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充满挑战和收获的2010年圆满结束了,瓦尔特在金属加工业可谓全面开花,成绩菲然。我们参与了多个专业的制造技术论坛,与行业客户进行了充分的交流。在珠海,我们参加了盛大的中国航展,并且在大会的技术论坛上发布了我们用于航空航天领域最新产品：在西安、在成都、在宁夏我们举办了专场的路演,参与了专业的技术交流活动,与当地的客户进行了充分的交流,为他们的加工难题出谋划策,使他们充分体验到了瓦尔特的高品质的技术服务。     

基于PLC的折弯机自动控制系统的研制

为提高伺服电机的定位精准性,充分利用了PLC作为逻辑控制器可靠性高的特点,设计了一种能够精确控制折弯角度的折弯机控制系统。介绍了折弯机的工作原理,提出了基于PLC、伺服系统、文本显示器的控制系统的解决方案。详细阐述了折弯机的工作流程,给出了硬件接线原理图以及折弯机控制系统的算法。通过一个程序实例,进行了折弯机的自动控制系统的模拟实验。实验结果表明,设计满足了系统的要求。     

抽油机的发展及抽油模式的改进

简述了抽油机的发展历程,分析了各阶段抽油机的特点及存在的问题.同时结合现阶段油田生产的特点,分析了节能抽油机的发展趋势.从一个新的角度分析了抽油机节能改进的方向.提出了"一机双井"的工作模式,做了简单的定性分析.     

面向网络化制造的开放式数控系统的研究

分析了网络化制造模式下数控系统的网络化要求,研究了网络化数控系统的功能和特点,构建了网络化数控系统的功能模型,并基于Internet/Intranet技术,采用Browser/Server模式建立了网络化数控系统的体系结构.研究开发了一种基于PMAC的网络化数控系统原型,并应用于北京交通大学教学型FMS.     

基于GPRS的交通信号控制系统的研制

简要提出了交通信号机与上位机通信的GPRS解决方案,介绍了DSP交通信号机的硬件集成,分别设计了交通信号机DSP端和上位机PC端的通信接口程序,并给出了系统的调试和联网安全措施,达到了技术实用、可靠性高,以及低成本的要求。     

基于特征的可进化切削数据库的设计

针对切削数据库的设计,提出了数据完备性定义,描述了生产现场采集数据的过程,提出了基于零件切削特性的特征模型,结合实例,描述了系统的进化机制.     

基于MATLAB的液压元件的设计

为了能够有效地对液压元件进行设计,深入地研究了MATLAB/Simulink在其中的应用.首先,分析了基于MATLAB/Simulink的液压系统的设计原理;接着,以安全阀喷头液压系统为例,设计了系统中各个液压元件的仿真模型;最后,进行了仿真分析,分别研究了安全阀出口压力和喷头流量的关系,以及喷头孔径对喷头流量的影响.仿真结果为液压元件的设计提供了有利的理论依据,验证了该方法的有效性.     

基于VB的虚拟应变仪的设计

为解决传统应变仪测量中存在的设备匹配,调试麻烦等不足,采用虚拟仪器技术,以VB为开发平台,设计了虚拟应变仪。系统由应变检测模块,数据采集模块,人机接口模块组成。系统充分利用了AD7710的特点简化了硬件设计,使用虚拟仪器技术拓展了应变仪的功能,满足了应变测量内容多样性的要求。试验表明,系统不仅具有较高的测量精度和稳定性,取得理想效果,而且具有较大的拓展空间。     

虚拟企业的客户关系管理系统的功能特征研究

介绍了客户关系管理的重要性,分析了虚拟企业的客户关系管理系统的功能特点,比较了与传统管理信息系统的区别,详细研究了系统的智能特点,分析了影响系统实施的关键因素.     

