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Integrated Computer Aided Manufacturing
1.INTRODUCTION
Today’s industry competes in a truly international marketplace. Efficient transportation networks have created a “world market” in which we participate on a daily basis. For any industrial country to compete in this market, it must have companies that provide economic high-quality products to their customers in a timely manner. The importance of integrating product design and process design to achieve a design for production system cannot be overemphasized. However, even once a design is finalized, manufacturing industries must be willing to accommodate their customers by allowing last-minute engineering-design changes without affecting shipping schedules or altering product quality.
Most U.S.-based manufacturing companies look toward CAD/CAM and CIM to provide this flexibility in their manufacturing system . Today ,the use of computers in manufacturing is common . Manufacturing system are being designed that not only process parts automatically ,but also move the parts from machine to machine and sequence the ordering of operations in the system. Figure 1 contains a plot of the economic regions of manufacturing. It should be noted that manual handcrafted goods will always have a market in the United States as well as abroad. This is also true of industrial products—there will continue to be a need for special one-of-a-kind items. The spectrum of one-of-a-kind goods through high-volume goods dictates that a variety of manufacturing methods be used to meet our various industrial needs. Some of these systems will look like the factories that our grandparents labored in, whereas others will take on a futuristic look. In the following sections, a discussion of flexible manufacturing systems is presented.
Figure 1 Volume versus variety regions for economic manufacturing
(Courtesy of Cincinnati Milacron.)
2.FLEXIBLE MANUFACTURING SYSTEMS
A flexible manufacturing system, or FMS as they are more commonly known, is a reprogram-able manufacturing system capable of producing a variety of products automatically. Since Henry Ford first introduced and modernized the transfer line, we have been able to perform a variety of manufacturing operations automatically. However, altering these systems to accommodate even minor changes in the product has been quite taxing. Whole machines might have to be introduced to the system while other machines or components are modified or retired to accommodate small changes in a product. In today’s competitive marketplace ,it is necessary to accommodate customer changes or the customer will find someone else who will accommodate the changes. Conventional manufacturing system s have been marked by one of two distinct features:
1. Job shop type systems were capable of producing a variety of product ,but at a high cost.
2. Transfer lines could produce large volumes of a product at a reasonable cost, but were limited to the production of one ,two, or very few different parts.
The advent of numerical control (NC) and robotics has provided us with reprogramming capabilities at the machine level with minimum setup time. NC machines and robots provide the basic physical building blocks for re-programmable manufacturing systems.
2.1.FMS Equipment
2.1.1Machines
In order to meet the requirements of the definition of an FMS, the basic processing in the system must be automated. Because automation must be programmable in order to accommodate a variety of product-processing requirements, easily alterable as well as versatile machines must perform the basic processing.
For this reason, CNC turning centers, CNC machining centers, and robotic workstations comprise the majority of equipment in these systems. These machines are not only capable of being easily reprogrammed, but are also capable of accommodating a variety of tooling via a tool changer and tool-storage system. It is not unusual for a CNC machining center to contain to 12 or more tools (right-hand turning tools, left-hand turning tools ,boring bars, drills ,and so on ) . The automatic tool changer and storage capabilities of NC machines make them natural choices for material-processing equipment.
Parts must also be moved between processing stations automatically. Several different types of material-handling systems are employed to move these parts from station to station. The selection of the type of material-handling system is a function of several system features. The material-handling system, first, must be able to accommodate the load and bulk of the part and perhaps the part fixture. Large, heavy parts require large , powerful handling systems such as roller conveyors guided vehicles or track-driven vehicle systems. The number of machines to be included in the system and the layout of the machines also present another design consideration. If single material handler must be at least as large as the physical system. A robot is normally only capable of addressing one or two machines and load-and-unload station. A conveyor or automatic guide vehicle(AGV) system can be expanded to include miles of factory floor. The material-handling system must also be capable of moving parts from one machine to another in a timely manner. Machines in the system will be unproductive if they spend much of their time waiting for parts to be delivered by the material handler. If many parts are included in the system and they require frequent visits to machines, then the material-handling system must be capable of supporting these activities. This usually can be accommodated by using either a very fast handling device of by using several devices in parallel, for example, instead of using a single robot to move parts to all the machines in the system, a robot would only support a single machine.
