1771-OG
1771-OG
1771-OG
數控機床作為一種柔性的、能的自動化機床，很好地解決了復雜、精密、小批量和多品種的零件加工問題。隨著數控機床設備在工業的廣泛應用，其運行的性也顯得愈發重要，的數控機床設備可以有效保護操作人員的人身，避免設備的頻繁故障，提高企業的生產力水平。
為了提高設備的等級，某動力公司位於的生產基地於2012 年啟動了設備防護改造工程，希望通過對機械加工設備的升級改造，避免由於設備功能的缺失或不完善可能導致的隱患，滿足長遠的 EHS目標，進一步提升企業的市場競爭優勢。
先讓們看看這家改造企業的背景：
該公司是一家多元化的動力管理公司，其生產的電力、流體動力和機械動力產品廣泛應用於建築、飛機、卡車、汽車、機械以及各種商業設施，年銷售額超過200億美元。此次改造的工廠是其位於的28個制造基地之一，主要生產各種液壓彎頭、接頭和管件等產品。
三重挑戰，如何個個擊破?
本次整改項目共涉及65臺套設備的機器改造，其中難度的是20臺 MAZAK數控機床的係統改造。
先，作為企業生產的核心設備， MAZAK數控機床的改造方案穩妥，只可成功，不可失敗。此外，MAZAK數控機床設備的使用率，設備每天工作16個小時，每小時開門20次，一年總計11.2 萬次的開門次數，這要求所用方案可靠和耐久，可以耐長期高負荷的運行條件。
令企業頭痛的是，原設備的PLC 係統代碼被保護，由於不能獲得原設備 PLC的代碼，改造時無法對設備做內部改變，但同時又要滿足數控係統機器的防護要求，新方案需要一個創新的設計思路。
總結來說，此次升級改造需要的不僅僅是係列產品，而是一個針對現有數控機床特點而設計的、完整的定制化解決方案。
好產品 ， 更要有好的解決方案!
憑借在美同類項目的成功應用經驗，以及遍布各地的專業而快速的銷售和執行隊伍，羅克韋爾自動化針對工廠現有設備的具體情況，為其量身定制了係統升級方案。
改造前，數控機床設備的均採用單回路形式，改造目標是實現級別category 3。
先，羅克韋爾自動化的項目實施團隊反復多次和工廠多個部門討論，查找資料，吃透原機器結構和控制原理，熟悉機器的各種狀態，包括：設置、數控編程、運行(手動和自動)、小批次和大批量、維護和調試狀態等，新改造方案考慮上述各個方面。
在充分了解設備情況後，實施團隊嚴格遵循機器標準(ISO 13849 和 IEC 62061)，增加防護係統並嵌入到現有係統中運行。
整體邏輯圖如圖1所示，新係統按照SIL 3標準來設計，新舊係統獨立而又並列運行，而且並行的輸入、串行的輸出將新係統和舊係統的措施有機結合起來，這種冗餘的結構設計是方案的一大亮點，保證了係統的穩定運行。
為保證改造方案的化，本次改造採用原型機試制和批量生產的方式。改造前，這些數控機床設備就在長期高負荷地運行，所以改造方案滿足苛刻的運行條件，不適宜一開始就批量改造，所以用19號機器先行改造，運行2個月後，針對效果提出進一步改進措施，而後全部用更新後的方案批量改造。
機器的耐久和穩定運行是本次改造的重要目標，為達成該目標，除了採用冗餘的係統架構外，實施團隊還採取了一係列的措施，包括：浮動推拉門、防震設計、通風防塵設計和備用回退選項等。
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