SINUMERIC 820C system for monitoring the operation of metal-cutting equipment

Contents

Introduction

Main part

SINUMERIC 820C ECC system for operation monitoring

metal cutting equipment

1 Analysis of monitoring of metal cutting equipment operation with the system

SINUMERIC 820 c

1.1 NC Equipment Control System Overview

1.2 Electrical diagrams and installation works

1.3 Reading of electrical schematic diagrams

2 SINUMERIC 820 c System Design for Metal Cutting Management

CNG 40 CNC E Machine Example Equipment

2.1 Introduction

2.2 Means of verification

2.3 Verification Methods

2.4 Safety requirements

2.5 Technical activities

2.6 Inspection Procedure

2.7 Energized check of control, automation, alarm circuits

3 Description of SINUMERIC 820c metal cutting equipment and system

example of CNG 40 CNC E

3.1 Technical description of components

3.2 Indication of led and other control elements on SCC

4 Calculation of technical and economic efficiency

4.1 Amount of annual depreciation charges before and after modernization

4.2 Main Working

4.3 Equipment downtime per year before and after upgrade

4.4 Repair workers

4.5 Accrual to social insurance

4.6 Power Costs

4.7 Expensive Process Tooling Costs

4.8 Repair and maintenance costs of the machine

4.9 Economic impact

4.10 Payback Period

Conclusion

List of sources used

Applications

Annexes A. Certificate project statement

Introduction

An important component of any automation in production is technological processes (TPs), which must provide high productivity, reliability, quality and efficiency in the manufacture of products.

A characteristic feature of the modern development of technology is the widespread introduction of automation methods and tools, caused by the transition to automated and automatic control of various production and technological processes, the creation of flexible production modules, systems, complexes and the like. In the modern economy, automation is one of the main areas of technological progress. And, of course, improvement of efficiency and quality projected by ACS, SAU, GPM, GPS. it is impossible without improving the reliability of control equipment (TCS).

The basis of automation of technological processes is the redistribution of material, energy and information flows in accordance with the accepted control criterion.

The main objectives of process automation are:

Increased efficiency of the production process.

Increased security.

Improving environmental friendliness.

Increase efficiency.

The objectives are achieved by:

improved quality of regulation;

increase of equipment availability factor;

improvement of ergonomics of process operators "work;

ensuring the reliability of information on material components used in production (including through catalog management);

storage of information on process progress and emergency situations.

Automation of technological processes within one production process allows you to organize the basis for the implementation of production control systems and enterprise control systems.

The SINUMERIK 802C ECU system under consideration has proved excellent in many years of its existence and modernization and has established itself in the market of various equipment in metal processing. Software control consists of a number of devices designed to perform certain functions: a software carrier on which the program of work of the equipment actuators is recorded; program input devices; a reader capable of sensing program symbols and converting them into electrical control signals; a converting device processing operating commands for movement of the machine actuators; drive of machine actuators; feedback system, which monitors compliance of performed movement of actuators with programmed parameters. During product planning, its possible environmental impacts are determined: therefore, many automation products meet the requirements of the EU RoHS Directive (Restriction o fHazardous Substances), and production complexes are certified according to DIN EN ISO 14001. The best example of this is the SINUMERIC820C system for controlling metal cutting equipment using the example of the CNG 40 CNC E machine.

The system of modern industrial mechanisms includes a complex of various systems: CNC devices, mini-computers, peripheral equipment, electric drives of auxiliary mechanisms, supply and main movement, power equipment, sensors, measuring devices, as well as electrical automation devices that control and coordinate the operation of mechanisms. Therefore, graduates of secondary educational institutions specializing in the design and operation of electrical equipment of machines, industrial robots, automatic lines should know the basics of electrical engineering, automation and applied computer technology, should be able to use technical literature, should understand the schematic diagrams of mechanism control. Of particular importance is the progress in electronics, which has a strong impact on electrical equipment.

General-purpose metal cutting equipment can be divided into machines that process body parts and parts of the type of bodies of revolution, as well as another peculiar group of machines with a complex kinematic structure - machines for processing the surfaces of teeth of wheels, worms, racks, etc.

Each of these machines consists of devices which cooperate, perform or contribute to the work for which the machine is intended. However, you can find common functional features for them. The following groups of actuators can be distinguished by purpose, characteristics and principles of operation, and therefore by control:

Shaping devices are machine tools associated with forming products and positioning processes, that is, moving the workpiece (or tool) along programmable coordinates during processing or before processing. A distinctive property of this group is that the path and path of motion can be changed depending on the program you enter.

