防竄焊接滾輪架竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)說明書[帶圖紙].doc

重慶理工大學(xué)畢業(yè)論文防竄焊接滾輪架：竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)目錄摘要····························································································IAbstract···························································································II1.緒論··························································································11.1國內(nèi)外焊接滾輪架發(fā)展現(xiàn)狀······················································11.2課題的研究內(nèi)容及意義·······························································22.防竄焊接滾輪架系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)及工作原理···········································22.1系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)·······································································22.2系統(tǒng)的工作原理·······································································33.筒體軸向竄動(dòng)的理論分析···································································33.1焊接過程中常出現(xiàn)的一些問題·····················································33.2軸向竄動(dòng)的主要原因·································································43,3滾輪架簡體軸向竄動(dòng)機(jī)理···························································53.4焊件不發(fā)生軸向竄動(dòng)的充分條件··················································64.筒體軸向竄動(dòng)的檢測、調(diào)節(jié)及執(zhí)行機(jī)構(gòu)設(shè)計(jì)···········································74.1軸向竄動(dòng)檢測··········································································74.2調(diào)節(jié)方式的選擇·······································································84.3調(diào)節(jié)執(zhí)行機(jī)構(gòu)的調(diào)節(jié)原理···························································94.4升降裝置的選型·····································································105.系統(tǒng)控制部分················································································125.1系統(tǒng)硬件部分設(shè)計(jì)··································································125.1.1PLC控制器····································································125.1.2步進(jìn)電機(jī)的計(jì)算與選型·····················································165.1.3步進(jìn)電機(jī)驅(qū)動(dòng)器的選用····················································215.1.4聯(lián)軸器的選擇································································225.1.5位移傳感器選型·····························································225.1.6限位開關(guān)選型································································235.1.7控制面板的設(shè)計(jì)·····························································235.2系統(tǒng)軟件部分設(shè)計(jì)··································································235.2.1防竄控制模式選擇··························································245.2.2主程序控制圖·································································255.2.3梯形圖程序···································································256.