汽车板簧冲压成型生产线中英文对照V0

美国DELTA 控制器用于板簧冲孔成型设备改造

北京市思路盛自动化系统集成有限公司 孙涛 slsheng@https://www.360docs.net/doc/1071091.html,

Joining workcells together and streamlining output from one stage to the next, if done correctly, is a surefire way to boost metalforming productivity. One company proving this out, Dayton Parts, Harrisburg, PA, manufactures for the vehicle aftermarket. Part of a manufacturing operation that dates to the 1920s, the company’s leaf-spring production process was upgraded this past year to automate and connect the leaf punching and forming processes into a smooth flow (Fig. 1).

将不同加工单元重新组合形成一条连续生产的设备一定会大大提高生产效率。美国Dayton Parts ，Harrisburg ，PA 一家做车辆配件设备的公司对此进行了成功的实践。这台设备1920年就投入使用了。最近这家公司将生产板簧的冲压和成型工序组合在一起形成了协调地连续作业。

Dayton Parts’ leaf springs,

made from 1?2- to 1-5?8-in.-

thick 6150-grade high-carbon bar stock, must be

heated to 1800 F in both

punching and forming

production steps. Before

the streamlining upgrade,

this meant heating the

springs twice. Now, with

the new closely coupled

arrangement, the leaf

springs need only one

heating prior to punching

and forming, saving energy

and time, and as much as

doubling process

throughput. Dayton 配件生产的板簧规格从1/2英寸（26.2 mm ）到1-5/8英寸厚（41.275mm ） 6150级高碳棒料材料，有冲孔和成型工序。在冲孔和成型工序前分别需要将零件加热到982摄氏温度。在改造前加工板簧需要两次加热。改造后重新组合加工工序，只要加热一次就可以完成冲孔和成型，既节能省时还能成倍提高产量。

The integrated Dayton Parts workcell has proven the advantage of close coupling and networking of processing stages. The updated line has reduced reheat and changeover downtime to a minimum, while achieving cycle times as short as 17 sec. per part. Fig. 1—This CAD rendering shows the forming station (right) and the punch press (left), with the furnace in the middle. Leaf-spring material moves right-to-left from the furnace to the punch press, and then left-to-right to the forming station. 这个CAD 图形中右边边是成型设备左边是冲孔设备加热炉在中间。板簧片由加热炉出来后移至左边完成冲孔再移至右边成型。

“We’re seeing 95 percent combined uptime for the machines,” says Joseph Garcia,

project manager for Dayton Parts, “and the material handling and energy savings for the company were sufficiently large to pay for this project in one year.”

组合在一起的加工工序充分展示了工序衔接距离短，每个工序衔接及时的好处。经过改造后的生产线避免了重复加热，衔接时间短到17秒。Dayton 配件的项目经理Joseph Garica 总结说：“改造后设备提升了95%的生产效率。材料消耗和能源的节省是如此大，我们一年就可以收回这个项目的投资。

Motion Controllers Ke y to Combined Processes

运动控制器是实现组合工序的关键 Achieving rapid cycle times for

the combined machine requires

precise control and close

communication between the motion operations performed in

the process stages. Supervisory

control is performed by a

programmable logic controller

(PLC), but to control the

individual motion axes, PLCs

with special capabilities for

multiaxis coordination are

required. At the

recommendation of local

distributor Penn-Air & Hydraulics of York, PA, Dayton Parts’

engineers chose the RMC150

and RMC75 motion controllers from Delta Computer Systems, Inc., Battle Ground, WA. 实现组合工序的高速生产要求在生产的每个环节都有精密控制和快速通讯交换数据。整个设备的整体控制可以通过PLC 来完成，但是各个定位轴的控制需要有多轴控制能力的PLC 来完成。 在当地分销商 Penn-Air & Hydraulics 的推荐下Dayton 配件的工程师选择了美国DELTA 计算机系统有限公司的RMC150和RMC75运动控制器。

The hot punch for the leaf-spring process is powered by six motion axes (Fig. 2) under control of the RMC150—no problem, as a single RMC150 can control and coordinate the motion of as many as eight axes simultaneously. A pusher axis advances the part against an end gauge, which is positioned by another motion actuator to oppose the pusher in order to set the length between the end of the plate and the center hole to be punched. Two centering jaws along the width of the plate activate to center the hole accurately along that width. The pusher and end-gauge axes travel via position control, Fig. 2—A detailed rendering of the hot punch shows the six motion-control axes used in its operation.

详细结构图展示冲孔设备六个轴的作用

while the centering jaws use position and force control. One jaw moves to a target position and the other jaw uses force control to clamp the part.

板簧热冲孔工序由六个运动轴通过RMC150来控制。RMC150最多可以同时控制8个轴。一个推动机构将零件推到末端调整机构，这个机构由另外一个轴定位以保证两个定位板的中心点正好是中心冲孔的位置。推动机构轴和端部调整机构轴都是位置控制。还有两个轴用来定位零件两侧，使零件在横向也在中间位置。两侧轴一个是位置控制另外一个是力控制来夹紧零件。 “The ability to

combine different

types of axis control

in one system was

very helpful,” says

Greg Shortridge,

Dayton Parts

electrical engineer.

