1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3 1734-RTB3
通常機床主軸電動機制動時，采用的是能耗制動方式，使電動機AB相輸入直流電源。
采用能耗制動方式使主軸電動機停止，主軸在低檔位低速旋轉(zhuǎn)時，大約需要0.5s，在高檔位高速旋轉(zhuǎn)時，大約需要2.5s。目前，采用的主軸電動機制動方法如圖1所示，先斷開KM1，再閉合開關(guān)KM2，從而斷開三相交流電源，接通直流電源，延時2.5s，認定主軸電動機停止旋轉(zhuǎn)，然后進行換刀或其它動作。
主軸以不同的速度旋轉(zhuǎn)時，采用能耗制動方式使主軸停止所需要的時間不同，采用同樣的能耗制動時間，延長無意義的加工輔助時間，降低了機床工作效率。另外，一旦開關(guān)KM2不能可靠閉合，或者直流電源保險斷開不能正常提供直流電，則主軸電動機只能在摩擦力的作用下減速，制動時間需要很長，但延時2.5s后，機床數(shù)控系統(tǒng)仍然認定主軸電動機已經(jīng)停止旋轉(zhuǎn)，此時機床進行換刀或其它動作容易造成事故。
因此，我們對機床主軸制動控制方式進行了改進設(shè)計，判斷主軸旋轉(zhuǎn)狀態(tài)，不采用延時2.5s，即認定主軸電動機停止旋轉(zhuǎn)的控制方式，而是實時監(jiān)控主軸旋轉(zhuǎn)狀態(tài)，當主軸旋轉(zhuǎn)低于一定轉(zhuǎn)速時，立即發(fā)出主軸停止完了信號。
2 主軸轉(zhuǎn)速監(jiān)測方案
在電動機的同步傳動軸上安裝一塊條形鐵片，和電動機同步旋轉(zhuǎn)，由接近開關(guān)對其檢測，每轉(zhuǎn)檢測到兩個脈沖信號，通過對脈沖信號的檢測而得知其轉(zhuǎn)速。檢測脈沖信號有兩種方案。
第一方案：在一定周期Tp內(nèi)讀取脈沖信號的個數(shù)N，PLC是一種順序控制器，它的程序是由前到后一步一步執(zhí)行，每執(zhí)行完一遍為一個掃描周期，然后從頭開始循環(huán)執(zhí)行。假如程序有2000步，每步執(zhí)行時間周期為30μs，則程序的掃描周期約60ms，掃描頻率約16Hz，能夠準確檢測出的脈沖頻率應(yīng)低于8Hz，當轉(zhuǎn)速的脈沖頻率大于16Hz，即轉(zhuǎn)速n≥480r/min時，PLC受其掃描頻率的影響，不能準確檢測出脈沖的個數(shù)，情況不好時，會出現(xiàn)高速時檢測的脈沖個數(shù)很少，誤判為電動機基本停止而進行下面動作，造成事故。此種方案只適用于主軸低速旋轉(zhuǎn)狀態(tài)的監(jiān)測。
第二種方案：檢測脈沖信號持續(xù)為“0”或“1”的時間T，當n<60r/min時，發(fā)出主軸停止完了信號。由于PLC程序執(zhí)行過程的延時，數(shù)控系統(tǒng)收到主軸停止信號，并執(zhí)行下面動作時，主軸已完全停止旋轉(zhuǎn)，n=60r/min所對應(yīng)脈沖信號持續(xù)為“0”或“1”的時間T為0.25s，因此我們把檢測脈沖信號的計時器設(shè)定為0.25s。同樣高速時也會出現(xiàn)脈沖測不準的情況，但不管情況多壞，在0.25s的時間內(nèi)“0”或“1”至少變化一次，因此可以準確地判斷主軸是否停止旋轉(zhuǎn)。此方案可以適用于主軸高速或低速旋轉(zhuǎn)時主軸制動狀態(tài)的檢測。在實際應(yīng)用中，我們采用了此方案。
3 PLC實現(xiàn)主軸能耗制動的控制方法
PLC設(shè)計程序中，X20.0為轉(zhuǎn)速脈沖信號的輸入，M05為主軸停止信號，Y50.0為主軸停止完了信號。
兩個計時器TM1、TM2分別判斷X20.0脈沖信號持續(xù)為“0”或“1”的時間是否達到設(shè)定的時間，只要有一個時間到達，即R100.1或R100.2變“1”，導(dǎo)致R100.3變“1”，此時M05為“1”，導(dǎo)致Y50.0輸出“1”，則發(fā)出主軸制動完了信號，實現(xiàn)了主軸停止的準確判斷。
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