焊缝余高自动磨削装置的研发

发布时间：2018-08-18 12:10

【摘要】：石油作为汽车等行业的主要燃料,进行安全和经济的运输尤为关键,采用双金属复合管的原油运输为当前最安全、最经济、最有效的运输方式之一。为提高大口径双金属复合管的复合质量,需要在复合前对外层碳钢金属管进行焊缝去余高处理。本论文基于汽车学院承接的纵向研究课题,进行了焊缝余高平整装置的研究。依据课题要求,并结合实际工作环境,设计了基于PLC闭环控制的自动磨削装置,主要包括砂轮磨削装置、自动进给装置和工艺磨削实验三个主要研究内容。首先,进行了磨削方式的确定、电机的选择、传动系统设计、砂轮及其切削方式的确定,并对这些机械结构参数进行了计算,完成了砂轮磨削装置的设计与样机制造;通过试磨削对砂轮磨削装置是否存在相互干涉和工作稳定性进行了实验分析,实验表明:各机械部分在运动过程不存在相互干涉,而且砂轮在管道内与焊缝的可控制在进给装置所调节的范围内;砂轮的线速度可以达到理论设计要求,各级传动在运动过程中也表现出较好的稳定性,存在的机械变形也在误差范围内。其次,对自动进给装置的硬件和软件进行了设计,硬件部分主要包括驱动器、传感器、PLC及触摸屏的选择及其相关参数的确定,并根据所选择的硬件对各模块流程图及其对应的控制程序进行了设计,实现了自动进给装置的手动和自动调节。通过模拟实验,验证了PID参数的自整定所获得的数值能够满足设计需要,同时,在完成手动控制后,程序能够根据磨削装置的位置情况正确判断何时进入自动进给模式,并且自动进给过程中能够克服机械磨削震动所带来的定位干扰,使焊缝的磨削余量达到理想范围内。最后,根据砂轮运动参数梯度变化值,采用样机对焊缝进行磨削实验,通过焊缝磨削质量的对比,获得其最佳磨削运动参数。实验证明该自动磨削装置能够在实际生产过程中完成对焊缝的磨削,满足企业要求的技术指标。为方便工人实际操作需要,制定了焊缝的加工工艺流程。
[Abstract]:As the main fuel in automobile industry, it is very important to carry out safe and economical transportation. The transportation of crude oil with bimetallic composite pipe is one of the safest, most economical and most effective transportation modes. In order to improve the composite quality of large-caliber bimetallic composite pipe, it is necessary to remove the residual height of the weld of the outer carbon steel metal pipe before recombination. Based on the longitudinal research subject of automobile college, this paper carries out the research of weld residual high leveling device. According to the requirements of the project and the actual working environment, an automatic grinding device based on PLC closed-loop control is designed, which mainly includes grinding wheel grinding device, automatic feed device and technological grinding experiment. Firstly, the grinding mode, motor selection, transmission system design, grinding wheel and its cutting mode are determined, and these mechanical structural parameters are calculated, and the grinding device design and prototype manufacturing are completed. The experimental results show that the mechanical parts do not interfere with each other in the process of motion. Moreover, the grinding wheel and weld seam can be controlled within the range regulated by the feed device, the linear speed of the grinding wheel can meet the requirements of theoretical design, and all levels of transmission also show good stability in the course of movement. The existing mechanical deformation is also in the range of error. Secondly, the hardware and software of the automatic feed device are designed. The hardware part mainly includes the choice of driver, sensor PLC and touch screen, and the determination of related parameters. According to the selected hardware, the flow chart of each module and its corresponding control program are designed, and the manual and automatic adjustment of the automatic feed device is realized. Through the simulation experiment, it is verified that the value obtained by self-tuning of PID parameters can meet the design needs. At the same time, after the manual control is completed, the program can correctly judge when to enter the automatic feed mode according to the position of grinding device. In the process of automatic feeding, the positioning interference caused by mechanical grinding vibration can be overcome, and the grinding allowance of welding seam can reach the ideal range. Finally, according to the change value of grinding wheel motion parameter gradient, the grinding experiment of weld seam is carried out by using a prototype, and the optimum grinding motion parameter is obtained by comparing the grinding quality of weld seam. The experimental results show that the automatic grinding device can finish the grinding of the weld seam in the actual production process and meet the technical requirements of the enterprise. In order to facilitate the practical operation of the workers, the welding process was developed.
【学位授予单位】：长安大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG596;TE973

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