Manipulating devices - designed to perform constant commands related to the automatic operation cycle of the equipment. They change cutting modes, direction and speed of machine mechanisms movement, control cooling, change cutting tool or workpiece, fix them, transport them and store them. The timing of activation and the sequence of their operation may vary. This is determined by the cycle automation program.

Auxiliary devices - service the processing process, for example, provide automatic waste assembly, lubrication of the machine, suction of mist and dust, operation of the hydraulic and pneumatic system and others. They usually have a self-contained control system. The first and partially second group of devices are the most important and complex in their control.

Electrical diagrams are created for electricians of all specialties, have various design features. Among the methods of their classification, the division is used:

fundamental;

mounting.

Both types of diagrams are interrelated. They complement each other's information, are carried out according to common standards, understandable to all users, and have differences in purpose:

schematic electric circuits are created for display of the principles of work and interaction of the making elements in order of priority of their operation. They demonstrate the logic embedded in the technology of the system used;

installation diagrams are manufactured as drawings or sketches of parts of electrical equipment, according to which the electrical installation is assembled, installed. They take into account the location, layout of components and display all electrical connections between them.

Relevance of the topic: due to the constant growth of requirements and the complexity of the tasks assigned to the equipment, synchronization and correct interaction between the actuators and the control system is required. Thus, the SINUMERIC 820 C ECC system is designed to monitor the operation of metal cutting equipment.

The purpose of the graduation qualification work is to study the SINUMERIC 820C ECC system for monitoring the operation of metal cutting equipment using the example of CNG 40 CNC E machine

To achieve this goal, a number of objectives can be identified:

study and systematize materials of technical literature on the organization and general principles of software management of metal cutting machines;

study the materials of the regulatory documentation for the execution of electrical diagrams and installation works;

analyze SINUMERIC 820C system connection for metal cutting equipment control using CNG 40 CNC E example

Study the technical documentation of metal cutting equipment

Object of study: SINUMERIC 820 C system.

Subject of the study: SINUMERIC 820C ECC system for monitoring the operation of metal cutting equipment using the example of the CNG 40 CNC E machine model.

Main part

Design of sinumeric 820 c system for control of metal cutting equipment using example of cng 40 cnc e machine

Due to the constant increase in requirements for the quality of production and processing of parts. This section discusses the design of SINUMERIC 820C for the management of metal cutting equipment using the CNG 40 CNC E. The equipment is equipped with the modern SINUMERIC 820 C ECC system. Therefore, the section covers a number of issues on the design of the SINUMERIC 820C system for controlling the operation of metal cutting equipment.

This section considers the processes as: means of verification, methods of safety requirements verification, technical measures, procedure of energized inspection of control circuits, automation and alarm.

2.1 Introduction

Reliable and safe operation of the electrical installation ensures the correct high-quality installation of electrical circuits in accordance with the diagrams.

This check includes the following activities:

familiarization with electrical schematic and wiring diagrams and cable log of electronic equipment;

check of compliance of the established EO to the project;

check of compliance of installed wires and cables with the design;

check of marking at the ends of wires and cable cores, its compliance with marking on terminal blocks of boards and panels;

installation quality check - laying and fixing of wires and cables, reliability of cable wires and conductors connection clamps;

check of electric circuits availability in accordance with diagrams - wiring;

check of energized electrical circuits.

2.2 Means of verification

The following devices are used to verify the correct installation of circuits:

electric probe;

ohmmeter or megaommeter;

visually tracking wires.

2.3 Verification Methods

Check of electrical circuits availability in accordance with diagrams (nickname).

visual inspection;

probe check;

check using handsets.

check of control, automation, alarm circuits under voltage.

determination of winding polarity.

2.4 Safety requirements

It is allowed to carry out organizational measures to check circuits in electrical installations with voltage higher than 1000 V along with the composition of the team of at least two people, one of which must have an electrical safety group not lower than IV. In electrical installations with a voltage of up to 1000 V, measurements are carried out by order of two employees, one of which must have an electrical safety group not lower than III.In electrical installations up to 1000 V, located in the premises, except for those especially dangerous with regard to electric shock, An employee with group III and the right to be a producer of work may conduct a single inspection.

In cases where the name of the circuit is included in the content of the commissioning work, it is not required to stipulate it in the order or order.

Admission to adjustment of electrical equipment in existing electrical installations is carried out by operational personnel, and outside of electrical installations - the responsible work manager or, if it is not appointed, the work manufacturer.

2.5 Technical activities

The list of necessary technical measures is determined by the person issuing the work order or order in accordance with section 3 and chapter 5.4. Intersectoral safety rules during operation of electrical installations

The circuits must be marked on the disconnected current-carrying parts, from which the charge is removed by means of their preliminary grounding.

