【畢業(yè)設(shè)計(jì)】柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
【畢業(yè)設(shè)計(jì)】柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì),畢業(yè)設(shè)計(jì),柴油機(jī),缸體,底面,組合,機(jī)床,總體,整體,夾具,設(shè)計(jì)
鹽城工學(xué)院畢業(yè)設(shè)計(jì)說明書 2006
柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
摘要：本設(shè)計(jì)課題為柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)。機(jī)床總體設(shè)計(jì)主要完成雙面銑組合機(jī)床的“三圖一卡”；擬訂夾具的結(jié)構(gòu)方案、繪制夾具總圖及其零件圖。
根據(jù)氣缸體尺寸、形狀、材料、加工部位的結(jié)構(gòu)和加工精度、表面粗糙度等要求，確定選用臥式雙面銑組合機(jī)床；為實(shí)現(xiàn)工件快進(jìn)和工進(jìn)配以移動(dòng)工作臺(tái)；被加工平面為大平面，材料為HT250，故刀具選擇硬質(zhì)合金端銑刀。夾具安裝在移動(dòng)工作臺(tái)之上。在被加工零件的定位方面，本方案采用了“一面兩銷”的定位方式，以達(dá)到較好的定位效果。夾緊是通過手動(dòng)夾緊，以四個(gè)壓板實(shí)現(xiàn)夾緊，這樣能很好的防止夾緊力作用下工件產(chǎn)生形變。由于被加工零件體積、重量較大，故采用支承板支承。另外通過夾具誤差設(shè)計(jì)分析，能夠較好地保證加工精度。
通過這樣的設(shè)計(jì)來達(dá)到加工要求，以便能完成對(duì)柴油機(jī)氣缸體頂?shù)椎拇帚姡瑵M足工廠制定的產(chǎn)量。
關(guān)鍵詞：組合機(jī)床； 夾具； 氣缸體； 銑削
The diesel of the overall modular machine tool and jig for thick mill the surface and bottom of cylinder body of the diesel engine
Abstract: The diesel of the overall modular machine tool and jig are designed for thick mill the surface and bottom of cylinder body of the diesel engine. The system design mainly completes “three charts and a card” about the two-sided mill modular machine-tool. The jig design is to complete the structure plan, the assembly drawing and the parts drawing.
According to the cylinder body size, the shape, the material, processing request and so on spot structure and processing precision, surface roughness, determined selects the horizontal-type two-sided mill aggregate machine-tool; In order to realize the work piece to enter quickly with the labor enters matches by moves the work table; Is processed the plane is the big plane, the material is HT250, therefore cutting tool choice hard alloy face cutter. The jig installs in moves above the work table. In is processed the components the localization aspect, this plan has used "two sells at the same time" the locate mode, by achieves the good localization effect. Clamps is through manual clamps, clamps by four clamps realizations, like this can very good prevent clamps under the action of force the work piece to have the deformation. Because is processed the components volume, the weight is big, therefore uses the support plate supporting. Moreover designs the analysis through the jig error, can guarantee the processing precision well.
I complete the design requirements according to such design, so that I can complete to the diesel engine was mad the cylinder body goes against the bottom the thick mill, satisfy the factory formulation the output.
Key words: modular machine-tool; jig; cylinder body ; milling
課題名: 柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
目 錄
1 前言………………………………………………………………………………1
2 機(jī)床總體設(shè)計(jì)…………………………………………………………………3
2.1 被加工零件分析………………………………………………………………3
2.2 機(jī)床結(jié)構(gòu)的確定………………………………………………………………3
2.3 本組合機(jī)床的特點(diǎn)………………………………………………………………3
2.4 切削用量的確定………………………………………………………………3
2.5 各部件的造型………………………………………………………………4
2.6 繪制“三圖一卡”………………………………………………………………7
3 夾具設(shè)計(jì)…………………………………………………………………………………12
3.1 概述……………………………………………………………………………………12
3.2 設(shè)計(jì)的前期準(zhǔn)備………………………………………………………………………13
3.3 定位裝置的確定……………………………………………………………………13
3.4 確定夾緊方案……………………………………………………………………16
3.5 其他元件的設(shè)計(jì)……………………………………………………………………18
3.6 夾具的公差配合及技術(shù)要求…………………………………………………………18
3.7 工序的精度分析……………………………………………………………………21
4 總結(jié)………………………………………………………………………………………25
5參考文獻(xiàn)…………………………………………………………………………………26
6 致謝……………………………………………………………………………………27
柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
摘要：本設(shè)計(jì)課題為柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)。機(jī)床總體設(shè)計(jì)主要完成雙面銑組合機(jī)
床的“三圖一卡”；擬訂夾具的結(jié)構(gòu)方案、繪制夾具總圖及其零件圖。
根據(jù)氣缸體尺寸、形狀、材料、加工部位的結(jié)構(gòu)和加工精度、表面粗糙度等要求，確定選用臥式雙面銑組合機(jī)
床；為實(shí)現(xiàn)工件快進(jìn)和工進(jìn)配以移動(dòng)工作臺(tái)；被加工 面為 面，材料為HT250， 具選 合
銑 。夾具 裝 移動(dòng)工作臺(tái) 。 被加工零件的定位方面，本方案 用 “一面 ”的定位方式，以
的定位 。夾緊 動(dòng)夾緊，以 實(shí)現(xiàn)夾緊， ?￠ 的￡?夾緊￥作用?工件§currency1形
'。“?被加工零件體?、?量 ， 用fifl fifl。 – 夾具?差設(shè)計(jì)分析，?? · ?加工
精度。
的設(shè)計(jì)? 加工要求，以??完成?柴油機(jī)氣缸體頂?shù)椎拇帚?，?工…制定的§量。
‰ ?：組合機(jī)床； 夾具； 氣缸體； 銑削
The diesel of the overall modular machine tool and jig for thick mill the
surface and bottom of cylinder body of the diesel engine
Abstract: The diesel of the overall modular machine tool and jig are designed
for thick mill the surface and bottom of cylinder body of the diesel engine. The
system design mainly completes “three charts and a card” about the two-sided
mill modular machine-tool. The jig design is to complete the structure plan, the
assembly drawing and the parts drawing.