2.1.2 Tooling and fixtures.
Versatility is the key to most FMSs, and as such the tooling used in the system must be capable of supporting a variety of products or parts. The use of special forming tools in an FMS is not typical in practice. The contours obtained by using forming tools can usually be obtained through a contour-control NC system and a standard mill. The standard mill then can be used for a variety of parts rather than to produce a single special contour. An economic of the cost and benefits of any special tooling is necessary to determine the best tooling combination. However, because NC machines have a limited of tools that are accessible, very special tools should be included.
One of the commonly neglected aspects of an FMS is the fixturing used. Because fixtures are part of the tooling of the system, one could argue that they should also be standard for the system. Work on creating “flexible fixtures” that could be used to support a variety of components has only recently begun. See Chapter 5.One unique aspect of many FMSs is that the part is also moved about the system in the fixture (or pallet fixture). Fixtures are made to the same dimensions so that the material-handling system can be specialized to handle a single geometry. Parts are located precisely on the fixture and moved from one station to another on the fixture. Fixtures of this type are usually called pallet fixtures, or pallets. Many of the pallet fixtures employed today have standard “T-slots” cut in them, and use standard fixture kits to create the part-locating and-holding environment need for machining.
3.COMPUTER CONTROL OF FLEXIBLE MANUFACTURING SYSTEMS
3.1 FMS Architecture
An FMS is a complex network of equipment and processes that must be controlled via a computer or network of computers. In order to make the task of controlling an FMS more tractable, the system is usually divided into a task-based hierarchy. One of the standard hierarchies that have evolved is the National Institute of Standards and Technology(NIST) factory-control hierarchy. (NIST was formerly the National Bureau of standards. NBS.) This hierarchy consists of five levels and is illustrated in Figures 2 and Figures 3 The system consists of physical machining equipment at the lowest level of the system. Workstation equipment resides just above the process level and provides integration and interface functions for the equipment. For instance pallet fixtures and programming elements are part of the workstation. The workstation typically provides both man-machine interface as well as machine-part interface. Off-line programming such as APT for NC or AML for robot resides at the workstation level.
The cell is the unit in the hierarchy where interaction between machines becomes part of the system. The cell controller provides the interface between the machines and material-handling system. As such ,the cell controller is responsible for sequencing and scheduling parts through the system. At the shop level integration of multiple cells occurs as well as the planning and management of inventory. The
Figure 3 The relationship between the data-administration (DAS) in the NIST architecture :(1)the topologies of the Integrated Manufacturing Data Administration System(IMDAS) data-administration system;(2)the net work data-communication network; (3)the hierarchical system of data-driven control: data preparation is implied in (4) the facility level of control
facility level is the place in the hierarchy where the master production schedule is constructed and manufacturing resource planning is conducted. Ordering materials planning inventories and analyzing business plans are part of the activities that affect t he production system. Poor business and manufacturing plans will incapacitate the manufacturing system just as surly the unavailability of a machine.
3.2 FMS Scheduling and control
Flexible manufacturing systems, like other manufacturing system can differ significantly complexity . This complexity is not only determined by the number of machines and the number of parts resident in the system, but also by the complexity of parts and control requirements of the specific equipment . Some FMSs require only a simple programmable controller to regulate the flow of parts though the system, whereas others require sophisticated computer control systems. In the following sections , example of FMSs and their control are presented.
The most simple FMS consists of a processing machine, a load/unload area, and a material handler (a one-machine system is the most simple FMS that can be constructed ). Operation of this system consists of loading the part(s) that move down a conveyor the machine. Once the part is loaded onto the machine , the robot is retracted to a “safe position” and the machining begins.
Although this is a very simple system, it illustrates several interesting design and control decisions that must be considered. If only a single part is to be processed in the system, a minimum number of switches and sensors necessary for the system. One requirement of the system is that the parts on the conveyor all have to be oriented in the same way. This is required so that the robot can pick up the part and deliver it to the NC machine in the same orientation every time. A proximity switch or micro-switch is required at the end of the conveyor to detect when a part is resident, and on the machine for the same purpose.
