CNC Rebuild Project and Its Implementation
After the feasibility analysis of the transformation is completed, the modification plan can be determined for the current situation of a certain machine or several machines. The general steps include: 1. Concrete steps Mechanical repair and electrical reform are combined. In general, electrical machines that need to be rebuilt are required. All need to be mechanically repaired. It is necessary to determine the requirements, scope, and contents of the repair; also the requirements and contents for the mechanical structural transformation due to the electrical transformation; and the requirements for the interleaving time between the electrical transformation and the mechanical repair and transformation. The integrity of the mechanical properties is the basis for successful electrical transformation. When it is difficult to do so first and then determine the transformation steps locally, the entire electrical part should be first converted into several subsystems, such as the CNC system, measurement system, spindle, feed system, panel control, and high-power components. The system is basically formed and interconnected to complete the work of the whole system. This will allow renovation efforts to reduce omissions and errors. In the work of each subsystem, it is necessary to do a relatively low-tech, high-volume work first, and then do technically demanding, demanding work, so that people's attention can be focused on key areas. According to the conditions of use, the system is selected for a certain machine or several machines to determine its environment, temperature, humidity, dust, power, light, and even whether there are any external conditions such as rodent damage. This protects the electrical system against interference and interference. Performance, self-cooling performance, air filtration performance, etc. can provide the correct basis, so that the transformed electrical system has a feasible use guarantee. Of course, the choice of electrical system must consider mature products, reasonable performance, practicality, spare parts and maintenance support, function to meet current and future development requirements for several years. The implementation of transformation of personnel and the transformation of responsibilities is a systematic project, and staffing is very important. In addition to the quality conditions of personnel, according to the size of the project, a reasonable determination of the number and division of labor is the key. Too few people are not conducive to work, and too many people are prone to confusion. According to the separate subsystems, the responsibilities of the personnel are determined, and there are master and subsidiary times to facilitate organization and coordination. If the project adopts a form of external cooperation, it is necessary to define the division of labor and determine the technical coordinator on the premise of clear objectives. Modification of the scope and period of the transformation Sometimes the electrical system of the CNC machine tool is transformed, which does not necessarily include all the electrical systems of the machine tool. The scope of the transformation should be determined according to the scientific determination and analysis. The period of shutdown modification is determined according to the actual situation of each company. The factors to be considered include the level of production tension, the level of personnel skills, the degree of preparation work, the size and complexity of the new system, and even the weather conditions. Don’t be overjoyed, eager to achieve success, and rush into battle, but also make reasonable arrangements to prevent delays. Second, the transformation of the technical preparation before the transformation of the technical preparation fully or not, to a large extent determines the success of the transformation. The technical preparations include: Mechanical part preparation The measurement, calculation, design, drawing, and part production of the large-scale mechanical modification required for the purpose of coordinating 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, clear requirements must be made, and the entire transformation work must be properly connected. The new system electrical data digestion new system has many new functions, new requirements, new technologies, so before the transformation should be familiar with technical information, including the system principle description, circuit diagram, PLC ladder diagram and text, installation and commissioning instructions, user manuals, programming manuals, etc. . There must be sufficient time for translation (input systems), digesting, collating, and checking of the above-mentioned materials, so that the ideas are clear and clearly structured. The conversion design of the interface between the old and new systems varies according to the scope of the transformation of each device. Some interface conversions must be designed in advance. If all the transformations are made, the electromechanical conversion interface, operation panel control and configuration, interconnection contacts, parameter measurement points, and maintenance positions should be designed. The operation and maintenance are required to be convenient and reasonable, and the lines are fluent, the number of small and medium-sized connections is small, and the interference between strong and weak electricity is minimal, and appropriate allowances are provided. For partial reconstruction, it is also necessary to consider the performance matching of the old and new systems, voltage polarity and size conversion, installation location, and digital-to-analog conversion. If necessary, a conversion interface must be created. The technical training of operators and programmers will inevitably bring new requirements to operators and programmers after the transformation of the machine's electrical system. Therefore, it is very important for operators and programmers to train new system knowledge in advance, otherwise it will affect the rapid transformation of the machine tool into production. The training content should generally include the new operation panel configuration, functions, and instructions; the new system's