簡易數(shu)控(kong)車床又叫(jiao)經(jing)濟型數(shu)控(kong)車床,是在普通車床的基礎上發展起來的,其自(zi)動控(kong)制(zhi)系統主要由單(dan)片機(ji)構成,通過控(kong)制(zhi)程序,控(kong)制(zhi)機(ji)床的縱向及橫向進(jin)給裝(zhuang)置(zhi)及換(huan)刀(dao)裝(zhuang)置(zhi),自(zi)動完成零件的加工。所以,簡易數(shu)控(kong)車床仍是機(ji)電一體化設備,因而在出(chu)現故障時也要從機(ji)床的機(ji)械結構和電氣控(kong)制(zhi)兩個(ge)方面(mian)綜合分析。
1.程(cheng)序運行后步(bu)進電機抖動不轉
這(zhe)一(yi)現象(xiang)一(yi)般是(shi)(shi)步(bu)進(jin)(jin)(jin)電(dian)(dian)(dian)機或(huo)其控制系統斷相造成的(de)。有可能是(shi)(shi)步(bu)進(jin)(jin)(jin)電(dian)(dian)(dian)機本身故障也可能是(shi)(shi)其驅(qu)動電(dian)(dian)(dian)路故障。首(shou)先檢(jian)查(cha)步(bu)進(jin)(jin)(jin)電(dian)(dian)(dian)機的(de)連接(jie)插頭是(shi)(shi)否(fou)(fou)接(jie)觸良(liang)好,若(ruo)接(jie)觸良(liang)好,可將*的(de)電(dian)(dian)(dian)機調(diao)換過來,以便驗證電(dian)(dian)(dian)機是(shi)(shi)否(fou)(fou)良(liang)好。若(ruo)調(diao)換電(dian)(dian)(dian)機后仍不(bu)能正常(chang)工(gong)作,則說(shuo)明其控制部分不(bu)正常(chang),可檢(jian)查(cha)驅(qu)動板上的(de)大功率(lv)三極(ji)管(guan)及其保護元件(jian)釋(shi)放二極(ji)管(guan),一(yi)般情(qing)況下,這(zhe)兩(liang)個元件(jian)
2.程序運行中工作臺突然停止
這(zhe)一(yi)(yi)(yi)現象一(yi)(yi)(yi)般是(shi)(shi)由機(ji)(ji)械(xie)故(gu)障(zhang)(zhang)(zhang)引起的(de),但也可(ke)能是(shi)(shi)控(kong)制系統(tong)發(fa)生故(gu)障(zhang)(zhang)(zhang)造(zao)成的(de)。這(zhe)時可(ke)先將工(gong)作臺退(tui)回(hui)原(yuan)點,重新啟(qi)動加工(gong)程序(xu),若工(gong)作臺總是(shi)(shi)運行(xing)到某一(yi)(yi)(yi)位(wei)置時停(ting)止,應(ying)該是(shi)(shi)傳動系統(tong)的(de)某一(yi)(yi)(yi)部(bu)位(wei)損壞、變形或(huo)被異(yi)物(wu)(wu)卡住(zhu)等(deng)。首先斷電,然后檢(jian)查(cha)(cha)絲(si)(si)母與絲(si)(si)杠(gang)(gang)間隙或(huo)溜板鑲條是(shi)(shi)否太緊、滾珠(zhu)絲(si)(si)杠(gang)(gang)的(de)滾珠(zhu)導槽(cao)內(nei)有無異(yi)物(wu)(wu)、絲(si)(si)杠(gang)(gang)有無彎(wan)曲變形、步進(jin)電機(ji)(ji)減(jian)速(su)器內(nei)柔(rou)性齒輪是(shi)(shi)否松動或(huo)異(yi)物(wu)(wu)卡住(zhu)等(deng)。若手動盤車沒(mei)有異(yi)常,則是(shi)(shi)控(kong)制系統(tong)故(gu)障(zhang)(zhang)(zhang),應(ying)按照故(gu)障(zhang)(zhang)(zhang)1進(jin)行(xing)檢(jian)查(cha)(cha)。
3.高速時步進電機丟步
