矿山支护用桁架自动成型及焊接设备的研发设计
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摘要
金川公司镍矿是我国最大的地下有色金属矿山,该公司的镍产量占国内总量的90%,因此,金川公司所坐落的金昌市有中国镍都的美称。但是,在公司进一步扩大生产量规模的时候,却受到了桁架生产低效率的制约。在对该公司的实际考察,发现该矿具有地应力高,围岩破碎的特点,因此,在开采矿石的过程中需要用到大量的支护桁架,目前,金川集团公司针对此类桁架采用的全是人工焊接的方法,不仅工人的劳动强度大、工作环境恶劣,而且对原材料和能源的浪费也比较大,特别是对焊条和电能的浪费十分惊人;其次,由于桁架的焊接质量参差不齐,给桁架的后续使用工作带来极大的不便。基于以上的原因,拟采用一种自动成型和焊接的方法来实现此类桁架的工业化生产,从而使焊接过程和焊接质量能够达到一种比较理想的目标。
本课题所设计的桁架自动焊接设备重点解决了顺序通电焊接防止电网污染及非直长筋料自动送进和准确定位问题,完成了矿山支护用桁架的自动焊接生产线的研制。它将机械设计、单片机技术、PLC技术、焊接自动化技术、气(液)压技术和上位机组态技术等集成在一起,实现了桁架焊接的自动化,很大程度上降低了工人的劳动强度;抛弃了手工电弧焊的方法,减少了对环境的污染,改善了工人的工作环境;由于采用电阻点焊和电阻对焊的方法,在生产过程中节约大量的焊条和电能,降低了桁架的生产成本;采用自动化焊接设备后也为公司节约了大量的劳动力,提高了公司的科学技术水平,从而增强了公司产品的市场竞争力。
本文从桁架成型焊接生产设备机械部分的设计出发,阐述了桁架成型焊接设备研发设计的全过程,其机械部分设计方案定为一条小型的焊接生产线。包括一台底环成型焊接设备和一台组装成型焊接设备。控制部分采用可编程控制器(PLC),焊接电源变压器的控制采用单片机控制(电阻点焊控制器),并且要实现单片机和可编程控制器的良好衔接。最后,本文在实际设计及现场调试的基础上,利用MATLAB软件做机械手定位系统的仿真,其仿真目的是使机械手理想的定位过程可以在理论上实现。并在理论上可确定控制器中的参数。
Jinchuan Nickel Mine is the largest undergrounded metal mines, the company's nickel output accounting for 90% in our nation ,.The Jinchuan company located in Jinchang city , because the city rich in nickel, it has known to the wold for nickel city. However, when the company expand the production of nickel further, they have to do with the lowly efficiency difficult in the process of production.through actual inspectin in the company,we found that people need a large number or supporting truss in the process of mining ore.but Jinchuan Group make the truss throng the old method at present.for example:they used to artificial welding methods,which increase workers intensity and make the conditions worse.at the other hand ,the raw materials and energy waste quite strong,especislly on the electrode waste very alarming.thirdly there is different in the quality of welding truss,it bring great inconvenience on the following use.considering above shortcomings,we intend to design an automatic molding and welding eqipument,which could keep the quality or welding and welding process to achieve industrislized production.which also make the quality of welding more desirable.
This automatic welding equipment solve the order of welding power grid to prevent pollution and non-straight long tendons material automatically sent to and accurate positioning.It also give the design of the mine supporting truss with the automatic production lines for welding.the machine make up of PLC technology,microcontroller technology, automation technology, welding, gas (liquid) pressure technology and PC technology, integrated configuration.The machine reduce the labor intensity of the workers to a large extent;We also abandoned the manual arcwelding method to reduce the environmental pollution and improve the working environment for workers;It due to resistance spot welding and resistance welding method in the production process saves. The electrode power also reduce the cost of production truss and save a lot of labor, thus could enhance the company's products in the market competitiveness.
