In recent years, with the development of computer networks, the application of enterprise resource planning (ERP) has become more and more popular, and the research and application of manufacturing execution system (MES) has also been highly valued by the industry. Induction heat treatment machine is a kind of clean heat treatment equipment, which conforms to the 3S standard of modern industrial production (Sure-reliable, Safe-safe, Saving-saving), and can be installed on the production line for online metal heat treatment. It has been widely used in mechanical heat treatment industry at home and abroad. Application, when manufacturing multi-function rotary quenching machine, we developed a numerical control system that supports fieldbus to enable the machine to support industrial Ethernet, which can exchange information with the workshop-level network and set the remote quenching parameters.

Introduction to multi-function rotary quenching machine

Induction heating is the use of electromagnetic induction to heat the conductor material. Its main advantages are: high efficiency, low cost, energy saving, and easy to achieve automatic control. Induction heating equipment for metal heat treatment mainly includes: heating power source, induction heat treatment machine tool, inductor and quenching transformer.

The multi-function rotary quenching machine is actually an automatic processing line with perfect protection function. It adopts a rotary structure to make the upper and lower materials are completed at the same working position, which is easy to operate. The machine can simultaneously process the same part. Three different surfaces, one workpiece can be quenched once on a quenching machine, and three identical or different parts can be quenched at the same time, and each processing station parameter has a certain flexible redundancy, which can be realized. Various quenching methods, such as simultaneous, continuous, continuous and multi-stage quenching, are mainly used in the automobile and motorcycle manufacturing industries to meet the quenching treatment of many varieties and small parts.

1. Integrated design

In order to reduce the floor space and installation cycle, the integrated design integrates the machine tool with the quenching liquid circulation system, the coolant circulation system, the heating power supply and the quenching transformer.

2, production line

CNC system design

Multi-function rotary induction hardening machine requirements: 1 three processing stations operate independently at the same time (equivalent to three machine tools); 2 continuous continuous change in speed without quenching; 3 with three stations not falling and the turntable not in place Correct the function. The conventional CNC system can not meet these functions, so we have developed a CNC system based on industrial PC, and realized the above functions by using thread technology under Windows 2000.

The industrial PC host is the core of the system. On the one hand, it detects and controls the moving parts of the machine tool. On the other hand, it is connected to the workshop-level network through the network card, so that the system can input the quenching parameters by remote computer, and can also display the working condition of the machine; PCI- 1240 is used for stepping motor speed and positioning control, and detects various abnormal signals of stepping motor; PCI-1751 is 48 TTL level parallel input and output boards, of which 32 channels are set as inputs for operating button input, including starting , pause, emergency stop button, three stations manual heating, liquid spray, rotation, switching, turntable fast forward and reverse, slow positive and negative reverse, three stations workpiece rapid rise and fall, slow rise and fall, etc.; 16 roads Set to output for turntable and three station stepper motor enable control. The PCL-724 is a TTL level input board for detecting signals such as in-position, lack of material, water shortage, and top abnormality. Since there is no level shifting and signal isolation on the board, the proximity switch level is 24V, so use PCLD-785 is used as input level conversion and signal isolation circuit; PCLD-885 is a 16-channel high-power relay output board with strong output drive capability, contact capacity is AC 220V5A; PCL720 is 64-channel switch input and output board. Here, mainly with PCLD-885, it controls the switching, heating, spraying, blowing and tempering of each station.

Anti-jamming design

Since the quenching machine is a special machine tool, the high-frequency or intermediate-frequency power supply used in the quenching machine uses the modulated wave output, and its radiation interference to the power grid and other equipment is particularly serious. For this reason, the control system adopts the following anti-interference measures.

software design

System software design mainly considers the versatility, reliability and ease of use of the software. To this end, we will focus on the following issues: 1 three stations use the heating power supply alone and the three stations share the heating power when switching functions; 2 three stations simultaneously run the software design independently, with simultaneous, continuous scanning, segmentation At the same time, segmental continuous scanning and other quenching functions; 3 should be able to store more than 100 workpiece quenching procedures, workpiece management, easy to query; 4 parameter input is convenient, no programming, people who do not understand the computer can complete the input of the workpiece parameters; 5 online help function, prompt operation at any time; 6 fault self-diagnosis, fault alarm prompt function.

Figure 6 shows the overall block diagram of the system software design. The computer runs the quenching program directly after power-on. The system initialization includes the initialization of each board, the operation parameters of the workpiece that was last run, and the operation panel "automatic/manual". The button position automatically switches to the corresponding main screen.

After entering the main program, the system periodically checks the status of the buttons on the operation panel "Auto/Manual", "Start", "Emergency Stop", etc., and triggers the corresponding events; in the automatic state, the system mainly completes the workpiece management, quenching parameter setting, turntable parameter setting, Stepper motor acceleration setting and automatic quenching function; in manual mode, the system mainly completes manual operation of each station, manual operation of turntable, ABC three-station and turntable zero setting, automatic homing function and manual parameter setting. The workpiece selection is completed in the workpiece management screen. After selecting the workpiece, the system first checks whether each station parameter file exists. If it does not exist, automatically creates each station parameter file name, and sets the prohibition running flag and gives a prompt. After the quenching parameters of each station are set, the system automatically cancels the prohibition running flag. The program exit section is not shown in the overall block diagram. The software exit includes two exit modes, one is to return to the WINDOWS2000 desktop, and the other is to directly exit the operating system and shut down.

Threading technology

Since three stations are running at the same time, the system sets 4 threads, three threads are used for quenching three stations A, B and C, one thread is used for the operation status indication of each station, and the index of the turntable is completed by the main program; During the quenching process, an abnormal situation occurs, the system immediately exits the quenching program, and an alarm is issued. An abnormality occurs in a certain station, which does not affect the operation of other stations; if the station is not in position or the dialing is not in place, the system automatically Find a place.

Remote parameter modification

Considering the cost problem, the program does not adopt C/S structure or remote ODBC. In order to support remote modification of quenching parameters, the software can be installed on the remote computer, and the parameter file can be copied to the machine control computer after modification of the parameter file. Then exit the application on the machine control computer and re-run.

in conclusion

The small induction heat treatment center is a nine-station induction heat treatment center that combines some aspects of compact, flexible, multi-axis, production line and computerization of induction heat treatment machine tools in the world. It has been in the north of Luoyang in China. Motorcycle Co., Ltd., Qianjiang Group Engine Division Heat Treatment Plant and other manufacturers applied to the quenching and tempering of motorcycle cranks. In September 2000, it was awarded the Technology Innovation Fund of SMEs by the Ministry of Science and Technology. The project code: 00C26224100631, in 2001 In September, it passed the technical appraisal hosted by the Henan Provincial Science and Technology Commission. After expert testing, the machine tool lifting repeat positioning accuracy ≤±0.03mm, the indexing positioning accuracy ≤±0.02°, the workpiece moving speed 1～300mm/s. Compared with similar machine tools (one power supply with three quenching machines), the small induction heat treatment machining center is obviously superior to imported similar machine tools in terms of function, price, structure, floor space, labor intensity, and processing efficiency. The protection aspect is equivalent to imported similar machine tools. The prototype of the machine tool was exhibited at the Beijing International Heat Treatment Exhibition in October 2001 and was well received by the industry.