汽车装配自动拧紧机

上海交通大学硕士学位论文汽车装配自动拧紧机姓名：黄健申请学位级别：硕士专业：仪器仪表工程指导教师：颜德田20080101345RS-4856FASTENINGMACHINEFORAUTOMOTIVEASSEMBLYABSTRACTThethesisfocusesonthefullyautomatedfasteningmachineforautomotiveassembly.Thearticleintroducestheprincipleanddesignoffasteningmachine.Thedefinitionoftorqueisgivenfirst,thetorqueduringfasteningprocessiscalculatedandthefactorsthanaffectclampingforceareanalyzed.Thenthefasteningprocess,aswellasnormalfasteningstrategies,isintroduced.Sothereadershouldhaveaclearawarenessoftheimportanceoftorquecontrollingandfasteningprocess.Thentheonespindlefasteningmachineisintroduced.Itfeaturesmoduledesigning,thespindleiscomposedofconnector,motor,gearbox,transducer,signalprocessing,andoutputshaftmodule.Thetorquetransduceriswiredfrom4straingaugesasWheatstonebridgeandhasthefeatureofzeroadjustmentandtemperaturecompensation.Thespindleisdrivenbyelectricbrushlessmotor,whichmakesitfreeofmaintenanceandaccuratelycontrolled.Theanglemeasurementisdonebymeasuringthevoltageatmotorpoles.Forcontrollingmodule,specialsoftware,self7testprocess,andsafetyprotectionsareintroduced.Onthebasisofthis,multispindlefasteningmachineisintroduced.ThearticlefocusesontheRS-485network;thecooperationbetweenmasterandslavecontrollermodules;thesynchronizationofmulticontrollers;thecontrolpanelandperipherals;thekeypointsindesigning;andtheevaluationoffasteningresults.KEYWORDS:torque,fastening,assembly,fasteningmachine101150%:AtlasCopco(CPGeorgesRenault)(Ingersoll-RAND)(BOSCH)(Cooper)80()1211:U4M14250Nm100Nm100Nm250Nm483451012-4--70%30~50%21211----13-70%30%~70%-212Webster122-1Fig2-1definitionoftorqueT=FxLxcos(¢)(2-1)TFL¢FL-KDTF'=(2-2)T=NmD=F'=kN14K=(0.030.35)10%2-22-2Fig2-2proportionoftorque-90%50%40%-10%0.10()0.18()50%2132-315dD——d1(D1)——d2——d2≈0.5(d+d1)P——S——n——n≤4P=nSψ——α——β——2-3Fig2-3parametersofscrewthreadTT12T2-4162-4Fig2-4frictiontorqueatsupportingsurface()212TT+T2acafFdtgfFrψρ′==++(2-3)aFaF2dcfcf=0.15fr04wfddr+≈wd0dM10~M68ftgρ′′==0.15(2-3)mmNdFTa•≈2.0(2-4)dmmaFNaF50%70%M1217222-5Fig2-fasteningprocess//1823231≤≤±50%2-6Fig2-6curveoftorquestrategy232+19≥≤≤≤≤2-7Fig2-7curveoftorquecontrolandanglemonitorstrategy±50%233+202-8+Fig2-8curveofanglecontrolandtorquemonitorstrategy≥-25%-70%±15±25%70~80%234212-9Fig2-curveofyieldpointstrategy≤x“”≤≥≤≤≤≤(∆T/∆α)NN∆αX%XN=16X%=5016°(32°)100%22311000Nm1Nm22202233-1Fig3-1spindlemodule323~5/23-2Fig3-2mechanicaltransmissionofspindle3-34141242350mm1413-3Fig3-3outputshaft133SlR×=ρ3-1R-----Ω25ρ------l------S------dR/R=K(3-2)K--------42242-103-4