“Using position and

force control, we

can ensure that the

parts are securely

held, at the same

time avoiding the

risk of damage due

to clamping them

too tightly. Dayton 配件的工程师 Greg Shortridge 说：“在一个控制系统中有位控和力控的轴对我们很有帮助，这样能准确定位，又能稳稳的保持在定位位置上，还不会因为力过大而夹坏零件。

“And we had never used force control before,” he adds. “But performing pressure/force control was simple using the Delta controllers.”

他还说：我们是第一次用力控制方式，没想到的是用DELTA 控制器做力控制很方便。 The last two of the six axes operate the punch, a 10-in.-bore hydraulic cylinder operated by a servo-hydraulic valve, and stripper.

六个轴中还有两个轴来分别控制伺服阀控制的254mm 缸径的液压缸驱动的冲头和去皮装置。

Magnetostrictive displacement transducers provide position feedback for the hydraulic cylinders that operate the punch, stripper and centering jaws, while the end gauge is positioned via a servo motor with absolute encoder to provide position feedback. The Fig. 3—The forming head establishes the bend in the leaf spring, which can be seen glowing hot. After the bend is established, the whole forming head lowers into quench oil to harden the leaf and set the bend in its final position.成型压头将图中炽热的板簧片折弯。折弯后整个成型压头下沉到油池中淬火将板簧片的形状固定。

pusher, operated by a hydraulic cylinder, also uses an absolute encoder indicating position.

驱动冲头的液压缸，去皮装置，横向对中轴的位置反馈都是磁致伸缩传感器。末端定位调整装置是伺服电机驱动，绝对位置编码器反馈。液压油缸驱动的零件推动机构的位置也是采用绝对值编码器。 “The new

controllers give us

very accurate

positioning,” says

Shortridge. “Every

axis can be

positioned to within

0.001 in.” Shortridge 介绍

说：”DELTA 控制

器定位精度很高，

可以实现0.025mm

的精密定位

The forming head

is operated by two motion axes, one to clamp the part in the frame for bending (Fig. 3) to its desired shape, and the other to move the frame vertically. The

clamp uses automatic pressure control when it engages, ensuring that the part clamps to a specific pressure in the form that establishes the appropriate bend to the leaf spring. This is accomplished via a PLC and automatic pressure regulator in conjunction with a proportional valve. When clamping the part, pressure is controlled via the regulator. When unclamping, an RMC75 two-axis electrohydraulic motion controller uses the proportional valve to smoothly open the form to the desired positon, adjustable by the operator for convenience.

成型压头由两个控制轴控制，一个轴将板簧夹在成型架构中并使其弯曲到预定的形状，另一个轴整体上下移动整个成型架构。夹紧是通过压力闭环控制来实现的，保证实现预先设定的力从而保证板簧实现折弯到设计要求的形状。这一过程是RMC75压力控制与比例伺服阀加上PLC 来实现的。夹紧过程中力可以随时设定。在夹紧松开时RMC75双轴控制器将成型架构松开到现场操作工可以随时设定的位置。

The second motion axis in the forming head, also controlled by the RMC75, lowers the frame into a quench oil bath to harden the part and set the formed curve. The motion Fig. 4—This Network Architecture screen shows the main PLC, remote I/O

panels, the three 15-in. operator touchscreens, network switches and router,

and the two new motion controllers. All information screens and operator functions are available from any of the three touchscreens. PLC ，远程IO ，三台15寸触摸屏，网络交换机，路由器，两台运动控制器的通讯结构图。三个触摸屏可以看到所有其他设备的信息并可以修改

controller uses position control to raise and lower the frame, controlling the cylinder via a proportional valve.

成型压头控制的第二个轴也是RMC75控制的，它将整个零件下沉到淬火油池中将板簧硬化并定型。运动控制器按位置闭环控制整个成型压头机构上下移动，油缸是通过比例伺服阀控制的。

“We used to just use a bang-bang valve to activate the cylinder that lowers the frame, but the shock caused by that was a problem,” says Shortridge. “Closed-loop control via the RMC motion controller, operating a proportional valve, gives us smooth accelerations and decelerations for the forming-head motion.”

Shortridge先生说：“以前整个成型压头机构的上升和下沉是通过开关阀控制的，运动过程中冲击很大，采用RMC75控制器实现闭环控制后整个设备的加减速过程都非常平顺稳定。

Speed y In stall Limits Dow ntime

改造周期短，减少了停机时间

Dayton Parts upgraded the leaf-spring operation in three phases, tackling the furnace, the hot punch and then the forming head. Each phase required four days of work over extended weekends to minimize downtime.

Dayton配件改造板簧设备分为三步进行的，先改造炉子，再改造冲孔，最后是成型压头。每一步安排了四天时间，并把周末用上连续作业以减少设备停机设计。

“We trained our maintenance personnel with a one-week, onsite training program focusing on using the PLC programming software for trouble-shooting,” says Shortridge, describing the ramp up. “To train the operators, we generated a work instruction, including safety information, setup and operating procedures, product quality-control requirements and troubleshooting information for the new equipment.”