計算機輔助制造
1.緒論
當今的工業(yè)的競爭已經是真正意義上的國際市場競爭。 高效的運輸網絡建立了一個我們每天都要參與的 “世界市場”。 對于任何工業(yè)化國家要參與這個市場競爭，就必須采用一種適時的方式為其客戶提供經濟、優(yōu)質的產品。將產品設計和過程設計進行集成的重要性，在產品系統(tǒng)被怎么強調都不為過。但是， 即使一種設計最終被落實， 制造業(yè)者一定愿意通過允許最后的工程設計變化，而沒有通過影響裝運進度表，或者改變產品質量來適應他們的用戶。
大多數(shù)美國的生產公司基于趨向計算機輔助設計（CAD）/計算機輔助制（CAM）和CIM為他們的制造系統(tǒng)提供靈活性。今天，計算機用于制造已經很平常?，F(xiàn)在不僅為零件生產設計制造系統(tǒng)，而且為零件從一臺機器運送到另一臺機器的命令順序設計了制造系統(tǒng)，如圖（1），它還包含一個經濟區(qū)域的制造經濟計劃在美國和其他國家，手工產品總是還有一些市場的，此外真正的工業(yè)產品對于特殊的“one-of-a-kind”技術項目還是需要的?！皁ne-of-a-kind”通過大量的貨物來表明、各種各樣的工業(yè)需要各種各樣的加工方法。 有些系統(tǒng)將看起來像我們的祖父母曾經工作過的工廠，而其它則呈現(xiàn)出一種未來派的情景。在后文中，我們將展開討論柔性制造系統(tǒng)。
圖（1）
2.柔性制造系統(tǒng)
柔性制造系統(tǒng)（FMS）像人們通常知道的那樣的，能使用一個可編程的制造系統(tǒng)自動地生產各種各樣的產品。 自從亨利·福特率先提出并且使流水生產線實現(xiàn)現(xiàn)代化，我們就已經能自動執(zhí)行多種生產的生產。 不過，改變這些系統(tǒng)甚至只作較小的變動，這些產品的生產都會變得相當繁重。 當其他機器或者零部件要經過修理或者廢棄，以適應這種蕭蕭的變化，整個機器才可能被引進到系統(tǒng)。 在今天的競爭性市場里，能適應客戶的各種變化是很必要的。傳統(tǒng)的制造系統(tǒng)以特征可劃分為以下兩種：
1.加工車間類型系統(tǒng)能生產多種產品，但是費用高。
2.流水線能以合理費用生產能大量產品， 但是僅局限于幾種不同零件的生產。
數(shù)控(NC)和機器人技術的時代已經來臨，這為我們提供了在最小準備時間里，使機器的程序重新調定。NC機床和機器人是重新可編程序的制造系統(tǒng)的基本物理組成部分。
2.1.柔性制造系統(tǒng)的設備
2.1.1機床
為了滿足柔性制造系統(tǒng)定義的要求，該系統(tǒng)的基本工藝應實現(xiàn)自動化。因為自動化必須是可編程的，以適應不同的產品要求，而易于改變，以及通用機床必須執(zhí)行這些工藝。計算機數(shù)控（CNC）車削中心、計算機數(shù)控（CNC）加工中心、及機器人工作站構成了這些設備。這些機器不僅僅是易于重新編程，同時也適應置于刀具存儲系統(tǒng)及刀具更換器中的不同刀具。通常CNC加工中心備有60多把或更多刀具（銑刀、鉆頭、鏜刀等）。對于CNC車削中心，備有12把或更多的刀具（右車刀、左車刀、鏜桿、鉆頭等）。書動機床的自動換刀器及刀庫使它們對材料的工藝裝備作出自然的選擇。