總結(jié)···························································································29參考文獻(xiàn)·························································································30文獻(xiàn)綜述·························································································31重慶理工大學(xué)畢業(yè)論文防竄焊接滾輪架：竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)I摘要焊接滾輪架是在焊接生產(chǎn)中與焊接工序相配一種輔助裝置。在大厚壁、大型化、高容量、耐磨蝕的鍋爐、石油、化工壓力容器的焊接過程中，由于筒體的幾何形狀的不規(guī)則（偏離理想回轉(zhuǎn)體）和焊接滾輪架的制造安裝誤差等原因，筒體在滾輪架上轉(zhuǎn)動(dòng)時(shí)，會(huì)不可避免的發(fā)生軸向竄動(dòng)，從而影響環(huán)縫的焊接質(zhì)量。本課題從理論上深入分析了筒體在焊接過程中產(chǎn)生軸向竄動(dòng)的主要原因，分析了筒體軸向位移的調(diào)節(jié)機(jī)理，同時(shí)提出了采用螺旋升降裝置和步進(jìn)電機(jī)傳動(dòng)，用PLC控制器以脈沖控制的方式使步進(jìn)電機(jī)精準(zhǔn)的控制升降臺(tái)的上升和下降的位移。此防竄焊接控制系統(tǒng)有效地解決了窄間隙埋弧焊、內(nèi)壁堆焊的問題，智能化控制焊接過程中出現(xiàn)的軸向竄動(dòng)，此設(shè)計(jì)實(shí)現(xiàn)了精密化、大型化、數(shù)字化、智能化等優(yōu)點(diǎn)。不僅提高了生產(chǎn)效率而且確保批量生產(chǎn)過程中焊接質(zhì)量的穩(wěn)定性，節(jié)省因竄動(dòng)進(jìn)行人工調(diào)節(jié)的時(shí)間，減少勞動(dòng)力，提高焊接的精度和質(zhì)量，降低成本。關(guān)鍵詞:竄動(dòng)理論分析竄動(dòng)檢測調(diào)節(jié)執(zhí)行機(jī)構(gòu)硬件部分設(shè)計(jì)軟件部分設(shè)計(jì)重慶理工大學(xué)畢業(yè)論文防竄焊接滾輪架：竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)IIAbstractWeldingrollerbedisintheweldingproductionandweldingprocesstomatchanauxiliarydeviceTheWeldingandProductioninthebigThick-Cliff、TheLarge-Scale、High-Content、Endure-AblationofthepressurevesseloftheBoiler、Oil、chemical,becauseofreasonoftheabnormityofgeometry-formofthecylinder(departureidealgyrationobject)andtheerrorofthemanufacture-installation,thecylinderwheelontherollerbed,inevitablyitwilloccuraxialdrifting,sothataffecttheweldingquality.Thistopicofcylinderwereanalyzedtheoreticallyintheweldingprocesstoproduceaxialchannelingmove,themainreasonoftheregulationmechanismofcylinderaxialdisplacementareanalyzed,atthesametimeputsforwardadoptingspiralliftinggearandstepmotordriving,PLCcontrollertocontrolbymeansofpulsetomakeprecisesteppermotorcontroldisplacementoftheriseandfalloftheliftingplatform.Theantichannelingweldingcontrolsystemcaneffectivelysolvethenarrowgapsubmergedarcwelding,theweldingproblem,intelligentcontrolintheweldingprocessoftheaxialchannelingmove,thisdesignimplementsthemotors,large-scale,digitalandintelligentadvantages.Notonlyimprovestheproductionefficiencyandensurethestabilityofweldingqualityinmassproductionprocess,saveforchannelingmanuallyadjusttime,reducethelaborforce,improvetheaccuracyofweldingandquality,reducecosts.Keywords:DynamicanalysisTheaxialdynamicdetectionAdjusttheactuatorThehardwarepartofthedesignSoftwarepartdesign重慶理工大學(xué)畢業(yè)論文防竄焊接滾輪架：竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)11緒論1.1國內(nèi)外焊接滾輪架發(fā)展現(xiàn)狀近年來，隨著我國改革開放進(jìn)程的深化，隨著中外合作合作生產(chǎn)和引進(jìn)技術(shù)生產(chǎn)的機(jī)械產(chǎn)品日益增多，促進(jìn)了我國焊接結(jié)構(gòu)用量的迅速增加。