This subject meet actual production as a main point,it also give the whole process of design options for truss forming welding equipment.The subject is designed as a small welding production lines,which include mechanical parts and control parts. In my design,welding method used mainly resistance spot welding and butt welding,molding process is a hard thrust cylinder shape, right triangle rings taken special molding.We adapt the programmable controller(PLC) as control parts, Finally, this paper use MATLAB software to do manipulator positioning system simulation in the actual design and debugging on the basis of the scene, its purpose is to enable simulation manipulator ideal location process which can achieve in theory. It also can determine the parameters in the controller in theory.
本课题所设计的桁架自动焊接设备重点解决了顺序通电焊接防止电网污染及非直长筋料自动送进和准确定位问题,完成了矿山支护用桁架的自动焊接生产线的研制。它将机械设计、单片机技术、PLC技术、焊接自动化技术、气(液)压技术和上位机组态技术等集成在一起,实现了桁架焊接的自动化,很大程度上降低了工人的劳动强度;抛弃了手工电弧焊的方法,减少了对环境的污染,改善了工人的工作环境;由于采用电阻点焊和电阻对焊的方法,在生产过程中节约大量的焊条和电能,降低了桁架的生产成本;采用自动化焊接设备后也为公司节约了大量的劳动力,提高了公司的科学技术水平,从而增强了公司产品的市场竞争力。
本文从桁架成型焊接生产设备机械部分的设计出发,阐述了桁架成型焊接设备研发设计的全过程,其机械部分设计方案定为一条小型的焊接生产线。包括一台底环成型焊接设备和一台组装成型焊接设备。控制部分采用可编程控制器(PLC),焊接电源变压器的控制采用单片机控制(电阻点焊控制器),并且要实现单片机和可编程控制器的良好衔接。最后,本文在实际设计及现场调试的基础上,利用MATLAB软件做机械手定位系统的仿真,其仿真目的是使机械手理想的定位过程可以在理论上实现。并在理论上可确定控制器中的参数。
Jinchuan Nickel Mine is the largest undergrounded metal mines, the company's nickel output accounting for 90% in our nation ,.The Jinchuan company located in Jinchang city , because the city rich in nickel, it has known to the wold for nickel city. However, when the company expand the production of nickel further, they have to do with the lowly efficiency difficult in the process of production.through actual inspectin in the company,we found that people need a large number or supporting truss in the process of mining ore.but Jinchuan Group make the truss throng the old method at present.for example:they used to artificial welding methods,which increase workers intensity and make the conditions worse.at the other hand ,the raw materials and energy waste quite strong,especislly on the electrode waste very alarming.thirdly there is different in the quality of welding truss,it bring great inconvenience on the following use.considering above shortcomings,we intend to design an automatic molding and welding eqipument,which could keep the quality or welding and welding process to achieve industrislized production.which also make the quality of welding more desirable.
This automatic welding equipment solve the order of welding power grid to prevent pollution and non-straight long tendons material automatically sent to and accurate positioning.It also give the design of the mine supporting truss with the automatic production lines for welding.the machine make up of PLC technology,microcontroller technology, automation technology, welding, gas (liquid) pressure technology and PC technology, integrated configuration.The machine reduce the labor intensity of the workers to a large extent;We also abandoned the manual arcwelding method to reduce the environmental pollution and improve the working environment for workers;It due to resistance spot welding and resistance welding method in the production process saves. The electrode power also reduce the cost of production truss and save a lot of labor, thus could enhance the company's products in the market competitiveness.
This subject meet actual production as a main point,it also give the whole process of design options for truss forming welding equipment.The subject is designed as a small welding production lines,which include mechanical parts and control parts. In my design,welding method used mainly resistance spot welding and butt welding,molding process is a hard thrust cylinder shape, right triangle rings taken special molding.We adapt the programmable controller(PLC) as control parts, Finally, this paper use MATLAB software to do manipulator positioning system simulation in the actual design and debugging on the basis of the scene, its purpose is to enable simulation manipulator ideal location process which can achieve in theory. It also can determine the parameters in the controller in theory.