可能(neng)是(shi)驅(qu)動電源(yuan)電壓降低(di),使步進(jin)電機(ji)(ji)輸出轉矩減(jian)小。應檢查驅(qu)動電源(yuan)部(bu)分(fen),當高(gao)壓開關三極管(guan)損壞后,高(gao)壓電源(yuan)天(tian)法接(jie)通,高(gao)速時(shi)步進(jin)電機(ji)(ji)輸出轉矩減(jian)少而丟步。也可能(neng)某處機(ji)(ji)械故障,所(suo)以還應檢查絲(si)杠、絲(si)母、溜板(ban)、步進(jin)電機(ji)(ji)減(jian)速器等處。當有(you)部(bu)件彎曲、變形、或有(you)異物(wu)時(shi)會使運(yun)行阻力增(zeng)大,低(di)速運(yun)行時(shi)現象不明顯,但高(gao)速時(shi)則不能(neng)*克服運(yun)行阻力。
4.程序運行結束刀具不回零(ling)點(dian)
一般是控制(zhi)系統(tong)故障。刀具(ju)在進給或在加(jia)工時(shi),步進電(dian)機(ji)運轉速(su)(su)度較低,而程序(xu)回(hui)零(ling)點(dian)(dian)時(shi),則要求快速(su)(su)退(tui)回(hui)。步進電(dian)機(ji)高速(su)(su)運行,采用高壓(ya)(ya)驅動電(dian)源(yuan)(yuan),以(yi)使輸出(chu)轉矩(ju)增大。控制(zhi)高壓(ya)(ya)驅動電(dian)源(yuan)(yuan)輸出(chu)的(de)有一開關三極(ji)(ji)管,當開關三極(ji)(ji)管損壞(huai)后,高速(su)(su)回(hui)零(ling)點(dian)(dian)時(shi)高壓(ya)(ya)電(dian)源(yuan)(yuan)打不開,步進電(dian)機(ji)輸出(chu)轉矩(ju)不夠,致使刀具(ju)不回(hui)到零(ling)點(dian)(dian)。更換開關三極(ji)(ji)管即可消(xiao)除。
5.刀具返回(hui)零(ling)點(dian)時越位(wei)
一般是(shi)機械傳動系統運(yun)行(xing)阻(zu)(zu)力太大引(yin)起。切(qie)削(xue)(xue)進(jin)給時(shi),刀架低(di)(di)速運(yun)行(xing),低(di)(di)電(dian)(dian)(dian)壓驅動,步(bu)(bu)進(jin)電(dian)(dian)(dian)機運(yun)轉(zhuan)轉(zhuan)矩小,不(bu)足以克服阻(zu)(zu)力造(zao)成丟(diu)步(bu)(bu)。而回(hui)零(ling)時(shi)步(bu)(bu)進(jin)電(dian)(dian)(dian)機高壓驅動,運(yun)行(xing)速度(du)高、轉(zhuan)矩大,又(you)沒有(you)切(qie)削(xue)(xue)阻(zu)(zu)力,步(bu)(bu)進(jin)電(dian)(dian)(dian)機不(bu)丟(diu)步(bu)(bu)。這樣去時(shi)丟(diu)步(bu)(bu)而返回(hui)時(shi)正常(chang)就會造(zao)成不(bu)回(hui)零(ling)現象。這時(shi)可檢查步(bu)(bu)進(jin)電(dian)(dian)(dian)機減速箱(xiang)內(nei)傳動齒輪或(huo)(huo)步(bu)(bu)進(jin)電(dian)(dian)(dian)機與絲(si)杠之間傳動齒輪上有(you)無鐵屑異物(wu),或(huo)(huo)溜板鑲條是(shi)否(fou)太緊使運(yun)行(xing)阻(zu)(zu)力增(zeng)大等。
6.加工后的(de)工件(jian)尺寸誤差很大(da)
一種可能(neng)是(shi)絲杠或(huo)絲母(mu)與車(che)床連接松動(dong)(dong)。空走時(shi)沒有吃刀阻力,溜板運(yun)行正常,加(jia)工(gong)時(shi)由于切削(xue)阻力增大(da),絲杠或(huo)絲母(mu)與車(che)床連接處松動(dong)(dong),造成加(jia)工(gong)工(gong)件(jian)尺(chi)寸漂移。緊(jin)固連接部分,故(gu)障即可消(xiao)除。另一種可能(neng)是(shi)電(dian)動(dong)(dong)刀架(jia)造成。如(ru)果換刀后(hou)刀架(jia)不(bu)能(neng)自(zi)動(dong)(dong)鎖緊(jin),切削(xue)時(shi)刀具偏(pian)離加(jia)工(gong)點,也會造成上述現象。這時(shi)應檢(jian)查(cha)刀架(jia)鎖緊(jin)裝置及刀架(jia)控(kong)制箱。
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