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Automation of Machining

Technology II. Jan Tomíček. Automation of Machining. Automation of machining. Is connected with the rising demands of society and industry development. Is the way to intensification of manufacturing – increasing productivity, improving quality and lowering costs

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Automation of Machining

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  1. Technology II. Jan Tomíček AutomationofMachining

  2. Automation of machining • Is connected with the rising demands of society and industry development. • Is the way to intensification of manufacturing – increasing productivity, improving quality and lowering costs • Is the way to improvements in manufacturing technology, spreading the technological possibilities and way to make the inovation cycle faster.

  3. Whatweneed to automate? • Tool management • Toolchange • Toolmovements • Spindle start, devices start • Materialloading • Finishedpieceremove

  4. AUTOMATION OF MACHINING Machine tools: • general-purpose, manually operated (conventional); - Theleadingpoweristheworker

  5. AUTOMATION OF MACHINING Machine tools: • automated: a) fixed automation – mechanisms: cams, gear wheels, links, levers, arms; mechanical stops, limit switches, etc. b) flexible automation – programcontrol, numerical control

  6. Fixed automation elements

  7. Cam Is a discorcylinderwith a curveshapedpath. A boss in support is in thepathand as thecamturnsthe support moves. Cam are connectedtogether to providecomplexmovementof support, feed, rotationandother.

  8. Cylindrical cam use – automatic lathe carriage

  9. Disc cam use – automatic lathe cross slide

  10. Fixed automation machine tools • automatic general-purpose machine e.g. a semiautomatic or an automatic lathe • single-purpose machine (usually unit-built) workpiece oriented function design • transfer line integrated workpiece transport system

  11. Unit-built machine

  12. Feed drive unit - EV

  13. Drilling spindle unit - BO

  14. Slide unit - SE

  15. Circular indexing table unit - TA

  16. Modular units design

  17. Single purposemachine • Just oneoperation, ofop. Step isdone. • Sometimes a batchofoperationsteps • Specialmachinedesigned to maximizetheproduction: • Multiple spindles • Highfeeddrives • Multiple clamping • Automatic part in feed • Specialtoolingusage

  18. Single-purpose machine efficiency

  19. Transfer line – a concept

  20. Transfer line – a schema

  21. Transfer line – a design

  22. Block machining transferline

  23. Transfer line station – an example

  24. 2) Flexibleautomation • (soft, programableautomation) isaimedatpieceandsmallbatchproductiondue to easyreprogramming. Two basic forms • Program sequencecontrol • Numericalcontrol

  25. Program sequencecontrol Thesequenceofmotionsandswitchingsiscontrolled by relays, timers, switches, perforatedtape, programablecylinders, plugboardsandothercontrollers. Easierreprogramming, limited program options, almost no adjustments

  26. Perforated tape Each line presents a different movement or switch. It has to be printed correctly, no error control. FYI: 8 line perforated paper tape can contain one byte of information in one column of holes. Normal pitch of columns is 2,54 mm. That means you need 2,6 m of tape to store 1kB of data. A dual-layer DVD is then approx. 22100 km of perforated tape.

  27. Numericalcontrol • The most important type ofautomation. Almostallofnewmachines are numericallycontrolled. Priciple: Machineandallofitsmovements are controlled by a program. Program is a list ofinstructionswrittenisspecific syntax andhavingspecificformat.

  28. Mechanical vs. numerical • Limitations – speed, lengthof program, possiblemotions on cams.

  29. FLEXIBLE AUTOMATION • Conventional machine tool

  30. FLEXIBLE AUTOMATION 2. NC machine tool (stand-alone)

  31. FLEXIBLE AUTOMATION 3. NC machine tool with tool magazine

  32. FLEXIBLE AUTOMATION 4. CNC machine tool

  33. Mechanization vs. automation • Mechanization – human power is replaced by machines, drives, hydraulic or mechanic devices • Automation – human control is replaced by sequentional machine, cams, computer, PLC controller

  34. Automation degree • Semiautomatic run – tools are changed automatically, blank or finished workpiece is renowed by operator • Automatic run – both the tool and pieces are placed and removed automatically by robot (line, tables)

  35. NC / CNC definition Originalyonly NC controlwasused. Program wasstored on tapeordiscandreadone line afteranother. Influence of rapid developmentofcomputersresulted to CNC control (Computernumericalcontrol). Nowthe program isloadedintocomputersmemoryandexecutedfromhere.

  36. CNC advantages

  37. Program sequence Subprograms • A link to anotherthenthefollowing line isenteredintomainprogramm. • Thissubprogramisexecuted. • Afterfinishingthis program wereturn to main program a wecontiueuntilendofmain program(M30)

  38. Basic principlesof CNC machines • NC/CNC machine consist of 3 basic elements. List of instructions – NC code – a mix of alphabecial and numerical information. Contaion information about movements, feed, speed, tool change and other machine functions (cooling, measuring) Control unit - control system – convertsthe program intosignalformachineandsendthem to machine(PLC controller) NC code Machine Control unit (system) Drive motor Sensing device

  39. Basic principlesof CNC machines • NC/CNC machine consist of 3 basic elements. Machinetool – fittedwith drive motor to operateslides, support andspindle. Alsowithswitches to start/stop specificfunctions Sensing device – optional(closedcircuit)- sensing device controlif a specificdemandwasfullfilled. Support feed, Table positionetc. NC code Machine Control unit (system) Drive motor Sensing device

  40. CNC machine tool

  41. Motions Threetypesofmotion • point-to-point motion – toolismoved to specificlocation, pathor speed ofmovebetweenlocationis not controlled. (drilling) • Linearcontrol – movementalongoneoftheaxesofthemachine. • Contouringcontrol – movementcanbemade in twoor more axessimultaneously.

  42. Motions Point-to-point controlLinearcontrolContouringcontrol (continual) drillingmillingmachines, lathesmachiningc.(milling, turning)

  43. CNC machining centre(MC) • MC combine a number of different machining processes in one operation

  44. Modular tool set

  45. Modulartool set – toolingsystem Allmanufacturersaroundtheworld Basic concept: • Holderwithstandadizedconecting part – ISO, BSK cone, CAPTO systemetc. • Extension bar – active (vibrationelimination) adujstableandbalanced • Quickchangetooltip/insert

  46. SECO - Combimaster

  47. Tool exchange

  48. Tool exchange

  49. Flexible cell – a concept

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