AUTOMATIZAREA PRELUCRARII

AUTOMATIZAREA PRELUCRARII
A fost dezvoltata odata cu cererea crescuta de productie industriala de catre
societate si de catre industrie
Reprezinta calea spre intensificarea productiei– creste productivitatea,
imbunatateste calitatea si scade costurile
Este calea spre imbunatatirea tehnologiei productiei, dezvoltand posibilitatile
tehnologice si caile spre inovarea rapiditatii in ciclul tehnologic
CE AVEM NEVOIE PENTRU A AUTOMATIZA
Managementul sculelor
Schimbarea sculei
Miscarea sculei
Dispozitive pentru pornirea AP
Incarcarea materialului SF
Indepartarea piesei produse
AUTOMATIZAREA PRELUCRARII

Masina unealta clasica (conventionala):

Scop general,
Operare manuala;
Munca operatorului este decisiva
AUTOMATIZAREA PRELUCRARII

Masina unealta automata:

a) automatizare fixa– mecanisme, came, cutii de viteze, leviere, cuplaje, mecanisme oprire-
pornire, limitatori de cursa etc.
b) automatizarea flexibila– programare CNC
ELEMENTE DE AUTOMATIZARE FIXA
CAMA
Este un disc sau un cilindru cu o cale de urmat de forma
curbata complexa. Un obiect se afla pe calea de urmat, si
se misca dupa directia longitudinala a camei atunci cand
aceasta are miscare de rotatie. Camele pot fi conectate
împreună in scopul de a oferi mișcarea complexă de sprijin,
de avans, de rotație și altele.
UTILIZAREA CAMELOR CILINDRICE–
DEPLASAREA CARUCIORULUI LA STRUNG
UTILIZAREA CAMELOR DISC–
SANIILE PORT CUTIT LA STRUNGURILE
AUTOMATE
1) MASINI UNELTE AUTOMATE FIXE

MU de scop general automat (ex. Strunguri automate sau semiautomate)

MU personalizate (de scop unic,) proiectate pentru un singur tip de piesa SF, linii de transfer
sisteme de transoprt al pieselor SF integrat
UNITATEA DE LUCRU A MU AUTOMATE
UNITATEA DE ACTIONARE
UNITATEA DE LUCRU
UNITATEA DE DEPLASARE
MASA CIRCULARA INDEXABILA
CONCEPTUL
MODULAR AL
MU
MASINA CU UNIC SCOP
Doar o singura operatie, pas cu pas…
Uneori realizeaza o lista de operatii impuse
MU are un design special destinat productiei:
 AP multipli
 Unitati de avans de viteza
 Sisteme de prindere multiple
 Avans automat al piesei SF
 Utilizarea sculelor speciale
EFICIENTA MU CU UNIC SCOP
CONCEPTUL LINIEI DE TRANSFER
SCHEMA UNEI LINII DE TRANSFER
LINIE DE TRANSFER – PROIECTUL
LINIE DE TRANSFER PENTRU PRELUCRARI
EXEMPLU DE STATIE DINTR-O LINIE DE TRANSFER
2) MU CU AUTOMATIZARE FLEXIBILA
Utilizeaza soft, automate programabile si este destinata productiei de piese mici cu
realizare usor de programat

Doua forme de baza

Control prin program secventia
Numerical control
CONTROL PRIN PSC (PROGRAM SEQUENCE CONTROL)
Secventa miscarii este realizata prin relee, banda perforata, cilindri programabili,
alte tipuri de control-ere…

Programarea este facila, optiuni de programare foarte limitate, fara posibilitati de

ajustare imediata
 BANDA PERFORATA

Fiecare linie prezinta o miscare diferita

sau o schimbare de pozitie. Trebuie sa fie
tiparita corect altfel erorile sunt de
nemodificat.

FYI:
Banda perforata cu 8 linii poate contine un byte de informatie pe o coloana de
perforatii. Pasul normal al coloanei este de 2,54 mm. Aceasta inseamna ca este
nevoie de 2,6 m de banda pentru a stoca 1kB de date. Un DVD dual-layer
contine aprox. 22100 km de banda perforata.
NUMERICAL CONTROL
 Este cel mai important mod de automatizare. Mai toate masinile de azi au NC.
Pricipiul:
Masina si toate miscarile sale sunt controlate prin program. Acesta este o lista de
instructiuni scrise intr-o sintaxa speciala si au un format special.
MECANIC VS. NUMERIC
Limitari – viteza , lungimea programului, miscarile posibile ale camelor.
MU CU AUTOMATIZARE FLEXIBILA

1. MU conventionala
MU CU AUTOMATIZARE FLEXIBILA

2. MU cu NC (stand-alone)
MU CU AUTOMATIZARE FLEXIBILA

3. MU cu NC cu magazin de scule
MU CU AUTOMATIZARE FLEXIBILA

4. NU cu CNC
MECANIC VS. AUTOMATIZARE

Mecanizare – puterea omului este inlocuita de masina, unitati de miscare, dispozitive

hidraulice sau mecanice

Automatizarea –controlul uman este inlocuit de catre masini secventiale, came, computere,
control-ere PLC
NIVELUL DE AUTOMATIZARE