零件必須在加工站點之間自動化的移動，采用了數(shù)種不同的物料輸送系統(tǒng)，把這些零件從一個站點輸送到另一個站點。物料輸送系統(tǒng)的選擇是數(shù)種系統(tǒng)特征函數(shù)。首先，物料輸送系統(tǒng)的選擇必須適應零件（或許是零件的夾具）的負荷及批量。大型的、重型的零件需要大型的、強力的輸送系統(tǒng)，如滾子輸送、導向小車、軌道驅動車輛系統(tǒng)。構成的機床數(shù)量及機床布置也提供了另一種設計上的考慮。如果用單一的物料輸送機來運送零件到系統(tǒng)內的所有機床，則運輸機的工作覆蓋面至少必須是和整個系統(tǒng)一樣大。通常一臺機器人定位于一兩臺機床或一個裝卸站。一臺輸送機或自動導向車可以擴大到數(shù)英里的工廠區(qū)域。物料輸送也可以以即時的方式將零件從一臺機床輸送到另一臺機床。如果系統(tǒng)內的機床耗費大量的時間在等待輸送零件的到來，則其生產率是不會高地。如果有許多種零件包括在系統(tǒng)內，而且這些零件要經常輸送到機床上，物料系統(tǒng)要能夠支持這些活動。通常由采用極快的輸送裝置或靠平行地使用幾種裝置來實現(xiàn)。例如：用一臺機器人支持一臺機床，而不是用一臺機器人運送零件到系統(tǒng)內的所有機床。
2.1.2刀具及夾具
用途多樣性是柔性制造系統(tǒng)的關鍵，由此，在系統(tǒng)中使用的刀具必須能夠支持多種零件及產品的生產。在柔性制造系統(tǒng)中，使用專用的或成型刀具并不典型。使用成型刀具得到輪廓，通?？梢酝ㄟ^輪廓書空系統(tǒng)或標準的銑刀得到。標準的銑刀可以用于各種不同的零件而不是只能加工單一的輪廓。使用任何專用刀具其利潤和成本的經濟分析都是必須的，以確定最佳的刀具組合。然而，因書空機床僅有有限數(shù)量的刀具可供存取，極少數(shù)的刀具應當包括在內。
柔性制造系統(tǒng)通常容易忽視的一個方面是所使用的夾具。因為夾具是系統(tǒng)中工具的一部分。人們會爭議這樣一個事實，對系統(tǒng)中的夾具也應標準化。工件裝在創(chuàng)制出的“柔性夾具”中，這種僅在幾年前才開始使用的夾具可以支持多種零件。許多柔性制造系統(tǒng)的獨特方面是零件裝在夾具（或隨行夾具）中而在系統(tǒng)中運動，夾具做成相同的尺寸，這樣物料輸送系統(tǒng)可以專門化去輸送單一的幾何形體，零件精確的定位在夾具上，同時隨同夾具從一個站點運動大另一個站點。這種類型的夾具，通常稱為隨行夾具。現(xiàn)在所應用的許多隨行夾具都加工出標準的T型槽，同時使用標準的夾具組件創(chuàng)建出適應于切削加工的零件的定位及夾緊的條件。
3.柔性制造系統(tǒng)的計算機控制
3.1 FMS構架
FMS是一個必須被通過一臺計算機或者計算機網絡控制的設備和過程的復雜的網絡。 為了使控制FMS的任務更易處理，系統(tǒng)通常被分成一個個基于任務的階層。 已經逐步成的標準之一的是國家標準與技術局(NIST)工廠控制階層。 (NIST以前叫國家標準局， NBS.) 這個階層由5 步組成， 在圖（2）表示了系統(tǒng)由物質機器加工設備，圖（3）系統(tǒng)的最低的組成部分。 工作站設備恰好處于過程水平面存在并且起著預防綜合和設備接口的作用。 例如棘瓜固定設備和編程要素也是工作站的一部分。 工作站通常提供人力機器接口和機器零件接口。 而脫機程序適合NC那種易于AML給機器人工作的工作站水平。
小屋是在在機器之間的相互作用階層的單位，并成為系統(tǒng)的一部分。 小屋控制器提供了那些機器和物質處理系統(tǒng)之間的接口。 照此，小屋控制器負責系統(tǒng)的排序和調度部分。車間水平的集成和多房間重現(xiàn)生成了存貨清單的計劃和管理。
圖（2）
圖（3）
3.2 FMS安排和控制
柔性制造系統(tǒng)，像其他制造系統(tǒng)一樣，能區(qū)別出零件之間較大的復雜性。 這復雜性不僅包括系統(tǒng)中機器的數(shù)量和確定的數(shù)量， 而且包括那些復雜性的部分和控制要求的那些具體設備。一些FMS只要求有一個簡單的可編程控制器就行了，而其它的還要求有復雜的計算機控制系統(tǒng)。在以后的章節(jié)里，還要提出一些FMS及其控制的例子。
