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The detailed process of the implementation of the CNC machine tool transformation project plan

Generally, a feasibility analysis report will be made before the CNC transformation of the machine tool, which comprehensively evaluates the risk and value of the project transformation, and provides a scientific basis for the investment decision of the enterprise.

The implementation plan of machine tool transformation mainly includes:

First, specific steps

◆ Combination of mechanical repair and electrical transformation

Generally speaking, machine tools that need to be electrically modified need to be mechanically repaired. It is necessary to determine the requirements, scope and content of repair; It is also necessary to determine the requirements and content of mechanical structure transformation due to electrical transformation; It is also necessary to determine the staggered time requirements between electrical retrofit and mechanical repair and retrofit. Mechanical integrity is the basis for a successful electrical retrofit.

◆ Easy first and then difficult, local first and then global

When determining the transformation steps, the entire electrical part should be divided into several subsystems, such as numerical control system, measurement system, spindle, feed system, panel control and strong current part, etc., and then interconnected to complete the whole system work after each system is basically formed. This reduces omissions and errors in retrofit work. In the work of each subsystem, the work with low technical and large workload should be done first, and then the work with high technical and delicate requirements should be done so that people’s attention can be concentrated on the key places.

◆ Select the system according to the conditions of use

For one or several machine tools, determine its environment, temperature, humidity, dust, power supply, light, and even whether there are external conditions such as rodent infestation, which can provide the correct basis for selecting the protection performance, anti-interference performance, self-cooling performance, air filtration performance, etc. of the electrical system, so that the transformed electrical system has a feasible use guarantee. Of course, the selection of electrical systems must take into account mature products, reasonable performance, practical performance, spare parts and maintenance support, and functions that meet the development requirements of current and future years.

◆ Implement the personnel and responsibilities involved in the transformation

Renovation is a systematic project, and staffing is very important. In addition to the quality of personnel, according to 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, and too many people are prone to chaos. According to the subsystems divided into each division, the responsibilities of personnel are determined, and there are primary and secondary, which is convenient for organization and coordination. If the project adopts the form of external cooperation, it is more necessary to define the division of labor and determine the technical coordinator under the premise of clear goals.

◆ Determination of the scope and cycle of transformation

Sometimes the transformation of the electrical system of the CNC machine tool does not necessarily include all the electrical systems of the machine tool, and the scope of the transformation should be determined according to scientific measurement and analysis. The cycle of shutdown and transformation is determined according to the actual situation of each enterprise, and the factors considered include the degree of production tension, the technical level of personnel, the adequacy of preparation, the size and complexity of the new system, and even the weather conditions. We must not be in a hurry to achieve great success, but we must also make reasonable arrangements to prevent procrastination.

Second, the technical preparation of the transformation

Whether the technical preparation before the transformation is adequate or not determines the success of the transformation to a large extent. Technical preparation includes:

◆ Mechanical part preparation

The measurement, calculation, design, drawing, and parts production of the mechanical overhaul that needs to be carried out in order to cooperate with the electrical transformation should 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 to properly connect with the entire transformation work.

◆ Digestion of electrical data of the new system

The new system has many new functions, new requirements, and new technologies, so you should be familiar with the technical information before the transformation, including system principle description, circuit diagram, PLC ladder diagram and text, installation and commissioning instructions, user manuals, programming manuals, etc. There should be ample time to translate (import system), digest, collate, and check the above materials, so that the thinking is clear and the hierarchy is clear.

◆ Conversion design of new and old system interfaces

According to the different scope of each equipment transformation, it is necessary to design the interface part conversion in advance, if all the transformation, the electromechanical conversion interface, the operation panel control and configuration, the interconnection part of the contact, the parameter measurement point, the maintenance location, etc., the operation and maintenance are required to be convenient and reasonable, the line is smooth, the small and medium-sized connection points are few, the strong and weak electrical interference is minimal, and there is an appropriate margin. For partial transformation, it is also necessary to consider the performance matching of the old and new systems, voltage polarity and size conversion, installation location, digital-to-analog conversion, etc., and if necessary, you need to make your own conversion interface.

◆ Technical training for operators and programmers

After the transformation of the electrical system of the machine tool, it will inevitably bring new requirements to the operators and programmers. Therefore, it is important to train operators and programmers in the knowledge of the new system in advance, otherwise it will affect the rapid production of the modified machine. The training content should generally include the new operation panel configuration, functions, and indication meaning; the functional scope of the new system, how to use it and how it differs from the old system; maintenance requirements; Programming standards and automation programming, and more. The focus is on understanding and understanding the operating instructions and programming instructions.

