Crankshaft quenchs engine control systems analysis and breakdown are handled

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The crankshaft that introduces from American TOCCO company quenchs machine, use at Kang Mingsi crankshaft (4B, 6B) of main shaft neck and connecting rod neck quench. Quench transformer is secured go up in transformer bracket, clamp orgnaization also installs inductor to go up in this bracket (graph 1) . Clamp oil cylinder is controlled by reversal valve of a magnetism of 2 4 electrify, transformer bracket by electro-hydraulic control of system of scale closed-loop control. Quench principle of transformer bracket movement: Crankshaft level puts clamping apparatus of park machine tool in, wear drive crankshaft to rotate by clamping apparatus head. Corresponding inductor is put on transformer (have 3 kinds of inductor) , clamp inductor, transformer bracket drops, make inductor falls on corresponding journal, start heat, at the same time crankshaft rotates. Right now, transformer bracket is in along with use position. Heat time arrives, inductor rises, drive of machine tool clamping apparatus is versed in this retroflexion to quench undertake quenching below fluid face. Move right by level of bracket of transformer of drive of odd axis numerical control, heat worker displacement arrives next place. After neck of a group of lever or journal temper by dipping in water are over, change corresponding inductor. After temper by dipping in water of the last position is over, transformer bracket returns null. One, transformer bracket is electro-hydraulic scale controls a system 1. Transformer bracket is electro-hydraulic system of scale closed-loop control is shown 2 times like the graph, model of a powerful person of servo of one P/Q scale is 5/3V 0811 402 106 (German Bosch company is produced) , this a powerful person combines flow control and pressure control in an a powerful person. The discharge of P1 → A and P2 → B scatters at pilot valve leave degree. The one PNSO of PSV that pump uses RACINE firm one 20HRM pump of one 52 variable lamina, pressure of transformer bracket oil cylinder is detected by pressure sensor. The signal of pressure sensor sends toward electronic pressure controller (P/Q controller) . The pressure value of the pressure value with this will real controller and set undertakes comparative, if former be less than latter, dictate a powerful person is opened (P1 → A) , dictate conversely circumfluence of a powerful person (A → T) . Transformer bracket is electro-hydraulic graph of principle of system of scale closed-loop control sees a picture 3, its block diagram sees a picture 4. The high-powered is used at closed-loop control scale servo a powerful person that German Bosch company rolls out, be a kind of successive action is electro-hydraulic dominate a powerful person or family. Because was used tall answer dc scale electro-magnet and corresponding amplifier, contain inside set buy detects electronic device and feedback closed circuit, use 0 mouth quadrilateral pilot valve, in be not being had in character of its output stable state dead band. Graph 2 medium pressure sensor, model is 0811 405 537. Component by stainless steel plated film (stretch material) layer resistor meet an emergency piece composition, use complete bridge circuit, the output voltage signal that carries temperature to compensate integrated circuit and pressure to become direct ratio (1 ～ 6V) , had adjusted accurately by manufacturer with sensitivity at 0 o'clock. Should notice to make sensor approachs the point that be measured as far as possible when installation, as far as possible perpendicular installation, insert head over heels to shut dead cubage in order to make automatic exhaust. Nextpage 2. The control mechanism of a powerful person of servo of scale of P/Q amplifier control (graph 3, graph 4) the P/Q amplifier that a powerful person of servo of one P/Q scale uses 5/3V, it includes a mother board mixes child board. Mother board is to contain amplifier of proportioning valve of positional feedback pilot together. Child board namely P/Q controller, be select a replacement. Child board insert it is on mother board, p/Q amplifier combines unit to use as a signal. This unit undertakes controlling to the pressure in closed-loop control loop and discharge. Input parameter is pressure P and discharge Q to give signal, and the real position that feedback value is real pressure and core of a powerful person. Proportioning valve amplifier and the function that P/Q controller combines are as follows: When P gives ＞ P to feedback, as flow control implement, namely pressure control is not effective; When P gives ＜ P to feedback, regard pressure as adjuster, undertake overlay to giving Q with one limiter form, right now child board the mixture signal of deferent P/Q arrives mother board, once arrive at calm pressure, limiter controls the input signal of displacement of core of a powerful person with respect to the monitoring pressure with meeting real ground, in order to make P gives =0 of one P feedback. After P gives ＞ P to feedback or pressure controller is shut, position of core of a powerful person is as corresponding as Q set-point. Q set-point limits is UE=0 ～ person 10V. Adjust to carry out significant pressure, light gives P to be no good, still must give Q, 10 10V(of general UE ＝ maximum) . TOCCO quenchs machine quench there are 3 kinds of actuating pressures in course of transformer bracket start: The pressure when rising 4.

The 8MPa, pressure when dropping 4.

4MPa, inductor heats the balance when crankshaft (along with move) pressure 3.

3MPa. 3 kinds of actuating pressure are dictated correspondingly by 3 potentiometer set set-point. Ascendant pressure set-point (1 set is worth potentiometer) for 4.