基于神经网络的产品装配成本的估算方法的研究

提出了基于神经网络的产品装配成本的估算方法 ,运用该方法对某铁路货车产品重要部件的装配成本进行了估算 ,并且与线性回归分析法进行了比较 ,结果表明基于神经网络的估算方法大大优于线性回归分析法。该方法为设计人员提供了成本方面的决策依据 ,达到了产品最终成本的有效控制 ,在产品装配成本的估算中是正确和有效的。     

基于MATLAB的硬态恒定切削力控制

针对硬态切削过程中径向力较大的特点 ,采用MATLAB/Simulink设计了硬态恒定切削力控制系统 ,并对该系统进行了恒力控制 ,分析了它的性能和精度     

Self-organizing fuzzy control of constant cutting force in turning

Constant force control is gradually becoming an important technique in the modern manufacturing process. Especially, constant cutting force control is a useful approach in increasing the metal removal rate and the tool life for turning systems. However, turning systems generally have nonlinear with uncertainty dynamic characteristics. Designing a model-based controller for constant cutting force control is difficult because an accurate mathematical model in the turning system is hard to establish. Hence, this study employed a model-free fuzzy controller to control the turning system in order to achieve constant cutting force control. Nevertheless, the design of the traditional fuzzy controller (TFC) presents difficulties in finding control rules and selecting an appropriate membership function. Moreover, the database and fuzzy rules of a TFC are fixed after the design step and then cannot appropriately regulate ones real time according to the system output response and the desired control performance. To solve the above problem, this work develops a self-organizing fuzzy controller (SOFC) for constant cutting force control to evaluate control performance of the turning system. The SOFC continually updates the learning strategy in the form of fuzzy rules, during the turning process. The fuzzy rule table of this SOFC can be begun with zero initial fuzzy rules which not only overcome the difficulty in the TFC design, but also establish a suitable fuzzy rules table, and support practically convenient fuzzy controller applications in turning systems control. To confirm the applicability of the proposed intelligent controllers, this work retrofitted an old lathe for a turning system to evaluate the feasibility of constant cutting force control. The SOFC has a better control performance in constant cutting force control than does the TFC, as verified in experimental results.     

Self-organizing fuzzy control of constant cutting force in turning

Constant force control is gradually becoming an important technique in the modern manufacturing process. Especially, constant cutting force control is a useful approach in increasing the metal removal rate and the tool life for turning systems. However, turning systems generally have nonlinear with uncertainty dynamic characteristics. Designing a model-based controller for constant cutting force control is difficult because an accurate mathematical model in the turning system is hard to establish. Hence, this study employed a model-free fuzzy controller to control the turning system in order to achieve constant cutting force control. Nevertheless, the design of the traditional fuzzy controller (TFC) presents difficulties in finding control rules and selecting an appropriate membership function. Moreover, the database and fuzzy rules of a TFC are fixed after the design step and then cannot appropriately regulate ones real time according to the system output response and the desired control performance. To solve the above problem, this work develops a self-organizing fuzzy controller (SOFC) for constant cutting force control to evaluate control performance of the turning system. The SOFC continually updates the learning strategy in the form of fuzzy rules, during the turning process. The fuzzy rule table of this SOFC can be begun with zero initial fuzzy rules which not only overcome the difficulty in the TFC design, but also establish a suitable fuzzy rules table, and support practically convenient fuzzy controller applications in turning systems control. To confirm the applicability of the proposed intelligent controllers, this work retrofitted an old lathe for a turning system to evaluate the feasibility of constant cutting force control. The SOFC has a better control performance in constant cutting force control than does the TFC, as verified in experimental results.     

铣削加工过程智能控制试验

在XK5140型立式数控铣床上建立了加工过程智能控制试验平台,其控制系统基于MATLAB的Simulink模型,通过编写S函数创建控制器模块。以铣削力为控制对象,对不同切深的工件采用不同的初始条件,进行铣削加工过程智能控制试验。使用该试验平台能实现铣削加工过程的智能控制,保持铣削力恒定,可防止刀具损坏,提高切削效率。     

Auto-tracking single point diamond cutting on non-planar brittle material substrates by a high-rigidity force controlled fast tool servo