最簡單的FMS由一臺處理器、裝載/卸載區(qū)域和原料處理機(一個最簡單的FMS可以只由一臺機器構成)。 這系統(tǒng)的操作包括了往下的一個傳輸裝置。一旦零件被裝到機器上，機器人縮回到一個“安全的位置”，然后機器開始加工。
雖然這是一個非常簡單的系統(tǒng)，但是它例舉了幾種有趣的設計和必須考慮的控制部件。如果在系統(tǒng)中，只有一個部分在運作，那么系統(tǒng)就只需要最小數(shù)量的開關和傳感器。系統(tǒng)所需要的是，所有傳輸帶上的零件使用同樣的方法定位。這還需要使機器人每一次都用同樣的定位方法能讓把零件裝在到數(shù)控機床上。在輸送裝置的末端發(fā)現(xiàn)有零件已到達的時候，需要一個行程或者微開關。
邵 陽 學 院
畢業(yè)設計（論文）開題報告書
課題名稱 數(shù) 控 十 字 滑 臺 的 設 計
學生姓名 羅 文
學 號 0340717005
院（系）、專業(yè) 機 械 與 能 源 工 程 系
指導教師 張 桂 菊
2007年02月28日
一、課題的來源、目的意義（包括應用前景）、國內外現(xiàn)狀
（1）課題的來源：隨著制造業(yè)的發(fā)展，人們深刻的感受到數(shù)控機床在生產中的地位是越來越重要，雖然近幾年我國組合機床的技術在不斷的發(fā)展，然而組合機床通用部件中的大型滑臺，至今仍主要是單坐標的滑臺。我們在對一些X－Y工作臺的研究調查中發(fā)現(xiàn)目前的簡易數(shù)控控制系統(tǒng)基本上是基于普通單片機，顯示為LED數(shù)碼管的系統(tǒng)，操作很不方便而且通用性不強。為此，本課題此基礎上設計了通用的2軸半數(shù)控控制器。其基本思想是采用最新的微處理技術和集成電路技術，提高系統(tǒng)集成度，從而提高可靠性，降低成本，減小體積。它具有良好的人－機交互界面，滿足一般2軸半數(shù)控系統(tǒng)的需要。（X－Y工作臺是指能分別沿著X向和Y向移動的工作臺）
（2）目的意義：本文通過對X－Y工作臺的機械系統(tǒng)、控制系統(tǒng)及接口電路的設計，闡述了機電一體化系統(tǒng)設計中的共性和關鍵的技術。該數(shù)控十字滑臺可靈活用于銑床和鉆床的數(shù)控改造，而且改造簡單方便，技術難度不大，可廣泛應用。
（3）國內外現(xiàn)狀：從上世紀80年代起，機床制造業(yè)的發(fā)展雖有起伏，但對數(shù)控技術和數(shù)控機床一直給予較大的關注。經過“九五”數(shù)控車床和加工中心（包括數(shù)控銑床）的產業(yè)化生產基地的形成，所生產的中檔普及型數(shù)控機床的功能、性能和可靠性方面已具有較強的市場競爭力。但在中、高檔數(shù)控機床方面，與國外一些先進產品相比，仍存在較大差距，這是由于歐美日等先進工業(yè)國家于80年代先后完成了數(shù)控機床產業(yè)進程，其中一些著名機床公司致力于科技創(chuàng)新和新產品的研發(fā)，引導著數(shù)控機床技術發(fā)展，如美國英格索爾公司和德國惠勒喜樂公司對用于汽車工業(yè)和航空工業(yè)高速數(shù)控銑床的發(fā)展，日本牧野公司對高效精密加工中心所作的貢獻，德國瓦德里希公司在重型龍門五面加工銑床方面的開發(fā)，以及日本馬扎克公司研發(fā)的車銑中心對高效復合加工的推進等等。相比之下，我國大部分數(shù)控機床產品在技術上都處于跟蹤階段。