According to the cylinder body size, the shape, the material, processing request
and so on spot structure and processing precision, surface roughness, determined
selects the horizontal-type two-sided mill aggregate machine-tool; In order to
realize the work piece to enter quickly with the labor enters matches by moves
the work table; Is processed the plane is the big plane, the material is HT250,
therefore cutting tool choice hard alloy face cutter. The jig installs in moves
above the work table. In is processed the components the localization aspect,
this plan has used "two sells at the same time" the locate mode, by achieves the
good localization effect. Clamps is through manual clamps, clamps by four clamps
realizations, like this can very good prevent clamps under the action of force
the work piece to have the deformation. Because is processed the components
volume, the weight is big, therefore uses the
1前言
根據(jù)工件加工的 要，以`′的 用部件為??，配以部分ˉ用部件組成的ˉ用機(jī)床，? 為組合機(jī)床。
˙¨用? ?、 ?、 量currency1§? ，?用?加工量 的 、?型ˇ體和ˇ體—工件，完成 、 、
面和 臺(tái)、 各 形狀 ，以及銑削 面和成形面。
用部件 組成組合機(jī)床的??。用?實(shí)現(xiàn)機(jī)床切削和進(jìn) 動(dòng)的 用部件， 工 切削 、?動(dòng)
裝置、動(dòng)￥ˇ、進(jìn) 臺(tái)等為動(dòng)￥部件。用以 裝動(dòng)￥部件的 用部件 a底 、′ 、′ 底 等?為fifl
部件。
組合機(jī)床的特點(diǎn)：
a 組合機(jī)床“70 90%的 用部件組成，?以??設(shè)計(jì)和制造o期。 要的 ， ?以部分
? 部進(jìn) 裝，以組成¨? 加工要求的 設(shè)備。 ?組合機(jī)床?? 造的?? ，其 用部件?以
? ? 用。
b 組合機(jī)床 按具體加工?象ˉ門設(shè)計(jì)的，?以按最佳工 方案進(jìn) 加工。
c 組合機(jī)床 ?以同 從幾 方向 用?把 具?幾 工件進(jìn) 加工， 實(shí)現(xiàn)集?工序，提高currency1§
率的最 途徑。
d.組合機(jī)床 工件一 裝夾?用? 實(shí)現(xiàn)? 同 加工，? ? ?各 相互 間的精度要求，提高
§品 量；減少 工件工序間的搬 ， 善 勞動(dòng)條件；減少 占·面?。
e “?組合機(jī)床 ?數(shù)零、部件 同—的 用部件，簡化 機(jī)床的維護(hù)和修理。
f 組合機(jī)床的 用部件?以組織ˉ門工…集?currency1§，? ?提高§品 量和技術(shù)水 ，降低制造成本。
隨著電子技術(shù)的飛速發(fā)展，根據(jù) ?量currency1§? 化、? ?量?品 currency1§高 化的要求，以及§品更
加速的特點(diǎn)，70年代以?發(fā)展 型組合機(jī)床----柔 組合機(jī)床。˙ ?用?位主 ˇ、?換主 ˇ、編碼
隨 夾具、 具的自動(dòng)更換，配以?編程序控制器（PC）、數(shù)字控制（NC）等，?任意 '工作循環(huán)控制和
驅(qū)動(dòng)系統(tǒng)，?靈活¨??品 加工的?調(diào)?'的組合機(jī)床。
我國，組合機(jī)床發(fā)展已?28年的歷史，其科研和currency1§都具?相當(dāng)?shù)??，?用也已深入 ￠? 。
當(dāng)前機(jī)械制造 實(shí)現(xiàn)§品更 ，進(jìn) 技術(shù) 造，提高currency1§ 率和高速發(fā)展必不?少的設(shè)備 一。
機(jī)床夾具 機(jī)床 加工零件 所使用的一 工 設(shè)備，用˙?準(zhǔn)確·定位工件與 具 間的相?位置，
即實(shí)現(xiàn)工件的定位與夾緊，以完成加工所學(xué)要的準(zhǔn)確相? 動(dòng)。
“?夾具?? · ?加工精度和提高勞動(dòng)currency1§率， 已成為機(jī)械加工?不?缺少的工 裝備。為 ¨
?機(jī)械制造 ?§品更 快、品 ?、? ?currency1§的要求，近些年?夾具設(shè)計(jì)的發(fā)展表現(xiàn) 以?幾 方面：
a 用夾具朝高精度、高 率、 范圍方向發(fā)展；
b ˉ用夾具的發(fā)展不僅注?高精度與高 率， 朝標(biāo)準(zhǔn)化與規(guī)格化方向發(fā)展；
c ￥發(fā)展?調(diào)整夾具與組合夾具；
b 發(fā)展? 機(jī)床使用范圍和 ?的夾具；