”我们还用一周的时间在现场培训我们的维护人员，针对PLC编程软件的故障诊断都进行了培训。针对操作工，我们制定了一个工作规范，包括安全规范，启动，操作步骤，产品质量保证和新设备的故障排查。

Communication Betw een Machines, Across Co mpan y Ensure Maximum Productivity

全厂范围内的设备之间的通讯保证了整体的生产效率

The combined Dayton Parts punching and forming workcell provides an example of how machine-to-machine communications can improve a process. The supervisory PLC, connected via a standard Ethernet network, interfaces to the two motion controllers and multiple human-machine-interface terminals, and via EtherCat (an Ethernet-based

fieldbus) to a series of input/output racks (Fig. 4). Communicating via the networks, the PLC adjusts cycle time of the furnace and sets the speed of subsequent stages in the line. For maximum productivity and also to ensure that heat transfer from the hot parts passing through the system doesn’t affect sensitive system components, it is critical that the process proceeds as smoothly and expediently as possible.

Dayton 配件的冲孔设备和成型设备的整合很好地说明了设备与设备之间的通讯可以改善整个生产流程。监控PLC 通过标准以太网与两个运动控制器通讯，同时还与多个人机界面进行通讯。另外通过Ethercat （一种以太网现场总线）来连接输入输出模块。通过通讯，主PLC 设定加热炉的工作周期时间并设定后续冲孔和成型工序的工作速度。为了尽可能提高生产效率又要尽可能避免炽热的零件将热量传给比较敏感的设备元件，就要求整个设备运行要平稳可控。 The local machine

network also connects

to the factory LAN so

that production

information is available

to corporate SPC and quality-analysis

software. This can help

optimize performance

and identify

maintenance issues

before they escalate.

现场设备通过工厂以太

网将生产信息发给了全

厂的SPC 和质量控制

软件。这可以优化整个

生产流程并在故障发生

前，提前安排设备维护

工作。 Job Recipes Speed Changeovers

不同零件生产参数的快速切换

The PLC connects to a Microsoft Access database containing the manufacturing

parameters of all leaf springs produced by Dayton Parts. The operator selects the leaf spring to make next via a touchscreen interface and the PLC downloads the appropriate process parameters to the temperature/pressure controllers, and motion sequences to the Delta motion controllers.

Fig. 5—The Dayton Parts system uses recipes, selectable using the touchscreens, to streamline production changeovers and ensure repeatability of the leaf-spring manufacturing process. Dayton 配件的产品加工参数配方通过触摸屏就可以下载并启用，时间短，准确无误，产品一致性好。

PLC连接到微软的Access数据库可以读取Dayton配件所生产的全部板簧的生产参数。

通过触摸屏操作人员选择下一个要生产的板簧的类型，PLC收到加工参数后把相应的参数下载到温度/压力控制器，将相应的动作参数传递给DELTA运动控制器。

“The system automatically processes via recipe (Fig. 5) to speed production changeovers and gain repeatability, which we didn’t have before,” says Shortridge. “We often have relatively small production runs where a spring may contain as many as 12 different leaves. In the old days, we would have to manually dial-in new furnace temperatures, forming pressures and quench-timer settings when we would change parts to be manufactured. This was time-consuming and could introduce errors and downtime that we can’t afford.”

“系统能够将不同产品的生产参数配方自动下载，这减少了产品转换时间并提高了产品一致性，这在之前是没有过的。我们经常生产一些小批量的板簧，但每一种板簧有多达12

种不同的簧片。过去改变簧片时我们需要手工设定加热炉的温度，成型压力，淬火时间。这很费时还会出现错误以导致严重的设备停机。”Shortridge先生说

To tune the motion, Shortridge used the set of tools provided by Delta Computer Systems. One of these tools, Plot Manager, enables the designer to visually and numerically compare an axis’ desired motion trajectory with the actual motion profile observed in a test run. With this visibility, control-loop parameter gains can be tweaked and the system re-run until the target and actual positions overlap on the plot, showing that the system is perfectly tuned.

设备优化运动过程中，Shortridge先生使用了DELTA 计算机系统公司提供的软件工具。特别用到了图形记录功能，他帮助技术人员查看和定量比较测试运行中实际运行轨迹和设定的运行图直接的区别。根据这种直观的比较，调整闭环控制参数，并重新运行以使得目标位置和实际运行位置完全重合，这才显示了系统已经达到了最优的状态。

“Without the new motion controllers and the accurate hydraulic proportional control they provide,” says Garcia, “this project would have been a lot more difficult to implement.”

Garcia最后说：“如果不是DELTA提供这么好的控制器以及该控制器对比例伺服阀的精确控制能力，完成这个项目将会是一件很头疼的事情。”

联系作者

电子邮件：slsheng@https://www.360docs.net/doc/1071091.html,