引文
[1]陈成全.基于单片机的全位置自动焊接控制系统的研究.西南交通大学.2005.05.01(51-53)
[2]王子才.控制系统设计手册.下册.北京:国防工业出版社,1993.3
[3]蔡兰.机械零件工艺性手册.北京:机械工业出版社,1995
[4]林述温,范扬波.机电装备设计.北京:机械工业出版社,2002.4
[5]王明顺,关守平,陈述平等.沈阳:一种分类机械手的研制与开发.东北大学学报(自然科学版),2006.9(57-59)
[6]刘忠伟.液压与气压传动.北京:化学工业出版社,2005.7
[7]姜焕中.焊接方法及设备.第二分册:电阻焊.北京:机械工业出版社,1981.9
[8]G..H.Lee,Design of Components and Layout of Machines for Material Handling.Adv Manuf Technol(2001)17:371-382
[9]A.C.Lin and R.Gian,A Multiple-Tool Approach to Rough Machining of Sculptured Surfaces.Adv Manuf Technol(1999)15:387-398.
[10]张昌青.电解镍板的自适应点焊控制器研制及其工艺性研究.兰州理工大学,2005.5.19(5-6)
[11]董杰.机械设计工艺性手册.上海:上海交通大学出版社,1991
[12]陈善本.焊接过程现代控制技术.哈尔滨:哈尔滨工业大学出版社,2001.5
[13]侯英玮.材料成型工艺基础.武汉:华中理工大学出版社,2002.3
[14]吴麒,杜继宏,解学书等.自动控制原理.上册.北京:清华大学出版社,1990-1992
[15]王建辉,顾树生.自动控制原理.哈尔滨:哈尔滨工业大学出版社,2006.1
[16]催桃瑞.控制系统的分析、设计、程序.西安:西北工业大学出版社,1985.12
[17]周万珍,高鸿斌.PLC分析与设计应用.北京:电子工业出版社,2004.9
[18]宋伯生.PLC编程理论、算法及技巧.北京:机械工业出版社,2005.4
[19]W.Y.Zhang,S.B.Tor and G.A.Britton,A Two-Level Modelling Approach to Acquire Functional Design Knowledge in Mechanical Engineering Systems.Adv Manuf Technol(2002)19:454-460.
[20]任致程.电动机变频器实用手册.北京:国电力出版社,2004.4
[21]廖常初.PLC应用技术问答.北京:机械工业出版社,2006.1
[22]汪晓平.PLC可编程控制器系统开发实例导航.北京:民邮电出版社,2004.7
[23]D.S.H yunA.Introduction to Control Systems.北京:世界图书出版公司,2000.6
[24]弭洪涛.PLC应用技术.北京:中国电力出版社,2004.2
[25]周东华,孙优贤.控制系统的故障检测与诊断技术.北京:清华大学出版社,1994.9
[26]Y.H.Lee,B.S.Sub,and D.S.Hyun.Anovel PWMscheme forathree-level voltage source inverter with GTO thyristors.IEEET rans.Ind.Appilcat,vol.32,no.2pp.260-268 March /April1996
[27]C.S.Lee,S.S.Kim,I.-C.Choi and H.M.Rho.Control System Design.北京:清华大学出版社..
[28]I.J.na,grath,m.gopatl著,刘文超,许渭州译.控制系统工程.北京:国家书店有限公司印行,1998.8
[29]胡昌华,许化龙.控制系统故障诊断与容错控制的分析和设计.北京:国防工业出版社,2000.7
[30]Sergio Busquets-Monge,Josep Bordonau,Dusban Booryevich,and Sergio Somavilla.The Nearest Three Virtual Space Vector PWM Modulation for the Comprehensive Neurtal- PointBalancing in the Three-Level NPC Inverter.IEEE Trans.PowerE lecrton.Letters,vol.2,March 2004.