+−+=433211RRRRRRUUIO3-300=U3241RRRR=3-4Fig3-4straingaugebridgemV/V1VR11R∆2R3R4R00=U1R∆0U∆0U∆1R∆()()IIIURRRRRRRRRRURRRRRRRRRRRRRRRUU++∆+∆=++∆+∆=+−+∆+∆+=∆34121111344321141433211110113-412RRn=3412RRRR=11RR∆()1121RRnnUUIO∆+=∆3-526()2111nnURRUKIO+=∆∆=3-6K3-6nIUn0=dndKK()()01142=+−nn1=nK21RR=43RR=3-43-53-63-73-83-9IU3-511121111RRRRRR∆++∆−=ε3-5OU+−∆−+∆+∆+=433221111RRRRRRRRRUUIO3-104321RRRR∆=∆=∆=∆4321RRRR===RRUiUo∆=3-11IIOIOUKRRUURRRRUU4141211141111111=∆=∆∆+∆=∆273-5Fig3-5quadricarmdifferentialcircuitOU11RR∆IUK=453-623-73-83-6Fig3-6pressuredirection3-73-8Fig3-7shapeofstaingaugeFig3-8straingaugeinstallposition28∆R=∆Rε∆RT∆Rε-∆RT-11.75mV/V233-9Fig3-9actualcircuit34BLDC16292343-10:Fig3-10principleofBLDC(24V)(110V/220V)(inverter)36(T1T6)(T1T3T5)(T2T4T6)PWM()sensor)--5-26KHzN-S120UVW/101100110010011001T1-T4T1-T6T3-T6T3-T2T5-T230T5-T4A+B-A+C-B+C-B+A-C+A-C+B-N-ST1-T66060UVW60Vc+5VVcmax+5VnVcVfbTm1%35120,606630313-11Fig3-11principleofanglemeasurement2VsinVcossin*cos)sin(cos*sin1sinViViwtVwtV+=+=θθ3-12cos)sin(VVarctg=θ3-13θRRθα=3-14320.01363-12Fig3-12signalpre-processingD/A500Kbaud45,,//333-13Fig3-13diagramofsignalprocessing3721CPUCPUPC/3-14Fig3-14functionblockofcontroller3422323PWM3-15Fig3-15principleofservodriver1Nm•50A•115/230V••.38/PLC//DB3738141635111/1124V10mA224V17,1920PLC24VPLCcommon3-16Fig3-16controllerinputwiring38214PLCPLC01363-172PLC24V24VPLC24VPLC24V3-17Fig3-17controlleroutputwiring392LCDRS23222125520I/OPLC2/373accessCNOMOISOUCLLCLCpCpk3-18Fig3-18fasteningresults3-19Fig3-19fasteningcurve383-20Fig3-20softwarestatisticalfunction31070705015039311------------300mV±0.5%312155403-213-22Fig3-21calibrationFig3-22calibrationwithjointsimulator3-23Fig3-23calibrationscreen4141CPU11214-1Fig4-1multispindlesketch4201RS-485RS-48542RS-485121910Mb/s200mVRS-485MasterSlave32RS-4852RS-4854-1RS-232RS-422RS-4854-1RS232RS422RS-485RS232RS422R485111101325040040020Kb/S10Mb/s10Mb/s+/-25V-0.25V+6V-7V+12V()+/-5V+/-15V+/-2.0V+/-1.5V()+/-25V+/-6V+/-6V(Ω)3K7K10054()30V/µsN/AN/A+/-15V-10V+10V-7V+12V+/-3V+/-200mV+/-200mV(Ω)3K7K4K()≥12K-3V+3V-1V+3V-7V+7V-7V+12V/434-2Fig4-2sketchofmastercontrollerRAMLED485432552016101-10120Nm611-1630Nm1610Nm44105Nm10120Nm630Nm11-161-101-23-411-164412344.3~1-1011-1611-1645I/O10301451011124-3Fig4-3wiringofsynchronizedfastening46PLC464-4Fig4-4timingchartoffasteningmachine1PLCPLC21134PLC547RS232RS422RS485RJ45ProfibusDevicenetModbus+ModbusTCPInterbus-SI/OI/OPLC47VIN148/////I/O492KBK484-54-6Fig4-5hangingmachineFig4-6floormachine4-7Fig4-7multiplehe