◆ Determination of debugging steps and acceptance criteria

After the renovation of the new electrical system, how to debug and determine the reasonable acceptance criteria is also an important part of the technical preparation. The commissioning work involves mechanical, hydraulic, electrical, control, sensing, etc., so it must be carried out by the project leader and other personnel cooperate. The debugging steps can be carried out from simple to complex, from small to large, from outside to inside, or local first and then global, first subsystem and then the whole system. The acceptance criteria are the assessment of the new system, and they must be realistic, as too high or too low a standard can have a negative impact on the retrofit work. Once the standard is determined, it cannot be easily modified because it involves all aspects of the entire renovation work.

Third, the implementation of transformation

Once the preparation is in place, the implementation phase of the transformation can begin. The implementation phases are chronologically divided into:

◆ Comprehensive maintenance of the original machine tool

After long-term use, the machine tool will have defects in mechanical, hydraulic, lubrication, cleaning and other aspects to varying degrees, so it is necessary to carry out comprehensive maintenance first. Secondly, the geometric accuracy and dimensional accuracy of the machine tool should be measured and recorded before a change. In this way, it can not only play a guiding and reference role in the transformation work, but also can be used for comparative analysis at the end of the transformation.

◆ Optimized adjustment of the retained electrical part

If the electrical system is partially modified, the retained electrical part should be maintained and optimized. For example, the replacement of parts of the strong current part, the maintenance of the motor, the drying and insulation of the transformer, the cleaning of pollution, the cleaning of the ventilation and cooling device, the optimization and adjustment of the servo drive device, the renewal of aging wires and cables, the fastening of connectors, etc. Only by doing a good job of optimizing the retained electrical parts can we ensure that the transformed machine tool has a low failure rate.

◆ The original system was dismantled

The dismantling of the original system must be carried out carefully according to the original drawings, and marks should be made on the drawings in time to prevent omission or over-demolition (in the case of partial transformation). In the process of dismantling, some deficiencies in the design of the new system will also be found, which should be supplemented and corrected in time, and the dismantled system and parts should be classified and properly kept, so as to be restored in case the transformation is unsuccessful or partially failed. If there is a certain use value, it can be used as other machine tool spare parts. Don’t throw it around.

◆ Reasonable arrangement of the new system location and wiring

According to the design drawings of the new system, the new system configuration is reasonably carried out, including box fixing, panel placement, line direction and fixing, adjusting the position of components, sealing and necessary decoration, etc. The connection work must have a clear division of labor, and someone will review and inspect it to ensure that the connection process is standardized, the wire diameter is appropriate, correct, reliable and beautiful.

◆ Debugging

Commissioning must be carried out in accordance with predetermined steps and requirements. Commissioning personnel should be cool-headed and keep records at all times so that problems can be found and solved. During the commissioning, the sensitivity of the safety protection system is first tested to prevent personal and equipment accidents. The debugging site must be cleaned up, and there are no superfluous items; each moving coordinate carriage is in the center of the whole stroke; if it can be tested without load, it will be loaded after no-load; if it can be simulated and tested, it will be simulated first and then it will be realized; if it can be manual, it will be manual and then automatic.

Fourth, acceptance and post-work

The acceptance work should be carried out in accordance with the established acceptance standards. The later work of the transformation is also very important, which is conducive to the improvement of the technical level of the project and the early commissioning of the equipment. Acceptance and post-work include:

◆ Acceptance of mechanical properties of machine tools

After mechanical repair and transformation and comprehensive maintenance, the mechanical properties of the machine tool should meet the requirements, and the geometric accuracy should be within the specified range.

◆ Acceptance of electrical control function and control accuracy

The functions of electrical control must be normal and sensitive and adjustable. The control accuracy application system itself (such as step size, etc.) is checked against standard measuring instruments (such as laser interferometer, coordinate measuring instrument, etc.) to achieve the accuracy range. At the same time, it should also be compared with the functions and accuracy of the machine tool before the transformation to obtain a quantitative index difference.

◆ Specimen cutting acceptance

You can refer to the relevant CNC machine tool cutting specimen standards at home and abroad, and carry out trial cutting with the cooperation of qualified operators and programmers. The cutting of the specimen can accept the stiffness, cutting force, noise, motion trajectory, associated action, etc., and it is generally not suitable to use product parts as the specimen.

◆ Acceptance of drawings and materials

After the transformation of the machine tool, the drawings (including schematic diagrams, configuration drawings, wiring diagrams, ladder diagrams, etc.), data (including various manuals), and transformation files (including various records before and after the transformation) should be summarized, sorted out and handed over to the file in a timely manner. It is very important to maintain the integrity, effectiveness and continuity of the data for the stable operation of the equipment in the future.

 

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