尤其是為滿足我國石油、化工、交通、能源等工業(yè)的迅猛發(fā)展，大厚壁、大型化、高容量、耐磨蝕、耐動(dòng)載的鍋爐、石油、化工壓力容器的用量更是日益增加，其接頭的焊接質(zhì)量要求也越來越高，并且在實(shí)際生產(chǎn)中要求有較高的生產(chǎn)效率。防竄焊接滾輪架就是在上述焊接生產(chǎn)中與焊接工序相配合，有利于實(shí)現(xiàn)焊接生產(chǎn)機(jī)械化，自動(dòng)化，有利于提高裝配焊接質(zhì)量，促使焊接生產(chǎn)效率提高的一種輔助裝置和設(shè)備。焊接滾輪架是借助主動(dòng)滾輪與焊件之間的摩接力帶動(dòng)焊件旋轉(zhuǎn)的變位機(jī)械。在筒形工件內(nèi)外環(huán)縫的焊接中，組合式焊接滾輪架逐漸取代長軸式、固定式等焊接滾輪架，獲得了廣泛的應(yīng)用，但如何合理的控制其焊接時(shí)的軸向竄動(dòng)及主動(dòng)輪的轉(zhuǎn)速仍值得分析。組臺(tái)式焊接滾輪架主要由主動(dòng)輪座、從動(dòng)輪座、支架三部分組成。支架相當(dāng)于機(jī)座，輪座坐在其上對工件起支承作用，其中主動(dòng)輪座還起驅(qū)動(dòng)作用。這三部分自成獨(dú)立單元，人們可利用其數(shù)量的協(xié)調(diào)變化組合成能驅(qū)動(dòng)各種長度、各種直徑、不同重量筒形工件的焊接滾輪架。但是，作為標(biāo)準(zhǔn)組臺(tái)，是由兩個(gè)支架和四個(gè)輪座組成的，其中至少有一個(gè)輪座是主動(dòng)輪座。我國在1990年頒布的焊接滾輪架的行業(yè)標(biāo)準(zhǔn)（ZBJ/T33003-1990）中規(guī)定：主動(dòng)滾輪的圓周速度應(yīng)在6－60m/h范圍內(nèi)無級可調(diào)，速度波動(dòng)量按不同的焊接工藝要求，要低于±5％±10％，滾輪轉(zhuǎn)速應(yīng)穩(wěn)定、均勻，不允許有爬行現(xiàn)象。按GB150規(guī)定制造的筒體類工件在防軸向竄動(dòng)滾輪架上進(jìn)行焊接時(shí)，在整個(gè)焊接過程中允許工件的軸向竄動(dòng)量為±3mm。國外于20世紀(jì)80年代中期推出的防止焊件軸向竄動(dòng)焊接滾輪架，能將焊件的竄動(dòng)量控制在±2mm以內(nèi)。我國近年來也有個(gè)別工廠生產(chǎn)過防竄動(dòng)滾輪架，但在實(shí)用性和可靠性方面，與國外產(chǎn)品相比還存在著差距。國外在80年代初期研制開發(fā)了一種防止工件軸向竄動(dòng)的焊接滾輪架。如瑞典伊薩（ESAB）、意大利安莎多（ANSALDO）和英國（BODE）公司等都推重慶理工大學(xué)畢業(yè)論文防竄焊接滾輪架：竄動(dòng)檢測及防竄控制系統(tǒng)設(shè)計(jì)2出了這種產(chǎn)品。國外所研制的防軸向竄動(dòng)焊接滾輪架與國內(nèi)常規(guī)的焊接滾輪架相比，增加了一套高可靠度的軸向位移自動(dòng)調(diào)節(jié)系統(tǒng)。在焊接過程中能同步調(diào)節(jié)筒體的姿態(tài)，使焊接過程可靠實(shí)施，大大提高了生產(chǎn)效率，同時(shí)可得到高質(zhì)量的焊接接頭。相比國外，我國防軸竄焊接滾輪架的研制還處于初始階段，據(jù)調(diào)查，至今國內(nèi)尚無正式廠家能夠制造抽比較成熟的產(chǎn)品，生產(chǎn)中主要是依靠引進(jìn)國外的設(shè)備，如蘭州石油化工機(jī)械廠、哈爾濱鍋爐廠、齊齊哈爾第一重型機(jī)械廠等，都是從國外引進(jìn)的防軸向竄動(dòng)的焊接滾輪架。這樣，一方面要花費(fèi)大量的外匯，另一方面也遠(yuǎn)遠(yuǎn)不能滿足國內(nèi)日益增長的焊接生產(chǎn)需要。1.2課題的研究內(nèi)容及意義本課題主要研究的內(nèi)容是：①深入分析出現(xiàn)竄動(dòng)的原因以及竄動(dòng)機(jī)理；②設(shè)計(jì)防竄滾輪架控制系統(tǒng)（包括控制部分軟硬件、梯形圖、電氣原理）；焊接滾輪架的軸向竄動(dòng)問題一直是各大企業(yè)及各使用者所關(guān)心的重要問題，本課題能從理論上有效的解決焊接滾輪架在焊接過程中出現(xiàn)軸向竄動(dòng)的問題，提高焊縫的精度和質(zhì)量；同時(shí)也提高我自己在這方面的知識(shí)。2防竄焊接滾輪架系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)及工作原理2.1系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)防竄滾輪架系統(tǒng)主要由驅(qū)動(dòng)滾輪架，從動(dòng)滾輪架，調(diào)節(jié)裝置，電氣控制系統(tǒng)，PLC，步進(jìn)電機(jī)等組成。主動(dòng)滾輪架的滾輪旋轉(zhuǎn)采用交流變頻電機(jī)驅(qū)動(dòng)、變頻調(diào)速，具有調(diào)速范圍寬，轉(zhuǎn)動(dòng)平滑性好等特點(diǎn)；從動(dòng)滾輪架裝置是由底座、滾輪、滾輪座、防竄滾輪裝置等組成，其底座固定；防竄滾輪裝置由從動(dòng)滾輪裝置和升降機(jī)構(gòu)組成，升降機(jī)構(gòu)包括蝸輪絲桿升降機(jī)構(gòu)、升降限位開關(guān)等。采用步進(jìn)電機(jī)驅(qū)動(dòng)升降機(jī)的升降，根據(jù)位移傳感器檢測到的工件軸向竄動(dòng)信號(hào)，自動(dòng)糾正工件的軸向竄動(dòng)。主要用于管道、容器、鍋爐、油罐等重型圓筒形工件的裝配與焊接。若對從動(dòng)滾輪的高度做適當(dāng)?shù)恼{(diào)整后還可進(jìn)行錐體、分段不等徑回轉(zhuǎn)體的裝配與焊接。