e 夾具的設(shè)計(jì)與制造 用 工 、 結(jié)構(gòu)、 材料。
畢業(yè)設(shè)計(jì)任務(wù)書
課題：柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
一、設(shè)計(jì)內(nèi)容
課題來源于生產(chǎn)。為保證柴油機(jī)氣缸體頂?shù)酌娴谋砻娲植诙燃拔恢镁?，設(shè)計(jì)一
臺(tái)頂?shù)酌娲帚娊M合機(jī)床。在完成“三圖一卡”的基礎(chǔ)上，主要完成其總體設(shè)計(jì)及夾具
設(shè)計(jì)。
二、設(shè)計(jì)依據(jù)
柴油機(jī)氣缸體材料為HT250，其硬度是HB180-240。要求該粗銑組合機(jī)床能夠
銑削氣缸體表面至Ra為6.3，頂?shù)酌娉叽缰?27±0.3，其他要求見被加工零件圖。
生產(chǎn)按兩班制進(jìn)行，每班工作6小時(shí)，年產(chǎn)量65000件
三、技術(shù)要求
1、機(jī)床應(yīng)能滿足加工要求，保證加工精度；
2、機(jī)床應(yīng)運(yùn)轉(zhuǎn)平穩(wěn)，工作可靠，結(jié)構(gòu)簡單；
3、裝卸方便，便于維修、調(diào)整；
4、盡量使用通用件，以便降低制造成本；
5、各動(dòng)力頭分別由電機(jī)拖動(dòng)，可單獨(dú)控制。
四、畢業(yè)設(shè)計(jì)物化成果的具體內(nèi)容及要求
1、設(shè)計(jì)說明書1份，達(dá)1萬字以上，且要符合規(guī)范要求；
2、設(shè)計(jì)圖樣全部用AutoCAD繪制，總的繪圖量達(dá)3張A0以上；
3、具體設(shè)計(jì)的圖樣有：
（1）機(jī)床聯(lián)系尺寸圖、被加工零件工序圖、加工示意圖、生產(chǎn)率計(jì)算卡
（2）夾具總裝圖和主要零件工程圖
可附其他實(shí)物及實(shí)驗(yàn)要求
五、畢業(yè)設(shè)計(jì)進(jìn)度計(jì)劃
起訖日期
工作內(nèi)容
備 注
06.03.06—06.03.07
布置任務(wù)
下達(dá)任務(wù)書
06.03.06—06.03.17
調(diào)查研究，收集資料，熟悉課題,畢業(yè)實(shí)習(xí)
06.03.20—06.03.31
總體設(shè)計(jì)，方案論證
06.04.10—06.05.10
部件、零件設(shè)計(jì)階段
06.05.11—06.05.25
編寫說明書
06.05.26—06.05.28
畢業(yè)設(shè)計(jì)預(yù)答辯
06.05.29—06.05.31
修改整理
06.06.01—06.06.02
復(fù)查材料
評(píng)閱
06.06.03—06.06.05
畢業(yè)答辯
06.06.06—06.06.08
材料整理裝袋
六、主要參考文獻(xiàn)：
1、葉偉昌主編.機(jī)械工程及自動(dòng)化簡明設(shè)計(jì)手冊(cè)(上冊(cè)).北京：機(jī)械工業(yè)出版社，2001
2、葉偉昌主編.機(jī)械工程及自動(dòng)化簡明設(shè)計(jì)手冊(cè)(下冊(cè)).北京：機(jī)械工業(yè)出版社，2001
3、胡家秀主編.機(jī)械零件設(shè)計(jì)實(shí)用手冊(cè).北京：機(jī)械工業(yè)出版社，1999．10
4、李益民主編.機(jī)械制造工藝設(shè)計(jì)手冊(cè).北京：機(jī)械工業(yè)出版社，1995．10
5、艾興等主編.金屬切削用量手冊(cè).北京：機(jī)械工業(yè)出版社，1996、10
6、范云漲等主編.金屬切削機(jī)床設(shè)計(jì)簡明手冊(cè).北京：機(jī)械工業(yè)出版社，1993．8
7、孟憲椅等主編.機(jī)床夾具圖冊(cè).北京：機(jī)械工業(yè)出版社，1991．4
8、韓敬禮等主編.機(jī)械電氣設(shè)計(jì)簡明手冊(cè).北京：機(jī)械工業(yè)出版社，1994．5
9、謝家瀛主編.組合機(jī)床設(shè)計(jì)簡明手冊(cè).北京：機(jī)械工業(yè)出版社，1999．10
10、楊培元等主編.液壓系統(tǒng)設(shè)計(jì)手冊(cè).北京：機(jī)械工業(yè)出版社，1995．10
11、大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1986
12、大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì)參考圖冊(cè).北京：機(jī)械工業(yè)出版社，1986
13、李云.機(jī)械制造工藝及設(shè)備設(shè)計(jì)指導(dǎo)手冊(cè).北京.機(jī)械工業(yè)出版社. 1996
14、薛源順.機(jī)床夾具設(shè)計(jì).北京.機(jī)械工業(yè)出版社.2000
15、李益民.機(jī)械制造工藝設(shè)計(jì)簡明手冊(cè). 北京.機(jī)械工業(yè)出版社.1993
七、其他
4
畢 業(yè) 設(shè) 計(jì) 說 明 書
柴油機(jī)氣缸體頂?shù)酌娲帚娊M合機(jī)床總體及夾具設(shè)計(jì)
專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
學(xué)生姓名
班 級(jí)
學(xué) 號(hào)
指導(dǎo)教師
完成日期
外文翻譯
專 業(yè) 機(jī)械設(shè)計(jì)及自動(dòng)化
學(xué) 生 姓 名 陶 金 丞
班 級(jí) B機(jī)制023班
