【摘要】：軸承是各類主機的重要基礎件,而鋼球又是球軸承的關鍵零件,鋼球在球軸承中作為滾動體起承載和傳遞負荷的作用。滾動軸承應具有長壽命、低振動、低噪音、小的旋轉(zhuǎn)力矩和高可靠性等基本性能。要實現(xiàn)上述性能,必須保證軸承各零部件的加工精度,鋼球、套圈、保持架的加工質(zhì)量對軸承振動都有影響,其中鋼球的加工質(zhì)量對軸承振動影響最明顯。鋼球在一些特殊條件下,常常需要特殊材質(zhì)的鋼球,同時采用相應的熱處理生產(chǎn)工藝改變其鋼件組織以增強鋼球的硬度、強度、耐磨性等,來實現(xiàn)不同環(huán)境下所要求達到的性能。為此研究開發(fā)既能大批量處理、又有高溫度均勻性和先進控制手段的全自動熱處理生產(chǎn)線就很有必要了。設計制造出滿足鋼球熱處理工藝要求的全自動生產(chǎn)線,能夠精確控制保證各加熱爐腔的溫度,實現(xiàn)全自動送料出料可以在保證加工質(zhì)量的同時減少人力提高生產(chǎn)效率。此外,實現(xiàn)各加熱區(qū)溫度可調(diào)可控,鋼球在各加熱區(qū)域行進速度可調(diào)、加熱保溫時間可控,可以使此生產(chǎn)線滿足多種型號軸承鋼球的加工處理,極大提高利用率和生產(chǎn)效率�；谝陨显�,本課題根據(jù)軸承鋼球的強度硬度需求,設計制造出一條可滿足多種型號軸承鋼球的熱處理工藝的生產(chǎn)線。本文采用多個馬弗罐式滾筒作為傳送元件;運用三相調(diào)功調(diào)壓器和PLC復合控制系統(tǒng)完成爐內(nèi)溫度分區(qū)控制,將整條生產(chǎn)線分成七個溫區(qū),每個溫區(qū)具有相對獨立的高溫電阻絲作為加熱單元,由PLC內(nèi)部的PID運算控制器驅(qū)動三相調(diào)功調(diào)壓器改變加載在高溫電阻絲上的電壓完成區(qū)域溫度控制;生產(chǎn)線的上料、送料、出料的控制由PLC及相應的繼電器與接觸器配合完成。針對不同型號的鋼球,通過上位機設置各溫區(qū)的加熱溫度及變頻器輸出頻率來調(diào)節(jié)加熱區(qū)域溫度及加熱時間。同時本文采用了MCGS軟件作為上位機控制軟件,實現(xiàn)了整個生產(chǎn)過程的可控、可視以及自動化。本文以PLC系統(tǒng)為控制核心,給出了生產(chǎn)線總體方案設計、機械部分設計及相關的電氣原理圖。簡要介紹了相關設備的選型,重點闡述了生產(chǎn)線的控制程序包括手動、自動運行程序、上位機對各部通訊控制的實現(xiàn)過程。通過上位機控制軟件與PLC及三相調(diào)功調(diào)壓器、變頻器的結合,實現(xiàn)了整條生產(chǎn)線的良好運行。
[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.
【學位授予單位】：武漢理工大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TG155

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