滚筒式钢球热处理生产线的研究与实现
发布时间：2019-01-09 09:26
【摘要】：轴承是各类主机的重要基础件,而钢球又是球轴承的关键零件,钢球在球轴承中作为滚动体起承载和传递负荷的作用。滚动轴承应具有长寿命、低振动、低噪音、小的旋转力矩和高可靠性等基本性能。要实现上述性能,必须保证轴承各零部件的加工精度,钢球、套圈、保持架的加工质量对轴承振动都有影响,其中钢球的加工质量对轴承振动影响最明显。钢球在一些特殊条件下,常常需要特殊材质的钢球,同时采用相应的热处理生产工艺改变其钢件组织以增强钢球的硬度、强度、耐磨性等,来实现不同环境下所要求达到的性能。为此研究开发既能大批量处理、又有高温度均匀性和先进控制手段的全自动热处理生产线就很有必要了。设计制造出满足钢球热处理工艺要求的全自动生产线,能够精确控制保证各加热炉腔的温度,实现全自动送料出料可以在保证加工质量的同时减少人力提高生产效率。此外,实现各加热区温度可调可控,钢球在各加热区域行进速度可调、加热保温时间可控,可以使此生产线满足多种型号轴承钢球的加工处理,极大提高利用率和生产效率。基于以上原因,本课题根据轴承钢球的强度硬度需求,设计制造出一条可满足多种型号轴承钢球的热处理工艺的生产线。本文采用多个马弗罐式滚筒作为传送元件;运用三相调功调压器和PLC复合控制系统完成炉内温度分区控制,将整条生产线分成七个温区,每个温区具有相对独立的高温电阻丝作为加热单元,由PLC内部的PID运算控制器驱动三相调功调压器改变加载在高温电阻丝上的电压完成区域温度控制;生产线的上料、送料、出料的控制由PLC及相应的继电器与接触器配合完成。针对不同型号的钢球,通过上位机设置各温区的加热温度及变频器输出频率来调节加热区域温度及加热时间。同时本文采用了MCGS软件作为上位机控制软件,实现了整个生产过程的可控、可视以及自动化。本文以PLC系统为控制核心,给出了生产线总体方案设计、机械部分设计及相关的电气原理图。简要介绍了相关设备的选型,重点阐述了生产线的控制程序包括手动、自动运行程序、上位机对各部通讯控制的实现过程。通过上位机控制软件与PLC及三相调功调压器、变频器的结合,实现了整条生产线的良好运行。
[Abstract]:Bearing is an important basic part of all kinds of mainframe, and steel ball is the key part of ball bearing. Steel ball acts as a rolling body to carry and transfer load in ball bearing. Rolling bearings should have long life, low vibration, low noise, small torque and high reliability. In order to realize the above performance, the machining accuracy of bearing parts and components and the machining quality of steel ball, ring and cage must be guaranteed to affect bearing vibration, among which the processing quality of steel ball has the most obvious effect on bearing vibration. Under some special conditions, steel ball often needs special material steel ball. At the same time, the corresponding heat treatment process is adopted to change the structure of steel parts to enhance the hardness, strength and wear resistance of steel ball, etc. To achieve the required performance in different environments. Therefore, it is necessary to develop a fully automatic heat treatment line with high temperature homogeneity and advanced control means. The design and manufacture of a fully automatic production line to meet the requirements of the steel ball heat treatment process can accurately control the temperature of each heating furnace cavity and realize the automatic feeding and discharging process which can guarantee the quality of processing and increase the production efficiency by reducing the manpower at the same time. In addition, the temperature of each heating zone can be controlled, the moving speed of steel ball in each heating area can be adjusted, and the heating and heat preservation time can be controlled, which can make this production line meet the processing of various types of bearing ball, and greatly improve the utilization ratio and production efficiency. For the above reasons, according to the demand of strength and hardness of bearing steel ball, this paper designs and manufactures a production line which can meet the heat treatment process of various types of bearing steel ball. In this paper, a number of muffle barrel type rollers are used as transmission elements. The three-phase power regulator and PLC compound control system are used to control the temperature in the furnace. The whole production line is divided into seven temperature zones, each of which has relatively independent high temperature resistance wire as heating unit. The PLC internal PID operation controller drives the three-phase power regulator to change the voltage loaded on the high temperature resistor wire to complete the region temperature control. The control of feeding, feeding and discharging of production line is accomplished by PLC and corresponding relays and contactors. For different types of steel balls, the heating temperature and heating time are adjusted by setting the heating temperature of each temperature region and the output frequency of frequency converter on the host computer. At the same time, the MCGS software is used as the host computer control software to realize the controllable, visual and automation of the whole production process. Taking the PLC system as the control core, this paper gives the overall design of the production line, the design of the mechanical part and the related electrical schematic diagram. This paper briefly introduces the selection of related equipment, and expounds emphatically the control program of the production line including manual and automatic operation program, and the realization process of the communication control of each part by the upper computer. Through the combination of PC control software, PLC, three-phase power regulator and frequency converter, the whole production line runs well.