學(xué) 號(hào) 0210110333
指 導(dǎo) 教 師 劉 道 標(biāo)
柔性制造
陶金丞譯
摘要：
在制造中，生產(chǎn)率和柔性之間經(jīng)常存在協(xié)調(diào)一致的問題。在該領(lǐng)域的一端是具有高生產(chǎn)率卻低柔性的連續(xù)生產(chǎn)線；在該領(lǐng)域的另一端是能提供最大柔性的獨(dú)立的計(jì)算機(jī)數(shù)字控制的機(jī)床，但它只能進(jìn)行低生產(chǎn)率的制造。柔性制造出在此連續(xù)統(tǒng)一體中間。在制造中總是需要一個(gè)系統(tǒng)，這個(gè)系統(tǒng)比單個(gè)機(jī)床能制造更大批量且用于更多制造過程，但仍保持起柔性。
關(guān)鍵詞：柔性制造、協(xié)調(diào)一致
柔性制造的定義：
計(jì)算機(jī)集成制造的前一部叫做柔性制造。
柔性在現(xiàn)在帶制造環(huán)境中是一個(gè)重要的特征。它意味著一個(gè)制造系統(tǒng)是用途多且適應(yīng)性強(qiáng)，同時(shí)又能進(jìn)行產(chǎn)量相對(duì)較大的制造。柔性制造系統(tǒng)是多用途的，這是因?yàn)樗苤圃於喾N多樣的部件。它適應(yīng)性強(qiáng)，因?yàn)樗芎芸斓丶右愿淖儊碇圃焱耆煌牧硪环N部件。這種柔性在競爭激烈的國際市場上可能成敗有別。
這是一個(gè)平衡的問題。獨(dú)立的計(jì)算機(jī)數(shù)字控制（NC）機(jī)床有著高度的柔性，但是只能處理批量相對(duì)較小的制造。正相反，系列連續(xù)生產(chǎn)線能進(jìn)行批來年感較大的制造，但都不靈活。柔性制造試圖運(yùn)用工業(yè)技術(shù)在靈活性與制造運(yùn)行之間達(dá)到最佳的平衡。這些工業(yè)技術(shù)包括自動(dòng)化的材料、處理、成組技術(shù)及計(jì)算機(jī)和分布數(shù)字控制。
柔性制造系統(tǒng)（FMS）是一個(gè)獨(dú)立的機(jī)床或一組機(jī)床服務(wù)于一個(gè)自動(dòng)材料處理系統(tǒng)/它是由計(jì)算機(jī)控制的而且有對(duì)刀具處理的能力。由于它有刀具處理能力并能受計(jì)算機(jī)控制，這樣的系統(tǒng)可以不斷地重新配置來制造更加多樣的部件，這就是它被稱作柔性制造系統(tǒng)的原因。
一個(gè)制造系統(tǒng)要成為柔性制造系統(tǒng)必須具備的要素有：
1． 計(jì)算機(jī)控制
2． 自動(dòng)處理材料能力
3． 刀具處理能力
柔性制造向全面集成化制造的目標(biāo)邁進(jìn)了重要的一步。它實(shí)現(xiàn)了自動(dòng)化制造過程的集成化。在柔性制造中，自動(dòng)化的制造機(jī)器（如車床、銑床、鉆床）和自動(dòng)化材料處理系統(tǒng)之間，通過計(jì)算機(jī)網(wǎng)絡(luò)進(jìn)行即時(shí)的溝通。
柔性制造的概況：
通過綜合幾個(gè)自動(dòng)化的制造概念，柔性制造系統(tǒng)全面集成化的制造目標(biāo)邁出了重要的一步，這些觀念是：
1． 獨(dú)立機(jī)床的計(jì)算機(jī)數(shù)字控制
2． 制造系統(tǒng)的分布式數(shù)字控制
3． 自動(dòng)化的材料處理系統(tǒng)
4． 成組技術(shù)
當(dāng)這些自動(dòng)化工藝、機(jī)器和觀念合成到一個(gè)集成的系統(tǒng)時(shí)，就產(chǎn)生柔性制造系統(tǒng)。在柔性制造系統(tǒng)中，人和計(jì)算機(jī)起了重要作用。當(dāng)然人的勞動(dòng)量比手工操作的制造系統(tǒng)要小得多。然而，人仍然在柔性制造系統(tǒng)的操作中起著至關(guān)重要的作用。人的任務(wù)包括幾個(gè)方面：
1． 設(shè)備故檢、維護(hù)和修理
2． 刀具的變換和設(shè)置
3． 安裝和拆卸系統(tǒng)
4． 數(shù)據(jù)輸入
5． 部件程序的變換
6． 程序的開發(fā)
柔性制造制系統(tǒng)設(shè)備象所有制造設(shè)備一樣，必須友人監(jiān)管以免出現(xiàn)失常、機(jī)器程序錯(cuò)誤，以及故障。當(dāng)發(fā)現(xiàn)問題時(shí)檢修人員必須確定問題的根源，然后給出正確的措施。人還要采取指定的措施來維修運(yùn)行不正常的機(jī)器。甚至當(dāng)所有系統(tǒng)都正 常運(yùn)行時(shí)，定期的維護(hù)也是必要的。
操作人員還要根據(jù)需要設(shè)置機(jī)床，換刀具、以及重新配置系統(tǒng)。柔性制造系統(tǒng)的刀具處理能力削弱了，但并有消除，在刀具變換和設(shè)置上仍需要人力。在裝卸柔性制造系統(tǒng)時(shí)也是這樣。一旦原材料被送到自動(dòng)化材料處理系統(tǒng)上，它就會(huì)以規(guī)定的方式，在系統(tǒng)中移動(dòng)。然而，初裝到材料系統(tǒng)處理系統(tǒng)仍然是由操作人員完成的；成品的拆卸也是同樣。
與計(jì)算機(jī)的交流仍需人力完成。人開發(fā)零件程序，通過計(jì)算機(jī)控制柔性制造系統(tǒng)。當(dāng)重新配置FMS制造另一種類型零件時(shí)，他們還在必要的時(shí)候變換程序。人在柔性制造系統(tǒng)中勞動(dòng)力密集型的成分越來越少，但仍然是很重要的。