[31]张文明.组态软件控制技术.北京:北京交通大学出版社,2006.8
[32]全中文工控组态软件MCGS用户指南.北京:北京昆仑通太自动化软件科技有限公司,2007.8
[33]袁秀英.组态控制技术.北京:电子工业出版社,2006.12
[34]吴作明.工控组态软件与PLC应用技术.北京:北航大学出版社,2005.3
[35]周美兰,周封,王岳宇.PLC电气控制与组态设计.北京:中国铁道出版社,2003.5
[36]薛定宇.控制系统仿真与计算机辅助设计.北京:机械工业出版社,2005.1
[37]Robert F.Harder,Ph.D,Dynamic Modeling and Simulation of Three-Piece Freight Vehicle Suspensions with Non-linear Frictional Behaviour Uising Rail,Proceedings of March 18-20,1999,Boston,pp.185-191
[38]Dvaid G.Ullman.Toward the Ideal Mechanical Engineering Design Support System.Research in Engineering Design 13(2002),56-64.
[39]Y.H.Lee,B.S.Sub,and D.S.Hyun.Anovel PWM schemefo rathree-level voltage source inverter with GTO thyristors.IEEET rans.Ind.Appilcat,vol.32,no.2pp.260-268March/April 1996
[40]王建平,靖新.利用PLC脉冲输出和高速计数功能实现轴的精确定位控制[J]沈阳建筑大学学报(自然科学)-Jan,2006,Vol122,No11
[41]耿晓宁,周广生.逼近式精确快速定位控制系统[J]电气时代2006年第8期
[42]姜国强.异步电动机自适应矢量控制系统研究.辽宁工程技术大学硕士学位论文.2004.6(6-15)
[43]李夙.异步电动机直接转矩控制.北京:机械工业出版社,1994.12
[44]周志刚.异步电机矢量控制系统研究.北方交通大学,2003.10(9-28)
[45]熊光楞.控制系统仿真与模型处理.北京:科学出版社,1993.7
[46]姜玉宪.控制系统仿真.北京:北京航空航天大学出版社,1998.8
[47]刘叔军.MATLAB 7.0控制系统应用与实例.北京:机械工业出版社,2006.1
[48]林雪松,周婧,林德新.MATLAB 7.0应用集锦.北京:机械工业出版社,2006.1
[2]王子才.控制系统设计手册.下册.北京:国防工业出版社,1993.3
[3]蔡兰.机械零件工艺性手册.北京:机械工业出版社,1995
[4]林述温,范扬波.机电装备设计.北京:机械工业出版社,2002.4
[5]王明顺,关守平,陈述平等.沈阳:一种分类机械手的研制与开发.东北大学学报(自然科学版),2006.9(57-59)
[6]刘忠伟.液压与气压传动.北京:化学工业出版社,2005.7
[7]姜焕中.焊接方法及设备.第二分册:电阻焊.北京:机械工业出版社,1981.9
[8]G..H.Lee,Design of Components and Layout of Machines for Material Handling.Adv Manuf Technol(2001)17:371-382
[9]A.C.Lin and R.Gian,A Multiple-Tool Approach to Rough Machining of Sculptured Surfaces.Adv Manuf Technol(1999)15:387-398.
[10]张昌青.电解镍板的自适应点焊控制器研制及其工艺性研究.兰州理工大学,2005.5.19(5-6)
[11]董杰.机械设计工艺性手册.上海:上海交通大学出版社,1991
[12]陈善本.焊接过程现代控制技术.哈尔滨:哈尔滨工业大学出版社,2001.5
[13]侯英玮.材料成型工艺基础.武汉:华中理工大学出版社,2002.3
[14]吴麒,杜继宏,解学书等.自动控制原理.上册.北京:清华大学出版社,1990-1992
[15]王建辉,顾树生.自动控制原理.哈尔滨:哈尔滨工业大学出版社,2006.1
[16]催桃瑞.控制系统的分析、设计、程序.西安:西北工业大学出版社,1985.12
[17]周万珍,高鸿斌.PLC分析与设计应用.北京:电子工业出版社,2004.9
[18]宋伯生.PLC编程理论、算法及技巧.北京:机械工业出版社,2005.4
[19]W.Y.Zhang,S.B.Tor and G.A.Britton,A Two-Level Modelling Approach to Acquire Functional Design Knowledge in Mechanical Engineering Systems.Adv Manuf Technol(2002)19:454-460.