Functionare semiautomatica – sculele se schimba automat dar piesele sunt inlocuite de catre
operatorul uman

Functionare automata – ambele operatiuni sunt realizate automat de catre un robot

CONCEPTUL NC / CNC
Initial doar controlul NC a fost utilizat. Programul era stocat pe banda sau pe disc
rula linie dupa linie.
Influenta dezvoltarii rapide a computerelor a condus la controlul CNC (Computer
numerical control). Programul este incarcat in memoria RAM si rulat de acolo de
catre procesor
 AVANTAJELE CNC
Optiuni Control NC Control CNC
Lungimea Programului Limitata de capacitatea de Nelimitat (HDD de peste
stocare 1TB)

Secventa de program Linie dupa linie Permite saritul peste

secvente de program
(inainte, inapoi) si a
subprogramelor
Sare la alte programe N/A DA
Cicluri stocate N/A DA
Corectia coordonatelor Doar manual Da, automat
Compensarea lungimii Doar manual Da, prograbil
sculei
Compensarea diametrului N/A Da, programabil
sculei
Citirea in avans N/A Da, mod continuu
Start dupa breakdown N/A DA
FINAL PARTEA I-A
 PROGRAM SEQUENCE

Subprograms
A link to another then the following line is entered into
main programm.
This subprogram is executed.
After finishing this program we return to main program a
we contiue until end of main program(M30)
 BASIC PRINCIPLES OF CNC MACHINES

 NC/CNC machine consist of 3 basic elements.

List of instructions – NC code – a mix of alphabecial and numerical information. Contaion
information about movements, feed, speed, tool change and other machine functions
(cooling, measuring)
Control unit - control system – converts the program into signal for machine and send them
to machine (PLC controller)

Control Machine
NC
unit Drive
code
(system) motor

Sensing
device
 BASIC PRINCIPLES OF CNC MACHINES

 NC/CNC machine consist of 3 basic elements.

Machine tool – fitted with drive motor to operate slides, support and spindle. Also with
switches to start/stop specific functions
Sensing device – optional(closed circuit)- sensing device control if a specific demand was
fullfilled. Support feed, Table position etc.

Control Machine
NC
unit Drive
code
(system) motor

Sensing
device
CNC MACHINE TOOL
MOTIONS
Three types of motion
1) point-to-point motion – tool is moved to specific location, path or speed of move
between location is not controlled. (drilling)
2) Linear control – movement along one of the axes of the machine.
3) Contouring control – movement can be made in two or more axes
simultaneously.
 MOTIONS

Point-to-point control Linear control Contouring control (continual)

drilling milling machines, lathes machining c.(milling, turning)

CNC MACHINING CENTRE(MC)

MC combine a number of different machining

processes in one operation
MODULAR TOOL SET
MODULAR TOOL SET – TOOLING SYSTEM
All manufacturers around the world
Basic concept:
1) Holder with standadized conecting part – ISO, BSK cone, CAPTO system etc.
2) Extension bar – active (vibration elimination) adujstable and balanced
3) Quick change tooltip/insert
SECO - COMBIMASTER
TOOL EXCHANGE
TOOL EXCHANGE
FLEXIBLE CELL – A CONCEPT
FLEXIBLE MANUFACTURING SYSTEM
CONVEYORS
Device used for transportation of blank and semiproduct in production

Types:
Belt conveyor
Pulley(rolls) conveyor
Cradle conveyor
CONVEYORS – BELT CONVEYOR
Used for small parts and loose material
Endless belt made of rubber, plastic particles, short boards (grids)
CONVEYORS – PULLEY(ROLLER) CONVEYOR
For large solid parts and products
Low force needed (gravity slide ways)
Use of pallets
 PALLET

Board used for transportation

Equiped with jigs and other
positioning elements

Together with pallete changer is used

for automatic blank material
loading and parts unloading
PALLET CHANGER
aka Switch table
2-4 pallets in one machine
LOADING OF BLANK/SEMIPRODUCTS
- Manual
- Accumulation conveyor
- Accumulating pieces to balance production
- Robot loading
- For single standing, large production usage (common machine tools)
- Line(conveyor) loading
- For FMS and large batch production (special machine tools)
LOADING
FLEXIBLE MANUFACTURING SYSTEM
Flexible manufacturing system for 4 types of automobile cylinder heads
(GM 3801 – 3811)

BZ 400 BZ 500 Other Reserve

Flexible to suit various part variants

9 Flexible transfer machines (some incorporating BZ 400 machining centers),
and 16 high-dynamic BZ 500 machining centers
Completely automated
Approximately 500,000 parts p.a.
PROCESS AUTOMATION AND INTEGRATION
LEVELS
AUTOMATION OF MACHINING
 EFFECTS OF AUTOMATION

- Cost reducing (per piece)

Machining costs
- Higher investments
- Speed improvement
- Productivity improvement

(Kc/pce)

Conventional tools
- Repeatability improvement

CNC tools

Cam‘s
FMS
Productivity
(pcs/hour)
Flexibility