柔性制造系統(tǒng)中的各層次控制都是由計(jì)算機(jī)來完成的。在刀具柔性制造系統(tǒng)中獨(dú)立的機(jī)床是由CNC來控制的。整個(gè)的系統(tǒng)是由DNC來控制的。自動(dòng)化的材料處理系統(tǒng)是由計(jì)算機(jī)來控制的，其他功能如數(shù)據(jù)收集、系統(tǒng)監(jiān)控、刀具控制、運(yùn)輸控制也是計(jì)算機(jī)控制的。人機(jī)交互是柔性制造系統(tǒng)中的關(guān)鍵。
柔性制造的歷史發(fā)展：
柔性制造產(chǎn)生于20世紀(jì)60年代中期，當(dāng)時(shí)英國莫林斯有限公司開發(fā)了24號(hào)系統(tǒng)。24系統(tǒng)是一個(gè)真正的FMS。然而，它從一開始就注定是失敗的，因?yàn)樽詣?dòng)化、集成和計(jì)算機(jī)控制技術(shù)還沒有發(fā)展到能夠恰好支持這一系統(tǒng)的程度。第一個(gè)FMS是超遷的開發(fā)。因此，最終因不能工作餓被放棄。
再20世紀(jì)60年代和70年代的期于時(shí)間里，柔性制造仍是一個(gè)學(xué)術(shù)觀念。然而，隨著復(fù)雜計(jì)算機(jī)控制技術(shù)在20世紀(jì)70年代末和80年代初的出現(xiàn)，柔性制造變成為可能。在美國最初的主要用戶是汽車、卡車和拖拉機(jī)制造商。
柔性制造的理由：
在制造中，生產(chǎn)率和柔性之間經(jīng)常存在協(xié)調(diào)一致的問題。在該領(lǐng)域的一端是具有高生產(chǎn)率卻低柔性的連續(xù)生產(chǎn)線；在該領(lǐng)域的另一端是能提供最大柔性的獨(dú)立的計(jì)算機(jī)數(shù)字控制的機(jī)床，但它只能進(jìn)行低生產(chǎn)率的制造。柔性制造出在此連續(xù)統(tǒng)一體中間。在制造中總是需要一個(gè)系統(tǒng)，這個(gè)系統(tǒng)比單個(gè)機(jī)床能制造更大批量且用于更多制造過程，但仍保持起柔性。
連續(xù)生產(chǎn)線能以高生產(chǎn)率制造大量的零件。這條生產(chǎn)線需要大量的準(zhǔn)備工作，但卻能造出大量的相同的零件。它的主要缺點(diǎn)是即使一個(gè)部件雜設(shè)計(jì)上有小的改變都能造成整個(gè)生產(chǎn)線的停產(chǎn)和結(jié)構(gòu)改變。這是一個(gè)致命的弱點(diǎn)，因?yàn)檫@意味著沒有高成本，耗時(shí)停工和變化生產(chǎn)線結(jié)構(gòu)是不能制造出不同的零件的，即使是來自同一個(gè)零件族。
傳統(tǒng)上計(jì)算機(jī)數(shù)字控制機(jī)床是用來制造少量在設(shè)計(jì)上稍有不同的零件。這種機(jī)床很適合這一用途，因?yàn)樗鼈兡苎杆俚馗淖兂绦蜷_適應(yīng)設(shè)計(jì)上小的或者更大的變化。然而，作為獨(dú)立的機(jī)床它們不能大量地或高生產(chǎn)率地制造零件。
柔性制造系統(tǒng)比獨(dú)立的計(jì)算機(jī)數(shù)控機(jī)床具有更大的生產(chǎn)能力和更高的生產(chǎn)率。它們?cè)谌嵝苑矫姹炔簧嫌?jì)算機(jī)數(shù)字控制機(jī)床，但它們卻相差不多，柔性制造的中間性能的特殊意義在于大多數(shù)鑄造要求中等量的的生產(chǎn)率來制造中等量的產(chǎn)品，同時(shí)有足夠的的柔性以快速改變結(jié)構(gòu)來制造另一個(gè)零件或產(chǎn)品。柔性制造填補(bǔ)了制造中長期存在的空白。
柔性制造以其基本能力給制造者提供了許多優(yōu)點(diǎn)：
1． 族內(nèi)具有柔性在一個(gè)零件
2． 隨意進(jìn)給零件
3． 同時(shí)制造不同的零件
4． 準(zhǔn)備時(shí)間和產(chǎn)品設(shè)計(jì)到投產(chǎn)的時(shí)間減少了
5． 機(jī)床的使用更有效
6． 直接和見解的人力成本減少
7． 能加工不同的材料
8． 如一臺(tái)機(jī)床故障能繼續(xù)進(jìn)行部分生產(chǎn)
柔性制造系統(tǒng)的軟件：
軟件是驅(qū)動(dòng)柔性制造系統(tǒng)的主要的不可件的因素。FMS所要求的軟件有兩個(gè)基本的層次：1.操作系統(tǒng)軟件和2.應(yīng)用系統(tǒng)軟件。操作系統(tǒng)軟件是最高層次，是計(jì)算機(jī)制造商特別規(guī)定的并對(duì)應(yīng)用軟件進(jìn)行監(jiān)督控制。應(yīng)用軟件通常是由系統(tǒng)供應(yīng)商開發(fā)和提供的，它包口所有的FMS的特定程序和例行程序。
FMS的應(yīng)用軟件是很復(fù)雜的，而且具有很強(qiáng)的專利性質(zhì)。對(duì)于很多公司來說，它體現(xiàn)了幾百名工人很多年開發(fā)努力的結(jié)晶。它通常是由幾個(gè)模塊組成。每個(gè)模塊又是有由一系列與系統(tǒng)內(nèi)部運(yùn)行的各種功能相關(guān)的計(jì)算機(jī)沉痼系和例行程序組成。這些包括從FMS主機(jī)下載的NC部分程序到機(jī)床控制器、運(yùn)輸和材料順序的開發(fā)、工件的工序、模擬和刀具管理。所有這些軟件模塊必須得到很好的餓設(shè)計(jì)，并且能夠可預(yù)測地、可靠地、相互作用地運(yùn)行以便FMS能達(dá)到最高的運(yùn)行效率和可接受的水平。設(shè)計(jì)不好的軟件使制造商不能獲得FMS的充分的柔性和潛能。
由于FMS軟件是柔性制造系統(tǒng)的命脈，它也是一個(gè)FMS的最復(fù)雜、最難以理解和在戰(zhàn)略上重要的方面。如果構(gòu)件和編碼得恰當(dāng)，進(jìn)行了反復(fù)地測試，并且充分地運(yùn)行的話，它可以使FMS達(dá)到前所未有的生產(chǎn)性能水平。應(yīng)補(bǔ)充說一句，所有完成的FMS軟件只有在客戶的工廠中、完全運(yùn)行中對(duì)該系統(tǒng)徹底的檢查后，才能被認(rèn)為是可接受的。