functional scope, usage, and differences from the old system; maintenance requirements; programming standards and automated programming, and so on. The key is to understand and get through the operating instructions and programming instructions. Commissioning steps and determination of acceptance criteria After the completion of the transformation of the new electrical system, how to commission and determine a reasonable acceptance criteria is also an important part of 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. The debugging steps can be carried out from simple to complex, from small to large, from outside to inside, and can also be performed locally first, then globally, and then after the subsystem is completed. The acceptance criteria is the assessment of the new system. When it is formulated, it must be practical and realistic. Excessive or too low standards 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 renovation work. Third, the transformation of the implementation of preparations ready, you can enter the transformation of the implementation stage. The contents of the implementation stage are divided into chronologically: The maintenance of the original machine tool After a long period of use, the machine tool will have defects in machinery, hydraulics, lubrication, and cleanliness to varying degrees. Therefore, it is necessary to carry out comprehensive maintenance first. Secondly, it should record the geometric accuracy and dimensional accuracy of the machine tool before it is changed. This can not only guide the transformation of the work of reference, but also at the end of the transformation for comparative analysis. Optimized adjustment of the retained electrical part If the electrical system is partially modified, maintenance and optimization of the retained electrical part should be carried out. Such as replacement of parts of high-voltage parts, maintenance of motors, drying and insulation of transformers, cleaning of pollution, cleaning of ventilation cooling devices, optimization of servo drive devices, update of aging wire and cable, fastening of connectors, etc. . Only fine tuning of the retained electrical parts can ensure that the rebuilt machine has a lower failure rate. The dismantling of the original system to dismantle the original system must be carried out carefully against the original drawings and marked on the drawings in a timely manner to prevent omissions or over-demolition (in the case of partial reconstruction). During the demolition process, some defects in the design of new systems will also be discovered. They should be promptly supplemented and amended. The systems and parts removed should be categorized and kept in a safe place so that they can be used again in the event of an unsuccessful or partial failure. There is also a certain use value, can be used for other machine tool spare parts. Don't avoid being overwhelmed. Reasonable Arrangement of New System Locations and Cabling According to the new system design drawings, the new system configuration will be rationalized, including box fixing, panel placement, line orientation and fixing, adjusting the position of components, sealing, and necessary decoration. There must be a clear division of labor in connection work, and some people review and test to ensure that the wiring process specifications, suitable diameter, correct, reliable and beautiful. Commissioning and commissioning must be carried out in accordance with pre-determined steps and requirements. Debugging personnel should be calm and record at any time in order to find and solve problems. In the process of debugging, first test the safety protection system sensitivity to prevent personal and equipment accidents. The commissioning site must be cleaned up with no extraneous items; each motion coordinate carriage is at the center of the full stroke; can be loaded with no-load test, loaded first after unloaded; simulated, first simulated and real action; manual, first manually Automatically. IV. Acceptance and Acceptance of Late-stage Work Recruitment The relevant personnel shall be invited to participate in the work and follow the established acceptance criteria. The post-renovation work is also very important. It is conducive to improving the technical level of the project and putting the equipment into production as soon as possible. Acceptance and subsequent work includes: Acceptance of machine tool mechanical properties After mechanical repairs and alterations 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 Functions and Control Accuracy Acceptance The various functions of the electrical control must achieve normal operation and sensitivity. The control accuracy of the application accuracy of the application system itself (such as step size, etc.) is compared with that of a standard measurement instrument (such as a laser interferometer, a coordinate measuring instrument, etc.) to within the accuracy range. At the same time, it should also be compared with the various functions and accuracy of the machine before the transformation to obtain the quantitative index difference. The cutting acceptance of the test piece can refer to the relevant domestic and foreign standards for cutting test pieces of CNC machine tools and conduct trial cutting under the cooperation of qualified operators and programmers. Specimen cutting can accept machine tool stiffness, cutting force, noise, motion trajectory, associated actions, etc. Generally, it is not suitable to use product parts as specimens. After drawings and data are accepted, the drawings (including schematics, configuration drawings, wiring diagrams, ladder diagrams, etc.), data (including various specifications), and alteration files (including various records before and after the renovation) shall be promptly Aggregate, organize, and transfer files. Maintaining complete, effective and continuous data is very important for the stable operation of the equipment in the future. Summing up and improving each time after the completion of the transformation should be summed up in a timely manner, which will not only improve the technical staff's business level, but also benefit the entire company's technological progress.
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