PCA-6154

PCA-6154
PCA-6154
PCA-6154

数控机床作为一种柔性的、能的自动化机床，很好地解决了复杂、精密、小批量和多品种的零件加工问题。随着数控机床设备在工业的广泛应用，其运行的性也显得愈发重要，的数控机床设备可以有效保护操作人员的人身，避免设备的频繁故障，提高企业的生产力水平。
　　为了提高设备的等级，某动力公司位于的生产基地于2012 年启动了设备防护改造工程，希望通过对机械加工设备的升级改造，避免由于设备功能的缺失或不完善可能导致的隐患，满足长远的 EHS目标，进一步提升企业的市场竞争优势。
　　先让们看看这家改造企业的背景：
　　该公司是一家多元化的动力管理公司，其生产的电力、流体动力和机械动力产品广泛应用于建筑、飞机、卡车、汽车、机械以及各种商业设施，年销售额超过200亿美元。此次改造的工厂是其位于的28个制造基地之一，主要生产各种液压弯头、接头和管件等产品。
　　三重挑战，如何个个击破?
　　本次整改项目共涉及65台套设备的机器改造，其中难度的是20台 MAZAK数控机床的系统改造。
　　先，作为企业生产的核心设备， MAZAK数控机床的改造方案稳妥，只可成功，不可失败。此外，MAZAK数控机床设备的使用率，设备每天工作16个小时，每小时开门20次，一年总计11.2 万次的开门次数，这要求所用方案可靠和耐久，可以耐长期高负荷的运行条件。
　　令企业头痛的是，原设备的PLC 系统代码被保护，由于不能获得原设备 PLC的代码，改造时无法对设备做内部改变，但同时又要满足数控系统机器的防护要求，新方案需要一个创新的设计思路。
　　总结来说，此次升级改造需要的不仅仅是系列产品，而是一个针对现有数控机床特点而设计的、完整的定制化解决方案。
　　好产品 ， 更要有好的解决方案!
　　凭借在美同类项目的成功应用经验，以及遍布各地的专业而快速的销售和执行队伍，罗克韦尔自动化针对工厂现有设备的具体情况，为其量身定制了系统升级方案。
　　改造前，数控机床设备的均采用单回路形式，改造目标是实现级别category 3。
　　先，罗克韦尔自动化的项目实施团队反复多次和工厂多个部门讨论，查找资料，吃透原机器结构和控制原理，熟悉机器的各种状态，包括：设置、数控编程、运行(手动和自动)、小批次和大批量、维护和调试状态等，新改造方案考虑上述各个方面。
　　在充分了解设备情况后，实施团队严格遵循机器标准(ISO 13849 和 IEC 62061)，增加防护系统并嵌入到现有系统中运行。
　　整体逻辑图如图1所示，新系统按照SIL 3标准来设计，新旧系统独立而又并列运行，而且并行的输入、串行的输出将新系统和旧系统的措施有机结合起来，这种冗余的结构设计是方案的一大亮点，保证了系统的稳定运行。
　　为保证改造方案的化，本次改造采用原型机试制和批量生产的方式。改造前，这些数控机床设备就在长期高负荷地运行，所以改造方案满足苛刻的运行条件，不适宜一开始就批量改造，所以用19号机器先行改造，运行2个月后，针对效果提出进一步改进措施，而后全部用更新后的方案批量改造。
　　机器的耐久和稳定运行是本次改造的重要目标，为达成该目标，除了采用冗余的系统架构外，实施团队还采取了一系列的措施，包括：浮动推拉门、防震设计、通风防尘设计和备用回退选项等。

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UCI SAD2002-160 NSFP SAD2002160
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Fujitsu PW6A FLM 600 Power Supply Card FC9616PW61
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ARO E212SD-120-A C9066 VALVE UN FROM . AB2
XC3S200AN-4FT2​56C BGA XILINX IC
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AMADA DEGA 304040 FUJITSU FANUC A02B-0027-C116 OPTION UNIT A02B0027C116
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Fairchild HPTL2601 Single Channel Optocoupler - 100
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Altera EPM7192EGC160-​15 MAX 7000 CPLD 160-PGA old stock
CRESTRON PW-2420RU Regulated Universal Power SUPPLY 24V
19 ALTERA IC ARRIA II GX 190K 1152FBGAEP2AG​X190FF35C5
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ORIGINAL INFINEON TT251N14KOF MODULE MODULES
DM7407N 7407N FAIRCHILD SEMICONDUCTOR 7407 SN7407N DM7407N DIP NSC FSC PARTS
33732 Moeller Electric M22-K01 Contactor 500V 642A
Fairchild TT6000-005 transducer 0-60psi 0-10VDC Terminal connection NIB
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MAXIM MAX1887EEE SSOP 16pin Power IC ChipShip From USA
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AIR REGULATOR 1/4NPT 300PSI 0.5-30PSI OUT FAIRCHILD
FAIRCHILD 20722 MODEL 20 AIR VOLUME BOOSTER 250 PSI MAX
Fujitsu 9600 E16B-9900-R370 PS10RK - MIXER CARD v.01 Ci
Analog Devices HOS-060SH Operational Amplifier Low Offset Fast Settling
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33627 Microswitch BZ-RQX167 Limit Switch with plunger 15A 125 250
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30412 Cutler Hammer HLA3250T Breaker Trip Unit 3 Pole 250A
6N135 FAIRCHILD 6N135 DIP-8
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Analog Devices AD IRDC 1732 Option 560
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FURNAS 14CF32BA NO BOX
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5164 Schiwa NT-SL Power Supply
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Fairchild Model 4500 Pneumatic Volume Booster 4514
Fairchild T7950-40603O4 Transducer 24VDC
23560 Automation Direct D2-12TA Output Module 18-110 VAC 0.3A
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Two boxes of tubes FU29 FU32 6PJ 6P6P 6N8P 6B8P
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