is necessary to have sufficient time to translate the above materials (import system), digest, sort and check, so that the ideas are clear and the layers are clear.
Conversion design of new and old system interfaces
According to the different scope of each equipment transformation, the interface part conversion needs to be designed in advance. If all the transformations are made, the electromechanical conversion interface, operation panel control and configuration, interconnection part contact points, parameter measurement points, maintenance positions, etc. should be designed, which requires convenient operation and maintenance. Reasonable, the line is smooth, the connection points are small, the interference between strong and weak is minimal, and the appropriate margin is available. For partial transformation, it is also necessary to consider the performance matching of new and old systems, voltage polarity and size conversion, installation position, digital-to-analog conversion, etc., if necessary, to make a conversion interface.
Technical training for operators and programmers
After the transformation of the machine tool electrical system, it will inevitably bring new requirements to the operation and programming personnel. Therefore, it is very important to train the operators and programmers in the new system knowledge in advance, otherwise it will affect the transformation of the machine tool into production. The training content should generally include the new operator panel configuration, function, indication meaning; the functional scope of the new system, the method of use and the difference with the old system; maintenance requirements; programming standards and automation programming. The focus is on understanding and working with the operating instructions and programming instructions.
Commissioning steps and determination of acceptance criteria
After the renovation of the new electrical system, how to debug and determine reasonable acceptance criteria is also an important part of the technical preparation work. The commissioning work involves mechanical, hydraulic, electrical, control, sensing, etc., so it must be carried out by the project leader and other personnel. The debugging steps can be from simple to complex, from small to large, from outside to inside, or first and then global, first subsystem and then complete system. The acceptance criteria are the assessment of the new system. It must be realistic when it is formulated. The standards that are too high or too low will have a negative impact on the transformation work. Once the standard is determined, it cannot be easily modified because it involves all aspects of the entire transformation work.
Third, the implementation of the transformation
Once the preparation is ready, you can enter the implementation phase of the retrofit. The content of the implementation phase is divided into chronological order:
Comprehensive maintenance of the original machine tool
After long-term use of the machine tool, there will be defects in mechanical, hydraulic, lubrication, cleaning, etc., so the first step is to carry out comprehensive maintenance. Secondly, the geometric accuracy and dimensional accuracy of the machine tool should be measured before the change. This can not only guide and reference the transformation work, but also can be used for comparative analysis at the end of the transformation.
Optimized adjustment of retained electrical parts
If the electrical system is partially modified, the maintenance and optimization of the reserved electrical parts should be carried out. Such as the replacement of parts in the strong electric part, the maintenance of the motor, the drying insulation of the transformer, the cleaning of the pollution, the cleaning of the ventilation cooling device, the optimization of the servo drive, the renewal of the aging wire and cable, the fastening of the connector, etc. . Only a fine optimization of the retained electrical parts can ensure that the modified machine has a lower failure rate.
Original system removal
The removal of the original system must be carried out carefully against the original drawings and marked on the drawings in time to prevent omissions or over-disassembly (under partial modifications). In the process of dismantling, some defects in the design of new systems will also be found. They should be supplemented and corrected in time. The removed systems and parts should be classified and properly kept in case of unsuccessful transformation or partial failure. There are certain use values ​​that can be used as spare parts for other machine tools. Don't be too big and big, throw it away.
Arrange the location and wiring of the new system reasonably
According to the new system design drawings, the new system configuration is rationally carried out, including box fixing, panel placement, line orientation and fixing, adjusting component position, sealing and necessary decoration. The work of connection must be clearly defined, and some people should review and inspect to ensure that the connection process specifications, wire diameter are correct, correct, reliable and beautiful.
debugging
Commissioning must be carried out in accordance with predetermined steps and requirements. The commissioning staff should be calm and record at any time in order to discover and solve problems. In the commissioning, first try to protect the sensitivity of the system to prevent accidents of people and equipment. The debugging site must be cleaned up and free of unnecessary items; each motion coordinate carriage is at the center of the full stroke; it can be loaded with no load test, first loaded after no load; can simulate the test, first simulate and then move; can be manual, first manual After automatic.
Fourth, acceptance and post work
The acceptance work shall involve the relevant personnel to participate and shall be carried out according to the established acceptance criteria. The post-reform work is also very important, it is conducive to the improvement of the project's technical level and the equipment to put into production as soon as possible. Acceptance and post work include:
Machine tool mechanical performance acceptance
After mechanical repair and modification and comprehensive maintenance, the mechanical properties of the machine tool should meet the requirements, and the geometric accuracy should be within the specified range.
Electrical control function and control accuracy acceptance
The functions of the electric control must be normal, sensitive. * Control the accuracy of the application system itself (such as step size) and standard measuring instruments (such as laser interferometer, coordinate measuring instrument, etc.) to check the accuracy range. within. At the same time, it should be compared with the functions and precision of the machine tool before the transformation, and the quantitative index difference can be obtained.
Test piece acceptance
It can refer to the standards of CNC machine tool cutting test pieces at home and abroad, and carry out trial cutting with the cooperation of qualified operators and programmers. The specimen cutting can accept the machine tool stiffness, cutting force, noise, motion trajectory, associated movements, etc. It is generally not appropriate to use the product parts for the test piece.
Drawings, data acceptance
After the machine tool is rebuilt, the drawings (including schematics, configuration drawings, wiring diagrams, ladder diagrams, etc.), materials (including various specifications), and transformation files (including various records before and after the transformation) should be summarized and organized. Hand over to the file. Keeping the data complete, effective and continuous is very important for the stable operation of the equipment in the future.
Summary, improvement
It should be summed up in time after each transformation, which is beneficial to improve the technical level of technicians and to the technological progress of the whole enterprise.
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