It is allowed to remove the earths installed during the preparation of the work station and prevent the start-up, and then install them again only at the direction of the manufacturer of the test work, after the grounding of the high voltage output of the test unit.

2.6 Verification Procedure

Check of electrical circuits availability in accordance with diagrams (nickname).

The correct installation within one panel, board, cabinet, apparatus can be checked by visually tracking the wires, especially when the wires are colored.

In other cases, the correct installation is determined by the nickname. Within the limits of accessibility from one place, wiring can be carried out using the simplest wiring device - an electric probe.

The integrity of this circuit is checked by placing the probe clamp at one point in the circuit and touching the probe pin at other points in the circuit.

For finding of the ends of the veins of the same name of a cable by means of the probe (drawing of SMK 15.02.07.DP.02.02.00.00) if there is known lived alone a cable, for example thinner or having a coloring arrive as follows: at the other end of the cable, the target core is connected to a known core, and at the proximal end of the cable, the probe clamp is connected to a known core, and the probe rod touches different cores until the probe light is lit, which will mean that a chain of the found core, the known core and probe has appeared.

As the reverse (known) probe core, a conductive cable sheath or grounded structures can be used. A simple ohmmeter or megaommeter can be used in this cable core search method. If the ends of the proprietary core are found, the devices will show zero Om (Kom, MOm).

2.7 Energized check of control, automation, alarm circuits

These energized circuits are checked after checking their correct installation, checking the operation of the devices of these circuits without voltage and checking the insulation resistance of the circuits, checking the reliability of all terminals in the circuits by shaking hands and screwdriver. The circuits are checked when the power circuit voltage is removed so that the electric receivers are not turned on.

At the first voltage supply to the circuit, the fuse in the circuit power supply circuit can burn or the machine can operate due to a short circuit to the housing (ground). In this case, it is necessary to find a short circuit when the circuit is disconnected from the network, which can be done by re-measuring the insulation resistance of the circuit relative to the housing at different points of the circuit, with disconnection of parts of the circuit, if necessary.

After the voltage is supplied to the circuit, the operation of all its devices is checked at all operation modes provided by the circuit.

It is possible to simulate emergency operation modes of the circuit by closing contacts of protection relays, process sensors to check the operation of protection, alarm and automation.

When checking electrical circuits under voltage, failures in the operation of individual elements of circuits and units are possible. These failures are very diverse, but can be reduced to several types:

absence of contact where it should be - disturbances in the operation of the contacts of the devices, weak clamps, wire damage;

presence of contact where it should not be - disturbances in the operation of the contacts of the devices, closure between the current-carrying parts, closure of the current-carrying parts to the equipment housing (ground fault);

availability of bypass circuit for current (shunting) - for example, by breaking through the button post housing past the button. The stroke causes self-actuation of the device, which can be with damp and conductive dust;

mismatch in the circuit of some devices or their parts, for example, the coil of the device to a voltage other than the voltage in the control circuit.

All these faults can occur periodically, making it difficult to find them.

Adjustment methods in such cases depend on the features of the scheme.

On the drawing of SMK.15.02.07 DP.02.03.00.00 a part of the scheme of management where it is possible to track troubleshooting at violations in operation of the KMZ actuator is shown.

suppose the KMZ starter is not activated. Then once again you need to check the actuation of the 5F machine in the control circuit. When it is switched on, it is necessary to check the presence of voltage at the output of the machine with a single-pole or two-pole indicator;

switch SA must be set to position H - Adjustment, since in this position the starter can be turned on independently of others;

if the starter is not switched on when the Start button is pressed, then it is necessary to check the presence of voltage on the terminal 1 of the coil, you can use a single-pole indicator;

there is tension. In this case, it is necessary to check the integrity of a suitable zero wire.

check the voltage on the starter coil with a bipolar indicator between points N and 1;

there is tension. Then you need to check the density of the clamps on the starter coil or touch contacts, if necessary, with its removal, grind the clamps from oxides, check the integrity of the coil winding. After that, the serviceable coil must work;

there is no voltage on the coil when determined by the bipolar indicator, the unipolar indicator shows the voltage at point 1. In this case, it is necessary to check the integrity of the zero wire suitable for the coil, the approach of the zero wire to the entire control circuit of the voltage check by the indicator at the outlet of the SF machine relative to the housings;

there is no stress at point 1. Check the voltage at point 2 If it is, check the clamps and integrity of wire 1 - 2;

there is no stress at point 2. Check voltage in, point 3 If it is available, check the contacts of relay KK and terminal of relay KK;