This paper presents auto-tracking single point diamond cutting, which can conduct precision cutting on non-planar brittle material substrates without prior knowledge of their surface forms, by utilizing a force controlled fast tool servo (FTS). Differing from traditional force feedback control machining based on a cantilever mechanism such as an atomic force microscope (AFM) that suffers from low-rigidity and limited machining area, the force controlled FTS utilizes a highly-rigid piezoelectric-type force sensor integrated with a tool holder of the FTS system to provide sufficient stiffness and robustness for force-controlled cutting of brittle materials. It is also possible for the system to be integrated with machine tools to deal with the difficulties in the cutting of large area non-planar brittle materials, which requires not only high machining efficiency but also a high stiffness. Experimental setup is developed by integrating the force controlled FTS to a four-axis ultra-precision diamond turning machine. For the verification of the feasibility and effectiveness of the proposed cutting strategy and system, auto-tracking diamond cutting of micro-grooves is conducted on an inclined silicon substrate and a convex BK7 glass lens, while realizing constant depths of cuts under controlled thrust forces.     

The effect of high frequency and duty cycle in electrochemical microdrilling

A useful method for increasing the metal removal rate and the tool life of turning systems is by controlling a constant cutting force. This study developed a hybrid self-organizing fuzzy and radial basis-function neural-network controller (HSFRBNC) for turning systems to maintain constant cutting force operation. The HSFRBNC uses a radial basis function neural-network to regulate both the learning rate and the weighting distribution of a self-organizing fuzzy controller (SOFC) in real time to appropriate values, instead of obtaining these values by trial and error. It not only eliminates the difficulties of finding appropriate membership functions and fuzzy rules in the design of the fuzzy logic controller but also solves the problem of determining suitable parameters of the SOFC. The HSFRBNC has better control performance than the SOFC for manipulating constant cutting force in the turning system, as shown in the simulation results.     

A new adaptive controller for constant turning force

A new computerised adaptive control constraint (ACC) system in turning with a constant cutting force constraint is described in this paper. It is shown that the ACC control system based on the fuzzy linguistic rules can achieve an automatic on-line adjustment of feedrate to optimise the production rate even under the variation of cutting conditions in turning operations.     

An intelligent feedrate scheduling based on virtual machining

Off-line feedrate scheduling is an advanced methodology to automatically determine optimum feedrates for NC code modification. However, most existing feedrate scheduling systems have limitations in generating the optimised feedrates because they use the material removal rate or the cutting force model which is dependent on cutting conditions. This paper proposes a feedrate scheduling system based on an improved cutting force model that can predict cutting forces accurately in general end milling situations. Original blocks of NC code were divided into smaller ones with the optimised feedrates to adjust the peak value of cutting forces to a constant value. The acceleration and deceleration characteristics for a given machine tool were considered for realistic feedrate scheduling. Moreover, a modified type of Z-map model was developed to reduce the entry/exit angle calculation error in the cutting force prediction and named the moving edge node Z-map (ME Z-map). Pocket machining experiments show that the proposed method is accurate and efficient in maintaining the cutting force at a desired level.     

Deep grinding of titanium alloy with continuous wheel correction

In deep grinding with continuous wheel correction, the cutting force is determined by the instantaneous cutting capacity. A mathematical model of the instantaneous cutting capacity is developed for all stages of grinding. On that basis, the force variation may be predicted. The ratio of the force components in deep grinding and also the instantaneous cutting capacity (reduced to unit vertical component of the grinding force) are constant in all stages. Formulas for the rated pressure and mean rated pressure are proposed.     

岩石切削过程中破坏机制的离散元分析

利用离散单元方法(DEM)对两种不同属性的花岗石样本模型进行了切割模拟,通过调整不同的切削参数计算并分析了岩石切削过程中的切削力、切削深度、切削比能及切削力倾角的变化规律,从细观上探讨了临界切深对岩石脆性破坏模式和塑性破坏模式及其转变的影响,指出了当切削深度逐渐增大时,破坏模式依次从塑性破坏模式到过渡破坏模式最后转变为脆性破坏模式,同时切削力倾角并不随切削深度变化。将离散单元法分析的结果与实际实验进行了比较,表明该方法是合理的。