Inverter to adjust the cutting parameters in a machine – inverter technology – H
Lower costs is to improve the enterprise market Competition An effective means of force. For Motorcycle Parts Machining sector, to reduce Tools Consumption, especially consumption of imports of expensive tools is an important aspect of reducing processing costs. In the tool material, workpiece material, processing size, cooling conditions constant, the cutting speed on tool life the greatest impact, and relatively easy to change.
In our shop cylinder head production line, processing, valve guides and seat of the bottom two-position, use the composite fine boring knife. Two-spindle box drive two knives, were processed into the valve and exhaust valves. Each of the two blades on each knife, the blade for the MA PA L company, the price is 800 yuan / piece. Originally part of each blade generally can only process 3000, while the blade of calibration process for the 8000 drill holes, hole / slice, the blade apparently low utilization. To this end, we adjust the spindle speed by frequency converter in order to seek economic and reasonable spindle speed.
2 spindle speed control with frequency converter
Now to one of the station as an example, the specific process.
Hardware options Original spindle motor model Y90S-2. Its parameters are as follows: power of 1.5kW, rated current of 3.4A, speed is 2840r/min, Connection to Y. To reduce the changes, to retain the original spindle motor constant, use Fuji FAN5000G9S series inverter. The inverter has the function, low noise, convenient operation. Spindle motor according to the parameters, select the rated capacity of the matching FRN1.5G9S-4JE inverter (rated capacity of 2.8kVA, rated current of 3.7A).
Control process Spindle power for testing Electrical Gas control wiring diagram. PLC output signal to the relay, the relay control of the inverter X1, FDW and CM terminals connected terminals, disconnect, and then control the inverter output frequency, the motor speed adjustment. In order to prevent the inverter or motor failure, failure to expand, the normally closed contacts connected in series converter alarm input AC power supply control circuit connector, you can cut off the inverter power supply in time. Function of inverter parameters through external Keyboard Panel To enter, the motor function of parameter settings from the inverter.
2.3 parameter settings To prevent damage to the inverter and motor, in order to give full play to the functions of inverter, the inverter must be configured properly function parameters.
Frequency setting Selection panel to set the keyboard mode, the specific frequency value from X1, X2, X3 terminal ON / OFF combinations to choose, this is the X2, X3 terminal disconnect, PLC only control the output terminal X1, so just set X1 terminal function set the corresponding parameters can F20 (frequency not exceed the motor frequency given frequency).
Acceleration / deceleration time setting Acceleration / deceleration time selection determines the speed control system for fast, if you choose a shorter acceleration / deceleration time will increase productivity; but if you choose to accelerate too short, the system may not start or over-current trip ; If the deceleration time is too short, the frequency dropped quickly, Electric motor Will enter the brake status, possible over-voltage tripping, it should not affect the processing conditions, the reasonable choice of acceleration / deceleration time value.
Overload current setting Inverter overload current of electronic thermal overload relay value, in order to protect the motor should be set to motor rated current, or slightly less than the rated value.
Automatically restart after instantaneous power failure
For security purposes, this parameter can not be set automatically after instantaneous power failure restart mode.
Set the number of motor pole
Order to show the correct speed synchronous motor shall be correctly set the parameters. Motor rated slip as small, according to ne = 2840r/min, can determine the motor synchronous speed n1 = 3000r/min, motor pole number is 2.
Security Fuji 5000G9S series inverter alarm, and the protecting self-diagnosis function is complete, the internal protection function is activated once the transducer caused shutdown, there are relay open (closed) signal output, in order to prevent failure of the expansion, the inverter alarm normally closed contacts in series in the inverter AC power input side of the contactor control circuit.
3 to change the cutting speed test
We have adjusted the motor speed (ie, cutting speed adjustment tool), and cutting performance, tool life (referring to the actual processing of each workpiece to the number of blades) made a detailed record . After several months of testing, obtained in the current working conditions, the speed and surface roughness, the general speed and tool life curve.
The results showed that: cutting speed between the 1700 ~ 1900r/min, the parts of the surface quality and blade life is better integrated indicators, as well as meeting productivity requirements. We work rate set at 1800r/min, reflected in better cutting performance and very stable.
4 Economic Benefit In practice Machine tool Transformation, in order to save, the converter removed, changing the Timing belt pulley with a diameter of methods to reduce the spindle speed, and reach test to determine the best rate.
To produce 300,000 cylinder head calculation:
Transformation of the former (n = 2840r/min):
Consumption of blade number: (300 000 ÷ 3000 pieces / tablets) × 4 = 400
Consumption rate: 400 × 800 yuan / piece = 320,000 yuan After transformation
(n = 1800r/min): consumption of blade number: (300 000 ÷ 4000 pieces / tablets) × 4 = 300
Consumption rate: 300 × 800 yuan / piece = 240,000 yuan
Clearly, to produce 300 000 cylinder head calculation, only the station to save money and 80,000 yuan per year, while the replacement of timing belt pulleys only 100 yuan. We use the same method on the processing of one pair of valve guides, and seat bottom of the spindle speed adjusted to determine the cutting speed when cutting at 1400r/min best, the workpiece can be processed per unit is about 3800.
We use nearly 10 devices on the spindle speed adjusted frequency converter test methods to improve the service life of blades a year to save money for the company nearly 30 million, received significant economic benefits. The practice of the past two years: cutting tools for use in different working conditions, the reasonable cutting speed are not the same. Inverter to change the cutting speed, the best selection of economic cutting speed. Speed your selection, by changing the pulley diameter, and (or) method of replacing the motor to change the cutting speed,
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