Disposal of Common Faults in CNC System of Φ160 Horizontal Boring and Milling Machine
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The SINUMERIK 810M CNC system of the Φl60 horizontal boring and milling machine is composed of a CPU module, a position control module, a memory module, a text graphic processing module, a CRT display, an interface module, an I/O module and an operation panel, etc. It is a channel type CNC. The system transmits data through the RS232C interface.
1 Analysis and Troubleshooting of Common Faults in Siemens SINUMERIK 810K System
(1) CPU monitoring alarm. If this alarm light is on, the system cannot be started and the CNC system is in a fault state. This can be found from the following aspects: faulty jumper terminals in the CPU module; EPROM memory failure; bus board damage; machine parameter error; Start chip damage. If the CPU monitoring alarm occurs in the running process, most of the hardware faults of the module or CPU cycle work errors;
(2) Self-diagnosis alarm of EPEOM memory. When this alarm occurs, the EPROM memory is actually damaged in rare cases, and is mostly caused by poor insertion of the memory module or the EPROM chip and the wrong insertion position.
(3) The data memory sub-mode battery voltage is low alarm. When this alarm occurs, the battery must be replaced when the system is powered on. Otherwise, the machine data and the PiE control program will be lost. After this, the machine data and the PiE control program are backed up and stored on the floppy disk. Loss of machine data and PLC control program, the use of transmission software to computer and SINUMERIK 810K serial network transmission;
(4) Roller surveillance alarm. Note that the actual moving speed of the coordinate axis is higher than the allowable value of the specified threshold speed of the monitoring threshold of the corridor, or the corresponding target axis cannot reach the required speed within the specified time at high speed or braking. This is mostly due to the improper setting of the KV coefficient. Or bad position feedback cable and pulse encoder. Or due to excessive mechanical clearance;
(5) Position feedback loop hardware failure. Indicates that the detected position feedback signal has a phase error or a short to ground or no signal at all. The position loop cable that can be detected is open circuited; detect whether the position module is faulty; use an oscilloscope to measure the phase of the position feedback signal to determine whether there is a problem with the cable and the position sensor.
2 Φl60 horizontal boring and milling machine failure caused by machine failure
(1) Machine out of control (ie, speed). These types of faults occur during the installation and adjustment of the machine. Most of the reasons are that the position or speed detection signal is abnormal, or the disconnection or polarity reversal becomes positive feedback. If the machine suddenly appears when it is running, most of the signal feedback line is broken due to the movement of the machine, or the CNC control board and the feed servo speed control unit failure;
(2) Machine vibration. Cause vibration, in addition to large mechanical clearance or poor hydraulic lubrication, etc., should check the position control and speed control unit settings are correct, analyze whether the machine vibration cycle is related to the feed rate, such as the feed rate, most This is due to the high speed loop gain of this axis. If it is related to the feed speed, most of them are caused by the too high position detection gain, and the position detection gain must be adjusted;
(3) The parts have poor machining accuracy. This is mainly because the symmetry of the dynamic tracking error value between axes has not been adjusted to the optimum state, or the machine tool has changed the transmission chain of each axis after a period of time.
3 method of fault diagnosis of CNC machine tools
(1) Φl60 horizontal boring and milling machine PLC control program for the machine tool to set more than a hundred alarm processing information, SINUMERIK 810M has hundreds of alarm information, according to the alarm content to find the source of the fault;
(2) Improper analysis of the principle. According to the composition principle of the numerical control system, it is possible to logically analyze the characteristics of each point and compare the measurements to locate the fault.
(3) Equivalent substitution method. Utilize the existing replacement of the standby board, and repair the replacement of the bad board;
(4) Division segregation method. The idea of ​​this method is to treat the machine tool as a block of “blocks.†Each block “block†is both independent and related, and the control system is similar in composition. It removes part of it and observes what happens because The signal at the fault location is not or abnormal. From the changed phenomenon, the fault point is determined;
(5) Measurement and comparison method. The printed circuit board of CNC system is generally equipped with terminals for testing, measuring the voltage and waveform of the terminals, working principle of the connection, analyzing the cause of the fault and the location of the fault.