【学位授予单位】：武汉理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG155
本文编号：2405443
[Abstract]:Bearing is an important basic part of all kinds of mainframe, and steel ball is the key part of ball bearing. Steel ball acts as a rolling body to carry and transfer load in ball bearing. Rolling bearings should have long life, low vibration, low noise, small torque and high reliability. In order to realize the above performance, the machining accuracy of bearing parts and components and the machining quality of steel ball, ring and cage must be guaranteed to affect bearing vibration, among which the processing quality of steel ball has the most obvious effect on bearing vibration. Under some special conditions, steel ball often needs special material steel ball. At the same time, the corresponding heat treatment process is adopted to change the structure of steel parts to enhance the hardness, strength and wear resistance of steel ball, etc. To achieve the required performance in different environments. Therefore, it is necessary to develop a fully automatic heat treatment line with high temperature homogeneity and advanced control means. The design and manufacture of a fully automatic production line to meet the requirements of the steel ball heat treatment process can accurately control the temperature of each heating furnace cavity and realize the automatic feeding and discharging process which can guarantee the quality of processing and increase the production efficiency by reducing the manpower at the same time. In addition, the temperature of each heating zone can be controlled, the moving speed of steel ball in each heating area can be adjusted, and the heating and heat preservation time can be controlled, which can make this production line meet the processing of various types of bearing ball, and greatly improve the utilization ratio and production efficiency. For the above reasons, according to the demand of strength and hardness of bearing steel ball, this paper designs and manufactures a production line which can meet the heat treatment process of various types of bearing steel ball. In this paper, a number of muffle barrel type rollers are used as transmission elements. The three-phase power regulator and PLC compound control system are used to control the temperature in the furnace. The whole production line is divided into seven temperature zones, each of which has relatively independent high temperature resistance wire as heating unit. The PLC internal PID operation controller drives the three-phase power regulator to change the voltage loaded on the high temperature resistor wire to complete the region temperature control. The control of feeding, feeding and discharging of production line is accomplished by PLC and corresponding relays and contactors. For different types of steel balls, the heating temperature and heating time are adjusted by setting the heating temperature of each temperature region and the output frequency of frequency converter on the host computer. At the same time, the MCGS software is used as the host computer control software to realize the controllable, visual and automation of the whole production process. Taking the PLC system as the control core, this paper gives the overall design of the production line, the design of the mechanical part and the related electrical schematic diagram. This paper briefly introduces the selection of related equipment, and expounds emphatically the control program of the production line including manual and automatic operation program, and the realization process of the communication control of each part by the upper computer. Through the combination of PC control software, PLC, three-phase power regulator and frequency converter, the whole production line runs well.
【学位授予单位】：武汉理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG155
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