electrical library Elec.ru;

there is no stress at point 3. Check the voltage at point 4, and if it is, check the integrity of wire 3 - 4, its clamps;

there is no stress at point 4. Check the contacts and clamps of the Start button, and if there is no voltage, check further towards the SF machine;

all checks before the Start button from the starter coil must be carried out when the Start button is pressed or the wire is connected parallel to it;

after elimination of malfunction in H - Adjustment selector switch position, you can try actuation of starter in P - Operation selector switch position. In this case, the dependence of the start of the KMZ starter on the start of the KM1 and KM2 starters is introduced, therefore, they should be turned on during the inspection;

if the CMR is not switched on, it is necessary to check the circuit from point 7 to point 17 (7 - 8 - 9 - 10 - 11 - 12 - 1517) in the same way;

instead of zero, the second pole of the control circuit may have a phase, that is, the control circuit voltage is 380 V. Then, when measuring or checking the voltage at different points in the circuit, the coil must be disconnected to the right of it in the circuit;

if there is a bypass of the Start button on the button element housing (the dashed line will be the self-actuation of the starter at the Set-up and Operation selector switch position, if KM1 and KM2 starters are turned on. In this case, cleaning the body of the button post from moisture and dust will help if it does not have burned tracks along the material of the body from breaking through its surface. In the presence of such tracks or traces of burning, the housing must be replaced, which is equivalent to replacing the entire element.

Explanations and examples of diagrams are given in the drawing SMK.15.02.07 DP.02.04.00

Description of metal cutting equipment using cng 40 cnc e and sinumeric 820c

The machine is connected to the electrical network according to the following parameters:

Voltage 400V 3 + PE + N

Frequency 50 Hz

Power consumption 15 kW

Maximum oscillation + 6, -10%

Protection in front of 25 A machine

Minimum section of drive cable

The machine can be connected and adjusted by specialists of appropriate qualifications. The machine is connected to the network only after it is installed. The junction box is located in the junction cabinet. The drive cable is driven through a sealing end bushing PG 29 which is located at the bottom of the distribution cabinet. The 6 mm2Cu drive cable is connected to the terminals in the letters U, V, W and RE. On the machine, it is necessary to observe phase alternation, namely, rotation of the field to the right. Otherwise, all motors will rotate in the opposite direction. On the foundation of the machine there is a protective terminal, which is used if the main protection is supplemented by protective connections.

Conclusion

In the final qualification work on the topic "SINUMERIC 820C System for Monitoring the Operation of Metal Cutting Equipment." The SINUMERIC 820C system connection was analyzed for subsequent use on metal cutting equipment using the example of the CNG 40 CNC E machine model. During the work, the material of the technical literature on the formation of tools and positioning was collected and studied. versions of ACS, it was revealed that a variety of processing options and the possibility of using various tools can be obtained by a limited number of forming movements. A feasibility study has also been carried out to introduce this system into production. The materials of regulatory documentation on execution of electrical diagrams and installation works are considered. Recommendations on the sequence of installation works are developed. The installation manual of the SINUMERIC 820C SCC has been studied. Connection diagrams of drives, feedback sensors and exchange signals of SINUMERIC 820C ECC are given.

The following general and professional competencies have been applied by me in the course of the thesis project.

Professional competencies

PC 1.1. Perform performance analysis of measuring instruments and automation equipment.

PC 3.2. Monitor and analyze operation of system parameters during operation.

PC 4.1. Perform analysis of automatic control systems taking into account the specifics of technological processes.

PC 4.3. To make schemes of specialized knots, blocks, devices and the systems of automatic control.

PC 5.2. Analyze reliability characteristics of automation systems.

General competencies (QA):

OK 1. To understand the essence and social significance of your future profession, to show steady interest in it.

OK 2. Organize your own activities, choose standard methods and methods for performing professional tasks, evaluate their effectiveness and quality.

OK 3. Make decisions in standard and non-standard situations and be responsible for them.

OK 4. Search and use information necessary for the effective performance of professional tasks, professional and personal development.

OK 5. Use information and communication technologies in professional activities.

OK 6. Work in a team and team, communicate effectively with colleagues, management, consumers.

OK 7. Take responsibility for the work of team members (subordinates), the result of completing tasks.

OK 8. Independently determine the tasks of professional and personal development, engage in self-education, consciously plan for advanced training.

OK 9. To be guided in conditions of frequent change of technologies in professional activity.

Thus, I consider the goals and objectives set and the final qualification work on the topic "SINUMERIC 820C ECC System for Monitoring the Operation of Metal Cutting Equipment" fulfilled.