[20]任致程.电动机变频器实用手册.北京:国电力出版社,2004.4
[21]廖常初.PLC应用技术问答.北京:机械工业出版社,2006.1
[22]汪晓平.PLC可编程控制器系统开发实例导航.北京:民邮电出版社,2004.7
[23]D.S.H yunA.Introduction to Control Systems.北京:世界图书出版公司,2000.6
[24]弭洪涛.PLC应用技术.北京:中国电力出版社,2004.2
[25]周东华,孙优贤.控制系统的故障检测与诊断技术.北京:清华大学出版社,1994.9
[26]Y.H.Lee,B.S.Sub,and D.S.Hyun.Anovel PWMscheme forathree-level voltage source inverter with GTO thyristors.IEEET rans.Ind.Appilcat,vol.32,no.2pp.260-268 March /April1996
[27]C.S.Lee,S.S.Kim,I.-C.Choi and H.M.Rho.Control System Design.北京:清华大学出版社..
[28]I.J.na,grath,m.gopatl著,刘文超,许渭州译.控制系统工程.北京:国家书店有限公司印行,1998.8
[29]胡昌华,许化龙.控制系统故障诊断与容错控制的分析和设计.北京:国防工业出版社,2000.7
[30]Sergio Busquets-Monge,Josep Bordonau,Dusban Booryevich,and Sergio Somavilla.The Nearest Three Virtual Space Vector PWM Modulation for the Comprehensive Neurtal- PointBalancing in the Three-Level NPC Inverter.IEEE Trans.PowerE lecrton.Letters,vol.2,March 2004.
[31]张文明.组态软件控制技术.北京:北京交通大学出版社,2006.8
[32]全中文工控组态软件MCGS用户指南.北京:北京昆仑通太自动化软件科技有限公司,2007.8
[33]袁秀英.组态控制技术.北京:电子工业出版社,2006.12
[34]吴作明.工控组态软件与PLC应用技术.北京:北航大学出版社,2005.3
[35]周美兰,周封,王岳宇.PLC电气控制与组态设计.北京:中国铁道出版社,2003.5
[36]薛定宇.控制系统仿真与计算机辅助设计.北京:机械工业出版社,2005.1
[37]Robert F.Harder,Ph.D,Dynamic Modeling and Simulation of Three-Piece Freight Vehicle Suspensions with Non-linear Frictional Behaviour Uising Rail,Proceedings of March 18-20,1999,Boston,pp.185-191
[38]Dvaid G.Ullman.Toward the Ideal Mechanical Engineering Design Support System.Research in Engineering Design 13(2002),56-64.
[39]Y.H.Lee,B.S.Sub,and D.S.Hyun.Anovel PWM schemefo rathree-level voltage source inverter with GTO thyristors.IEEET rans.Ind.Appilcat,vol.32,no.2pp.260-268March/April 1996
[40]王建平,靖新.利用PLC脉冲输出和高速计数功能实现轴的精确定位控制[J]沈阳建筑大学学报(自然科学)-Jan,2006,Vol122,No11
[41]耿晓宁,周广生.逼近式精确快速定位控制系统[J]电气时代2006年第8期
[42]姜国强.异步电动机自适应矢量控制系统研究.辽宁工程技术大学硕士学位论文.2004.6(6-15)
[43]李夙.异步电动机直接转矩控制.北京:机械工业出版社,1994.12
[44]周志刚.异步电机矢量控制系统研究.北方交通大学,2003.10(9-28)
[45]熊光楞.控制系统仿真与模型处理.北京:科学出版社,1993.7
[46]姜玉宪.控制系统仿真.北京:北京航空航天大学出版社,1998.8
[47]刘叔军.MATLAB 7.0控制系统应用与实例.北京:机械工业出版社,2006.1
[48]林雪松,周婧,林德新.MATLAB 7.0应用集锦.北京:机械工业出版社,2006.1
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