軟件設(shè)計(jì)的模塊化并不一定以為著使用相同或類似的軟件模塊的所有都是一樣的。很多FMS用戶有特殊的和內(nèi)行才懂的各種要求來適應(yīng)于他們自己的應(yīng)用和操作考慮。這樣的一些要求可能會(huì)包括特殊的FMS軟件模塊來連接一個(gè)新的FMS和已存在的自動(dòng)存儲(chǔ)和檢索系統(tǒng)?；蛘?，使FMS從主機(jī)上直接接受生產(chǎn)要求和零件工序信息。
總之，像其他計(jì)算機(jī)軟件一樣，F(xiàn)MS軟件，就像開發(fā)和為之編碼的人一樣，獨(dú)立而各具特點(diǎn)。重要的是生產(chǎn)環(huán)境下它能做什么并運(yùn)行得如何。
Flexible Manufacturing
Abstract:
In manufacturing there have always been tradeoffs between production rates and flexible. At one end of the spectrum are transfer lines capable of high production rates, but low flexible. At the other end of the spectrum are independent CNC machines that offer m aximum flexible, but are capable only of low production rates. Flexible manufacturing falls in the middle of the continuum. There has always been need in manufacturing for a system that could produce higher volume and production runs than could independent machines, while still maintaining flexibility.
Key words: flexible manufacturing, tradeoffs
Flexible Manufacturing Defined
The step preceding computer-integrated manufacturing is called flexible manufacturing.
Flexible is an important characteristic in the modern manufacturing setting. It means that a manufacturing system is versatile and adaptable, while also capable of handling relatively high production runs. A Flexible manufacturing system is versatile in that it can produce a variety of parts. It is adaptable because it can be quickly modified to produce a completely different line of parts. This flexible can be the difference between success and failure in a competitive international marketplace.
It is a matter of balance. Stand-alone computer numerical control machines have a high degree of flexibility, but are capable of relatively low-volume production runs. As the opposite end of spectrum transfer lines are capable of high-volume runs, but they are not very flexible. Flexible manufacturing is an attempt to use technology in such a way as to achieve the optimum balance between flexibility and production runs. These technologies include automated materials, handing, group technology, and computer and distributed numerical control.
A flexible manufacturing system (FMS) is an individual machine or group of machines served by an automated materials handing system that is computer controlled and has a tool handing capability. Because of its tool handling capability and computer control, such a system can be continually reconfigured to manufacture a wide variety of parts. This is why it is called a flexible manufacturing system.
