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Spindle motor for CNC machines integrated with the machine tool spindle

2016-11-08View Original

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1. High speed and high precision: Speed and precision are two important characteristics of CNC machines; they have a direct impact on processing efficiency and product quality. Currently, CNC systems use processors with higher bit counts and frequencies to improve the system’s basic processing speed. At the same time, very large-scale integrated circuits and multi-microprocessor architectures are employed to enhance the system’s data processing capabilities, that is, to improve the speed and accuracy of interpolation calculations. It also employs a linear servo feeding system in which a linear motor directly drives the machine tool table, offering excellent high-speed and dynamic response characteristics. Feedforward control technology is employed to **reduce** the tracking lag error, thereby improving the machining accuracy during corner cutting. To meet the requirements of ultra-high-speed machining, CNC machines feature a design in which the spindle motor and the machine’s spindle are integrated into one unit, thereby combining the variable-frequency motor with the spindle. The bearings used in the spindle motor are of types such as magnetic levitation bearings, hydrostatic and hydrodynamic bearings, or ceramic rolling bearings. Currently, ceramic tools and diamond-coated tools have begun to be used. 2. Multifunctional machining centers equipped with automatic tool-changing mechanisms (with a tool magazine capacity of over 100 tools) can perform various machining operations such as milling, boring, drilling, turning, reaming, enlarging holes, and threading on the same machine. Modern CNC machines also utilize multiple spindles and multi-faced cutting, which allows for different types of machining on different parts of a single part at the same time. Thanks to its multi-CPU architecture and hierarchical interrupt control, the CNC system enables simultaneous part processing and program programming on the same machine, achieving what is known as \"processing in the foreground and editing in the background\". To meet the requirements of flexible manufacturing systems and computer-integrated systems, CNC systems are equipped with long-distance serial interfaces; they can even be connected to a network to enable data communication between CNC machines, as well as allowing direct control of multiple CNC machines. 3. Intelligent modern CNC machines will incorporate adaptive control technology, which automatically adjusts the operating parameters in response to changes in cutting conditions, thereby maintaining an optimal operating state during processing. This leads to higher precision in machining and lower surface roughness, while also extending the lifespan of cutting tools and improving the production efficiency of the equipment. It features self-diagnosis and self-repair capabilities; throughout its operation, the system continuously performs self-diagnosis and checks on both the CNC system itself and various devices connected to it. Once a fault occurs, measures such as shutting down the system are taken immediately, along with fault alarms that indicate the location and cause of the fault. It can also automatically take the faulty module offline and activate the backup module to meet the requirements of an unattended operating environment. To meet higher requirements for fault diagnosis, the trend is to adopt artificial intelligence expert diagnostic systems. 4. Automation of CNC programming: With the development of computer application technologies, CAD/CAM graphical interactive automatic programming is now widely used, representing a new trend in the advancement of CNC technology. It uses CAD-generated part machining drawings, and through calculations and post-processing of the tool path data in the computer, it automatically generates NC part machining programs, thereby achieving integration between CAD and CAM. With the development of CIMS technology, a fully automated programming method that integrates CAD/CAPP/CAM has emerged. The main difference between this approach and programming using CAD/CAM systems is that the processing parameters required for programming do not need to be entered manually; they are obtained directly from the CAPP database within the system. 5. Maximizing reliability: The reliability of CNC machines has always been the key indicator that users are most concerned about. The CNC system will use circuit chips with higher integration levels, relying on large-scale or very large-scale specialized and hybrid integrated circuits in order to reduce the number of components and enhance reliability. By softwareizing hardware functions to meet the requirements of various control functions, and by adopting a modular, standardized, universal, and serialized hardware structure for the machine tool itself, it is possible to increase the volume of hardware production while also facilitating production organization and quality control. It also enables fault diagnosis and alarm generation for the hardware, software, and various external devices within the system by automatically running various diagnostic programs such as online diagnostics and offline diagnostics. Use alarm alerts to promptly resolve faults; employ fault-tolerance techniques and a \"redundant\" design for critical components to enable self-recovery from failures; utilize various testing and monitoring technologies to provide automatic protection in the event of production deviations, tool damage, interference, power outages, and other unexpected situations. 6. Miniaturization of control systems: The miniaturization of CNC systems facilitates the integration of mechanical and electrical components into one unit. Currently, very large-scale integrated components and multi-layer printed circuit boards are primarily used, along with three-dimensional mounting methods, which enable electronic components to be installed at high density and thereby significantly reduce the space occupied by the system. Replacing traditional cathode ray tubes with new types of color LCD thin displays will further minimize the size of CNC operating systems. This makes it easy to install it on machine tool equipment, thereby facilitating the operation of CNC machines. According to the China State Railway Group, in the first half of this year, **the railways invested 265.13 billion yuan in fixed assets, a 12.7% increase on a year-on-year basis; 2,226 kilometers of new railway lines were put into operation. In terms of volume, railway investment in the first half of the year accounted for only about 20-30% of the annual planned investment amount. However, Wang Mengshu, an academician of the Chinese Academy of Engineering, said, “The situation for railway construction is very good at present, with strong momentum in all aspects. A peak in railway construction will occur in the second half of the year, and railway investment this year is expected to exceed the set target of 800 billion yuan.” ”Therefore, it is clear that railway construction investment will enter a period of sustained growth and increased activity in the second half of the year. Furthermore, the steady progress of the Belt and Road Initiative has also brought about numerous opportunities for infrastructure investment. Infrastructure is a priority area in the development of the Belt and Road Initiative. There is also a strong demand for infrastructure in most countries along this initiative, and numerous projects related to railways, highways, energy systems, ports, information technology, and industrial parks are being accelerated in their implementation. Infrastructure cooperation within this region presents huge market opportunities. Shen Danyang, a spokesperson for the Ministry of Commerce, revealed that from January to June, Chinese companies undertook 1,401 foreign contracting projects in 60 countries along the Belt and Road Initiative, with new contract values amounting to 37.55 billion US dollars. Obviously, for the construction machinery industry, which is closely linked to infrastructure investment, each of these developments represents numerous opportunities for growth.

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