34V; Next step-down force set-point (2 set are worth potentiometer) for 3.

35V; Balance pressure set-point (3 set are worth potentiometer) for 1.

68V numerical value is moved through the hand beforehand buy set, when moving, by PLC program choosing is connected. 2, because the main problem that controls systematic existence and breakdown processing technique control component of systematic hydraulic pressure to reach electric ageing of yuan of parts of an apparatus, the machine tool uses profit for a time unusual, appear in crankshaft to heat or quench in working process, quench transformer bracket oil attacks pressure to be not stabilized, fluctuate to random law moves and cannot quench, lose reaction when the job again sometimes, cause inductor damage. 1. When pressure of hydraulic pressure system interferes inductor to load oil cylinder of the clamp inside transformer to have clamp action, after transformer hand wears the instant to drop, rise again. Because inductor clamp oil cylinder controls loop and control of transformation Q oil cylinder loop is common an oily source (see a picture 2) , when movement of clamp oil cylinder, oily pressure instant drops considerably, cause scale servo to import the instant to break had pressed big, a powerful person of scale wait month has not enough time to shut, produce transformer bracket instant to drop thereby breakdown. An one-way a powerful person is added in the system (A, one F of ROD does not have this a powerful person in primary system) , the word accuses to prevent be broken suddenly by oily source to a powerful person with fluid in solving primary system had pressed big and the pressure of generation interferes a problem. 2. Systematic pressure does not stabilize hydraulic pressure system in working process, graph 2 in finger of watch of oily source pressure keeps swinging, at the same time transformer bracket also follows oscillatory. Because gasoline tank oil is lukewarm not tall, the release inside reason oil pump is not large, distribute oil dish without the problem, only the cone of core of voltage regulator a powerful person of oil pump wears away, cause systematic pressure to have regular ground vibration. Ravel oil pump booster, grinder is repaired on grind core of pressure regulator valve, eliminate cone of core of a powerful person to wear away groove, breakdown phenomenon is eliminated. 3. Pressure of transformer oil cylinder is not pressed firmly surely drop button, make transformer bracket is down a movement. Bracket is in drop in the process, fall sometimes half or fall to fall cannot stop how long to move up, stop an inter sometimes, stop in sometimes on do not move, move suddenly downward again. Create this kind of appearance, the input that the most possible reason is P/Q amplifier gave trouble partly. Via checking discovery: Of potentiometer group chose a component to give trouble, relay becomes loose between plug and electrical outlet, the contact is undesirable, the input statement that creates P/Q amplifier is not stable update 3 relay and electrical outlet, breakdown eliminates: Already introduced EAS, series now small-sized PLC: Will pick the set voltage cost that tells scale servo a powerful person, the action is more credible. 4. Transformer bracket shakes crankshaft is heating in the process, transformer bracket does not have regular ground vibration up and down, sometimes oil cylinder is broken pressure bigger, cause inductor damage. Refer to a graph 3, create this one appearance, the most possible reason has two kinds: ① scale amplifier is disturbed; Component of ② system feedback (namely pressure sensor) gave trouble. Check via careful platoon (measure amplifier of value of instruction potentiometer set, scale to input value and pressure sensor feedback to be worth) , discover pressure P gives signal to come the line between P/Q amplifier box, because ageing is reached,be heated the interference of circuitry of systematic power supply, the signal that causes input P/Q amplifier is lack fidelity reach not stable; Because hydraulic pressure is oily water content is higher, pressure sensor is damaged, cause feedback signal abnormal, with amplifier of P/Q of the reintroduce after pressure set-point overlay, cause trouble thereby. Change line, pressure sensor and hydraulic pressure oil; Will electronic-controlled the line between ark and P/Q amplifier box is worn inside iron pipe, make line screen, after raising interference rejection ability to carry out, breakdown is eliminated, the system stabilizes the job. 3, brief summary 1. One P/Q of 5/3V scale servo a powerful person combines flow control and pressure control in an a powerful person, can realize control of closed circuit pressure and open loop flow control. When pressure of implementation closed circuit is controlled, adjust to carry out significant pressure, not only should give P value, still must give Q value. When choosing scale amplifier, must choose match one stature board, choose namely match an appropriate P/Q controller. And when realizing flow control, do not need to deserve to use P/Q controller. 2. Be in electro-hydraulic in scale control system, must notice the effective screen of line is protected, only such ability make the system works normally. Should notice the pressure stability of hydraulic pressure oily source at the same time, pressure is fluctuant cannot too big, otherwise the system cannot work normally. The input of scale amplifier carries signal control, had better use but program controller (PLC) control, and the relay that does not use a convention controller. Such, systematic permanent worker makes stability can rise considerably. 3. The point that be measured is approached as far as possible when sensor is installed, notice to install direction, so that obtain measured value well and truly. CNC Milling CNC Machining