The key elements necessary for a manufacturing system to qualify as an FMS are as follows:
1. Computer control
2. Automated materials handling capability
3. Tool handling capability
Flexible manufacturing represents a major step toward the goal of fully integrated manufacturing. It involves integration of automated production processes. In flexible manufacturing, the automated manufacturing machine (i.e., lathe, mill, dill) and the automated materials handling system share instantaneous communication via a computer network. This is integration on a small scale.
Overview of Flexible Manufacturing
Flexible manufacturing takes a major step toward the goal of fully integrated manufacturing by integrating several automated manufacturing concepts:
1. Computer numerical control (CNC) of individual machine tool
2. Distributed material control (DNC) of manufacturing systems
3. Automated materials handling systems
4. Group technology (families of parts)
When these automated processes, machines, and concepts are brought together in one integrated system, an FMS is the result. Humans and computers play major roles in an FMS. The amount of human labor is much less than with a manually operated manufacturing system, of course. However, humans still play a vital role in the operation of an FMS. Human tasks include the following.
1. Equipment troubleshooting, maintenance, and repair.
2. Tool changing and setup.
3. Loading and unloading the system.
4. Data input.
5. Changing of parts programs.
6. Development of programs.
Flexible manufacturing system equipment, like all manufacturing equipment, must be monitored for bugs, malfunctions, and breakdowns. When a problem is discovered, a human troubleshooter must identify its source and prescribe correctives measures. Humans also undertake the prescribed measures to repair the malfunctioning equipment. Even when all systems are properly functioning, periodic is necessary.
Human operators also set up machines, change tools, and reconfigure systems as necessary, The tool handling capability of an FMS decreases, but does not eliminate, human involvement in tool changing and setup. The same is true of loading and unloading the FMS. Once raw material has been loaded onto the automated materials handling system, it is moved through the system in the prescribed manner. However, the original loading onto the materials handling system is still usually done by human operators, as is the unloading of finishes products.