基于這一現(xiàn)實，為了加速振興我國的機床制造業(yè)，當前宜加強如下五方面的研究和發(fā)展工作：(1)以高速化為先導，提高數(shù)控機床的綜合性能。(2)加快數(shù)控機床向高效柔性化和高精化發(fā)展的步伐，推進mm級精度機床工程的規(guī)劃和實施。(3)加強發(fā)展多功能復合加工的數(shù)控機床來提高單件和中小批量生產的加工精度和高效柔性化。(4)對于中大批量生產、發(fā)展快速重組制造系統(tǒng)(Rapidly Reconfigurable Manufacturing System簡稱RRMS)和可重構機床(Reconfigurable Machine Tool簡稱RMT)將是一個合理的解決方案。(5)發(fā)展網絡制造單元以適應數(shù)字化企業(yè)的構建。
二、課題研究的主要內容、研究方法或工程技術方案和準備采取的措施
（1）主要內容：隨著制造業(yè)的發(fā)展，人們深刻的感受到數(shù)控機床在生產中的地位是越來越重要，雖然近幾年我國組合機床的技術在不斷的發(fā)展，然而組合機床通用部件中的大型滑臺，至今仍主要是單坐標的滑臺。本課題設計以單片機作為控制系統(tǒng)的X-Y型工作臺（X－Y工作臺是指能分別沿著X向和Y向移動的工作臺）。通過對X-Y型工作臺機械結構設計和控制電路接口的設計，闡述了機電一體化設計中的共性和關鍵技術。
（2）工程技術方案及措施：機械傳動方面，設計時仍采用的傳統(tǒng)方式。一軸配備一對減速齒輪，選滾珠螺母副，軸承支撐。結構雖然簡單，但可以滿足強度各方面的要求，而且所有零部件價格便宜訂購方便,這樣就減小了生產的難度。
由于在設計要求中明確指出此工作臺為數(shù)控裝置，有獨立的數(shù)控操作和控制系統(tǒng)，這就對工作臺運動的控制提出了要求，在設計時優(yōu)先選擇步進電機作為動力源，采用單片機控制，這樣就能滿足設計所提出的要求。
該數(shù)控十字滑臺可靈活用于銑床和鉆床的數(shù)控改造，而且改造簡單方便，技術難度不大，可廣泛應用。
三、現(xiàn)有基礎和具備的條件
控制工程實驗室：實驗樓215室，主要儀器： PT數(shù)控轉臺1臺，XY軸步進數(shù)控工作1臺，四軸運動控制平臺2臺，液壓PLC控制系統(tǒng)，機械手控制系統(tǒng)，D/A和A/D轉換系統(tǒng)，MCS-51主機板1套，直流數(shù)字安培表，直流數(shù)字毫安表，指針式交流電流表。提供中國期刊網、提供超星數(shù)字圖書館有關圖書，萬芳數(shù)據資源庫，讀秀知識庫，CNKI數(shù)據資源系統(tǒng)。
四、總的工作任務，進度安排以及預期結果
工作任務和預期結果：本文通過對X－Y工作臺的機械系統(tǒng)、控制系統(tǒng)及接口電路的設計，了解機電一體化系統(tǒng)設計中的共性和關鍵的技術。
進度安排：
2006.12.20 ~ 12.31：選定課題題目交給指導老師，通過老師綜合分析和思考后，最后確定論文題目。
2007.2.20 ~ 2.28： 根據指導老師下達的畢業(yè)論文任務書，確定論文的主要內容并寫好開題報告，交給指導老師。
2007.3.1 ~ 3.5： 根據設計任務書并查閱相關資料，確定設計方案。
2007.3.6~ 5.16： 在現(xiàn)有基礎條件下，定期和指導老師聯(lián)系，進行課題論文的編寫，完成初稿。
2007.5.16 ~ 5.22： 根據指導老師的修改意見修改論文，并根據標準的論文格式打印除論文修改稿，
并于22前交給指導老師。
2007.5.23 ~ 5.28： 通過指導老師審定，畢業(yè)論文按要求設計完畢。
2007.6.7~6.10： 畢業(yè)論文答辯。
五、指導教師審查意見
指導教師（簽名）
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六、教研室審查意見
教研室主任（簽名）
年 月 日
七、院（系）審查意見
院（系）主任（簽名）
年 月 日
備 注