1771-OG
1771-OG
1771-OG
数控机床作为一种柔性的、能的自动化机床,很好地解决了复杂、精密、小批量和多品种的零件加工问题。随着数控机床设备在工业的广泛应用,其运行的性也显得愈发重要,的数控机床设备可以有效保护操作人员的人身,避免设备的频繁故障,提高企业的生产力水平。
为了提高设备的等级,某动力公司位于的生产基地于2012 年启动了设备防护改造工程,希望通过对机械加工设备的升级改造,避免由于设备功能的缺失或不完善可能导致的隐患,满足长远的 EHS目标,进一步提升企业的市场竞争优势。
先让们看看这家改造企业的背景:
该公司是一家多元化的动力管理公司,其生产的电力、流体动力和机械动力产品广泛应用于建筑、飞机、卡车、汽车、机械以及各种商业设施,年销售额超过200亿美元。此次改造的工厂是其位于的28个制造基地之一,主要生产各种液压弯头、接头和管件等产品。
三重挑战,如何个个击破?
本次整改项目共涉及65台套设备的机器改造,其中难度的是20台 MAZAK数控机床的系统改造。
先,作为企业生产的核心设备, MAZAK数控机床的改造方案稳妥,只可成功,不可失败。此外,MAZAK数控机床设备的使用率,设备每天工作16个小时,每小时开门20次,一年总计11.2 万次的开门次数,这要求所用方案可靠和耐久,可以耐长期高负荷的运行条件。
令企业头痛的是,原设备的PLC 系统代码被保护,由于不能获得原设备 PLC的代码,改造时无法对设备做内部改变,但同时又要满足数控系统机器的防护要求,新方案需要一个创新的设计思路。
总结来说,此次升级改造需要的不仅仅是系列产品,而是一个针对现有数控机床特点而设计的、完整的定制化解决方案。
好产品 , 更要有好的解决方案!
凭借在美同类项目的成功应用经验,以及遍布各地的专业而快速的销售和执行队伍,罗克韦尔自动化针对工厂现有设备的具体情况,为其量身定制了系统升级方案。
改造前,数控机床设备的均采用单回路形式,改造目标是实现级别category 3。
先,罗克韦尔自动化的项目实施团队反复多次和工厂多个部门讨论,查找资料,吃透原机器结构和控制原理,熟悉机器的各种状态,包括:设置、数控编程、运行(手动和自动)、小批次和大批量、维护和调试状态等,新改造方案考虑上述各个方面。
在充分了解设备情况后,实施团队严格遵循机器标准(ISO 13849 和 IEC 62061),增加防护系统并嵌入到现有系统中运行。
整体逻辑图如图1所示,新系统按照SIL 3标准来设计,新旧系统独立而又并列运行,而且并行的输入、串行的输出将新系统和旧系统的措施有机结合起来,这种冗余的结构设计是方案的一大亮点,保证了系统的稳定运行。
为保证改造方案的化,本次改造采用原型机试制和批量生产的方式。改造前,这些数控机床设备就在长期高负荷地运行,所以改造方案满足苛刻的运行条件,不适宜一开始就批量改造,所以用19号机器先行改造,运行2个月后,针对效果提出进一步改进措施,而后全部用更新后的方案批量改造。
机器的耐久和稳定运行是本次改造的重要目标,为达成该目标,除了采用冗余的系统架构外,实施团队还采取了一系列的措施,包括:浮动推拉门、防震设计、通风防尘设计和备用回退选项等。
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