Humans are also needed for interaction with the computer. Humans develop parts programs that control the FMS via computers. They also change the programs as necessary when reconfiguring the FMS to produce another type of part or parts. Humans play less labor-intensive roles in an FMS, but the roles are still critical.
Control at all levels in an FMS is provided by computers. Individual tools within an FMS are controlled by CNC. The overall system is controlled by DNC. The automated materials handling system is computer controlled, as are other functions including data collection, system monitoring, tool control, and traffic control. Human computer interaction is the key to the flexibility of an FMS.
Historical Development of Flexible Manufacturing
Flexible manufacturing was born in the mid-1960s when the British firm Molins, Ltd. developed its System 24. System24 was a real FMS. However, it was doomed from the outset because automation, integration, and computer control technology had not yet been developed to the point where they could properly support the system. The first FMS was a development that was ahead of its time. As such, it was eventually discarded as unworkable.
Flexible manufacturing remained an academic concept through the remainder of the 1960s and 1970s. However, with the emergence of sophisticated computer control technology on the late 1970s and early 1980s, flexible manufacturing became a viable concept. The first major users of flexible manufacturing in the United States were manufacturing if automobiles, trucks, and tractors.
Rationale for Flexible Manufacturing
In manufacturing there have always been tradeoffs between production rates and flexible. At one end of the spectrum are transfer lines capable of high production rates, but low flexible. At the other end of the spectrum are independent CNC machines that offer maximum flexible, but are capable only of low production rates. Flexible manufacturing falls in the middle of the continuum. There has always been need in manufacturing for a system that could produce higher volume and production runs than could independent machines, while still maintaining flexibility.
Transfer lines are capable of producing large volumes of parts at high production rates. The line takes a great deal of setup, but can turn out identical parts in large quantities. Its chief shortcoming is that even minor design changes in a part can cause the entire line to be shut down and reconfigured. This is a critical weakness because it means that transfer lines cannot produce different parts, even parts from within the same family, without costly and time-consuming shutdown ad reconfiguration.
Traditionally, CNC machines have been used to produce small volumes of parts that differ slightly in design. Such machines are ideal for this purpose because they can be quickly reprogrammed to accommodate minor or even major design changes. However, as independent machines they cannot produce parts in large volumes or at high production rates.
An FMS can handle higher volumes and production rates than independent CNC machines. They cannot quite match such machines for flexible, but they come close. What is particularly significant about the middle ground capabilities of flexible is that most manufacturing situations require medium production rates to produce medium volumes with enough flexibility to quickly reconfigure to produce another part or product. Flexible manufacturing fills this long-standing void in manufacturing.
Flexible manufacturing, with its ground capabilities, Flexible offers a number of advantages for manufacturers:
1. Flexible within a family of parts.
2. Random feeding of parts.
3. Simultaneous production of different parts.
4. Decreased setup time and lead time.
5. More efficient machine usage.
6. Decreased direct and indirect labor costs.
7. Ability to handle different materials.
8. Ability to continue some production if one machine breaks down.
FMS Software
Software is the vital invisible element that actually drives the FMS. There are basic levels of software required for an FMS: 1.operating system; 2.application software. Operating system software is the highest lever, is computer manufacturer specific, and executes supervisory control over the application software. Application software is usually developed and supplied by the system supplied and includes all the FMS specific programs and routines.
Application software for an FMS is complex, highly proprietary, and for many companies, represents several hundred worker-years of development effort. Generally, it is composed of several modules, each of which is made up of a series of computer programs and routines relating to various functions performed within the system. These include NC part programs download from the FMS host computer to machine tool controllers, traffic and material-handling management, work-order generation, work piece scheduling, simulation, and tool management. All these software modules must be well designed and function predictably, reliably, and interactively in order fir the FMS to perform at peak operating efficiencies and acceptable levels. Poorly designed software prevents manufacturers form achieving the full flexibility and potential capacity of FMS.
FMS software, because it is the life blood of a flexible manufacturing system, is also the most complex, least understood, and strategically important aspect of an FMS. Structures and coded properly, tested rigorously, and functioning adequately, it can make an FMS productive at unprecedented performance levels. It should be added that all completed FMS software can only be considered acceptable after it has been thoroughly checked out with the system in complete operation in the customer’s plant.
Modularity of software design does not necessarily imply that all system using the same or similar software modules are created equal. Many FMS users have highly specific and esoteric requirements to suit their own applications and operating concerns. Some of these might include specific FMS software modules to couple an already existing automatic storage and retrieval system (ASRS) to a new FMS or to have the FMS directly receive production requirements and part scheduling information from the host computer.
Overall, FMS software, like other types of computer software, is as different and autonomous as the people who develop and code it. What counts is what it does and how well it performs in a manufacturing environment.
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