51304156-100咨询***：18506919598（卢工）***：3127821951.主轴故障特征XK713华中数控铣床在使用过程中，主轴系统常见故障特征主要表现有三方面：(1)换刀机构卡滞，刀具无法从主轴中卸下。(2)未装刀具夹紧时主轴能正常运转，装上刀具夹紧后不运转。(3)在正常的加工过程中，主轴经常停止工作，加工过程自动结束。2.主轴结构与工作原理主轴系统主要由主轴和拉刀夹紧机构组成。由电机通过同步齿形带带动主轴转动;拉刀夹紧机构主要拉紧刀具并夹紧，由步进电机带动蜗轮蜗杆转动，使蜗轮轴上的齿轮带动齿条上下移动，齿条下移推动拉刀杆解脱刀具，齿条上移，拉刀杆在弹簧力的作用下，拉紧刀具并锁紧，完成刀具的装卸;两者运动互锁。夹紧控制与工作原理如图1、图2所示。3.主轴系统故障原因分析与维修(1)换刀机构卡滞使刀具无法从主轴中卸下。原因有：蜗杆蜗轮机构和扇形齿轮齿条机构存在较大的齿形误差或齿侧间隙，常产生机构卡滞故障，在齿条下压拉刀杆时，使拉刀杆下移不到位或欠到位，刀具无法卸下;松刀位置磁性传感器***可靠性差，传感器***板螺钉压紧刚性不够，在机床加工振动或受热条件下，容易产生***误差，使步进电机松刀控制指令信号执行欠足，拉刀杆下移欠到位，刀具无法卸下。维修方法：修配齿形误差和调整齿侧间隙，使蜗杆蜗轮机构和扇形齿轮齿条机构运动灵活，更换传感器***板，增大其刚度和改善***方式，使其***可靠。(2)主轴未装刀具夹紧时能运转而装上刀具夹紧后不运转。原因：拉刀机构回位弹簧力偏弱，使蜗轮/扇形齿轮回位转角存在误差，紧刀位置磁性传感器感应信号未达到接通主轴电机控制继电器信号的要求，主轴电机无法接通而不能工作;未装刀具夹紧时主轴能运转是由于拉刀机构回位弹簧无拉刀作用反力，回位弹簧有足够的回位力推动扇形齿轮轴转动使铁芯处于正常位置，锁紧磁性传感器感应信号正常可接通主轴电机。维修方法：增加回位弹簧预紧力，足以推动扇形齿轮轴转动到可靠位置;调整紧刀位置磁性传感器的安装位置，使其信号足以接通主轴电机控制继电器，主轴电机能被通电运转。同时修改或增加控制系统步进电机的控制脉冲量，即扇形齿轮轴转位值。(3)正常加工过程中，主轴经常停止工作，加工过程自动结束。主要原因是位置磁性传感器***板刚度不够和***不可靠，机床加工振动使位置磁性传感器安装位置发生变化，特别是磁性传感器与铁芯间隙增大，磁性传感器的位置感应信号不足以驱动主轴电机的控制继电器接通或在加工过程中突然断开，从而终止加工过程自动结束。另外，机床长期连续运转后，主轴系统发热，磁性传感器***板存在热变形，磁性传感器与铁芯间隙增大(0.1～0.3mm)，改变了磁性传感器位置感应信号，使主轴电机的控制继电器在加工过程中突然断开而终止，加工过程自动结束。维修方法：更换传感器***板，增大刚度和改善***方式;调整磁性传感器与铁芯间隙，使感应信号足以驱动主轴电机的控制继电器。GSHevi-DutyElectric145kVA550Delta460Y/266DT1961H145TSTransformer460YMicroMotionD100S-SS-A150MassFlowSensorMicroMotionD100SSSA150IntelPWA147262-001RevA/PWA1003137-08YMJSNP05831PLCPBA147242-001PCBYokogawaDX1012DAQSTATIONDigitalRecorderDX1012-1-4-2/A2?/M1S2100-240VACDXHoneywellNIMModem51304511-100RevGPLC51304510-001RevDYamatakeMeasurexMoore39ACM24BANPLCACM16139-76RAPACS+QuadLog1613976RControlModuleLantechREMPowerBoard550-011-01DCControllerStretchWrapperSP168084ISLT33BaslerElectricBE1-32RO/UPowerSolidStateProtectiveRelayD2FE1RC0N3FExideA53A2DigitalPLC118302416CModuleBoard101072431DEK184343BoschCNCNC-SPSPC176024NCSPS047972-3027BatteryBoardPLCBentlyNevada7200DVTP-RDualThrustMonitor7200DVTPRPLCModuleBentleyBentlyNevada7200DualProbeMonitor7200-RVDP72564-52-04-03-?05-01-01-15200mVOnan300-1625FirstStartSensorMaster3001625GeneratorControllerMeterBentlyNevada3300/61DualVectorMonitor3300/61-02-01-0?1-00-00-00PLC5milsGSHevi-DutyElectric300kVA480208Y/120T2H300Transformer3PH300KVA208YOrbisphereLaboratoriesAnalyzerModel3600/320OxygenControllerOzoneAnalyserBentlyNevada3300/03SystemMonitor01-00PLCModuleACTech125HPQ14125BQCSeriesVariableSpeedVSACMotorDrive125HP460VStanfordResearchSystemsPPM100PartialPressureMonitorSRSModelPPM100ScientificColumbusCT-510P-A7ProcessControlCurrentTransducerCT510PA7WaltronuAI9070HydrazineAnalyzerAqualertK2014-419BDisplayInterfaceTesterExideA5A1TransferControlBd118302758P10PLCModuleBoard101072962P13WatlowDC3C-3024-K200DIN-a-miteSolidStatePowerControlDC3C3024K200REMANFoxboroIDP10-T22A21F-M?1VFlowControl3626PSI4-20mA12.3-42VDCFOXCOMSTI42686-0720OF4100OptoFenceOF4172BXTran***itterLightCurtain42686072072"YokogawaVR204S2-0/A2/D2ViewRecorderVR200100-240VACVR204VR200BoschCC220NPLCCardrackChassisD-6471124Volt7AwithFanRack5slotsGSHevi-DutyElectric112kVA600208Y/1203PHT7H112STransformer112kVA208YADT4520-373SignalSystemControlUnitAssemblyPLCP-437584FireR992600316BaslerElectricBE1-81OUFrequencyRelayT3EE1LA7N1FT3EE1LA7N1FBE181O/UAutomatedLogicM4106pControlModuleM4106pM4106PLCM4106P2MBALCHVACMoore773D011NNANNPLCI/PAC15972-71I/PTransducerModule4-20mA45PSIGADT4520-229SignalSystemControlUnitAssemblyPLC26-FD-45201P-422173FireSiemensSIMOREGDCDrive6RA7013-2FV62-015A10HPDCConverter6RA7018-6FV62-0?ZTaylor6007BG10000DSerialI/OPCBoard6007BG10000-DABBPCBPLCELOF50672-000TouchscreenDisplay1860LOperatorInterface18"TouchsystemsinHammondD063JCLB1TH63kVA460230Y/133DriveIsolationTransformer63KVA230YKST-20A500VA220V/100V/20V50/60HzTransformerKST-20A500VAMurataToyoDaykin201-0221AuxiliaryPowerTransformerDisconnectSwitch2010221WaltronuAI9030SodiumIonAnalyzerK2014-419BDisplayInterfaceTesterMonitorBaslerElectricBE1-32RPowerRelayD3EE1RA0N1FD3EE1RA0N1FBE132RSolidHyTork-280120PSIG/wTufline316SS3"Valve/wWestlockBeaconActuator2007NAPV575SqFtPlateandFrameHeatExchanger150PSI316StainlessPlatesSSRusselectricModel2000AutomaticTransferSwitchControlSystem1500116001PLCcems2000SIXNET61-COUNT-16PSC261COUNT16PLCBoardDaykinGPFS-03LOTransformerDisconnectSwitch1.5kVAGPFS03480V3.4AmpsBentlyNevada3500/20RackInterfaceModulePLCPWA125744-02350020350020SparlingTigerMagFlowmeterFM655Size12316SS1.63OffsetTigerMag19.564GParkerGT6-L8GT6GeminiStepperServoModuleGT-L5/8GT6L8BentlyNevada3300/30SixChannelTemperatureMonitor3300/30-02-01-0?1-00-00PLCDynicsCH12THI04T1NTF1?40IndustrialTouchscreenDisplayCH12THDranetzBMIDataNodeSeries5500Model5530T5536VoltageModuleDataNodeBoschZE-602PCI/OBoard041706-409401ZE602041706409401Landis&Gyr1011581004RevB11011577000RevB11011579000RevBPLCChillerHitranAP0671-1Type:ACClass:AA35MicroHInductor450/PHAmperesTransformerMGM225KVA480to208Y/120in3REncl.3PHTransformerAC370-Q0232225KVA208YAltronicEPC-200CEPCEnginePerformanceControllerEPC200COperatorInterfaceOnan300-2014ParallelingControl3002014GeneratorControllerMeterOrbinox20-3636KnifeGateVal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