Abstract: This article discusses strategies for resolving bottlenecks in the application of CNC machine tools, focusing on the bottlenecks encountered in the process from the machine tool itself to its use. The aim is to help application companies better understand and master how to effectively avoid problems in the connection and application of CNC machine tools, thereby reducing unnecessary losses and waste, through a series of bottleneck examples.
Keywords: Bottleneck solutions in CNC machine tool applications
Analysis of bottlenecks in the field of CNC machine tool applications and Countermeasures
YAN En-gang
(Tianshui Spark Machine Tool Co., Ltd., Tianshui, Gansu 741024, China)
Abstract : Articles by CNC machine tools products from equipment used to link points along the "bottleneck", discusses the application process to solve the "bottleneck" approach. Aims through a series of "bottleneck" examples, so that applications business more effectively understand and master how to avoid the areas of CNC machine tools in the link and some of the problems in the application process, reduce unnecessary losses and waste.
Keyword : CNC machine tools Application Bottleneck Countermeasure
I. Overview
With the rapid development of CNC technology, CNC machine tools have permeated various industrial fields. Integrating modern precision mechanics, computers, sensing and detection, information processing, and other multidisciplinary technologies, they are characterized by high efficiency, high precision, high automation, and high flexibility. They have become the mainstream equipment in contemporary machinery manufacturing, the foundation and core of modern advanced manufacturing technology, and an inevitable trend in the development of the machine tool industry today.
As is well known, the application of CNC machine tools has not only greatly improved machining performance, enabling precise machining of complex parts that traditional machine tools cannot handle, effectively improving machining quality and efficiency, but has also brought progress to changing the production model of the traditional machinery industry, and has also brought about changes in people's work patterns. However, years of practice have shown that due to the limited popularization of CNC technology, many enterprises still lack understanding and awareness of the performance and application of CNC machine tools to varying degrees. Many problems still exist in the selection of CNC machine tools and their deployment, creating a "bottleneck" not only in the link between the machine tool and its use, but also in the application and management of CNC equipment. This results in low utilization rates of CNC machine tools, with some even remaining in a state of long-term paralysis, unable to play an effective role. Therefore, solving this "bottleneck" is an important issue that cannot be ignored in the field of CNC technology today.
II. Bottlenecks and Countermeasures
1. Providing complete and standardized technical conditions for main engine manufacturers is an effective way to solve the "bottleneck".
When selecting CNC machine tools based on processing requirements, enterprises typically need to go through several stages, including market research, comparative analysis, and demonstration, to ultimately provide machine tool manufacturers with machines that meet their specific needs.
The technical conditions required for the process define the system configuration, basic performance, technical parameters, and equipment specifications of CNC machine tools. These conditions serve as the basis for the design input of the mother machine, and their completeness and accuracy lay the foundation for future applications of CNC machine tools. However, in reality, bottlenecks caused by non-standard technical conditions are common, leading to numerous adverse effects on the subsequent use of CNC equipment. Examples include: the selected CNC system's functional configuration failing to meet the enterprise's specific processing requirements; insufficient machine tool capacity to handle corresponding workpiece processing; equipment specifications not meeting workpiece processing requirements; improper CNC system selection failing to provide the required industrial Ethernet interface, necessitating system replacement due to transmission speed limitations; a semi-closed-loop control configuration instead of a fully closed-loop one, resulting in compromised machining accuracy; and a mismatch between spindle frequency conversion speed regulation and load characteristics, affecting normal operation. These examples demonstrate a lack of understanding and awareness of CNC machine tool performance and system functional configuration, creating bottlenecks in the process. This not only increases investment costs for enterprises but also affects equipment lifespan, causing losses to varying degrees.
2. Integrity of random technical documents - Resolving the "bottleneck" in the linked data.
After CNC machine tools are installed, debugged, and finally accepted and handed over for use, the completeness of their accompanying technical documents is crucial for the subsequent application of the equipment. This is also important for companies using CNC machine tools.
It is an important link that cannot be ignored.
Due to incomplete technical documentation such as drawings and manuals, equipment malfunctions cannot be repaired, random information on CNC system password settings is missing, and machine tool parameters cannot be modified when the settings are not entered, and complete system backup files are not provided during the acceptance period, making it impossible to restore normal use when machine tool data is lost. Many companies' CNC machine tools have experienced downtime of several months, or even a year or longer after the warranty period due to this problem, which seriously affects normal production and causes incalculable losses to the companies.
Before a CNC machine tool is finally accepted and put into use, verifying the completeness of the accompanying technical documents is an essential step for the user company.
3. Increase efforts to popularize basic CNC knowledge, fully develop the rational use of CNC functions, achieve scientific management, and solve the "bottlenecks" in application and management.
Currently, among companies using CNC machine tools, management is not standardized enough, and application capabilities are generally problematic, creating a "bottleneck" in application. Specifically, this manifests in the lack of standardization in CNC machine tool systems.
Limited understanding and insufficient development and utilization of system functions have resulted in a limited variety of processed parts and low efficiency. A lack of in-depth understanding of machine tool control principles, especially the principles of the entire system, leads to difficulties in troubleshooting machine malfunctions, resulting in high downtime, limited programming capabilities, low utilization of CNC machine tools, and unscientific and unstandardized equipment management. A lack of basic CNC knowledge also creates management bottlenecks. Field observations show that operating environments containing dust, static electricity, humidity, metal shavings, and waste liquid not only alter the specific working environment but also contribute to machine tool failures. Arbitrary alterations to ventilation and heat dissipation in electrical and control boxes reveal insufficient radiator capacity, causing malfunctions. Regular equipment maintenance using ducts to clean metal shavings allows foreign objects to enter the position detection grating ruler, causing scratches on the steel strip surface and irreparable damage to the grating pitch, necessitating replacement. Lack of preventative measures against coolant during processing allows liquid to splash into the main servo motor, causing smoke and abnormal damage, requiring shutdown for repair or replacement. In summary, the main reason for this is a lack of understanding of the fundamentals of CNC technology and its insufficient application, particularly among equipment management departments. While effectively utilizing CNC equipment, it is crucial to improve understanding and mastery of the basics of CNC systems to establish scientific and standardized management practices. Only in this way can equipment be managed effectively to meet practical application needs and maximize equipment utilization. Therefore, increasing the dissemination of basic CNC knowledge, raising awareness among all staff, and striving to cultivate a talent pool integrating CNC technology and management are important strategies for addressing the "bottleneck" in the application and management of CNC machine tools.
4. Improve power quality and grid quality to solve the "bottleneck" caused by the power grid on the reliability of CNC machine tools.
In the application of CNC machine tools, the quality of the enterprise's power supply system will affect the reliability of the CNC system. For example, harmonics in the power grid can interfere with the CNC system through the power supply.
Simultaneously, it generates electromagnetic radiation to surrounding electromechanical equipment; some signals, after transmission, form secondary radiation. This interference, superimposed on the signal, can cause signal measurement and control distortion and malfunctions in the CNC system, resulting in position control drift. The interference to the measurement unit directly affects the measurement and control accuracy. The electromagnetic noise generated by the directly driven motor is conducted to other equipment in the system through the power supply network; it is also emitted externally through connected wires, or the interference is introduced into other circuits through impedance coupling grounding loops. The interference path can be very long. In severe cases, the interference signal can enter the civilian network along the power supply transformer, making electrical equipment connected to the distribution busbar a remote victim. Power fluctuations that exceed the normal range can also affect the instability of system control, cause equipment to malfunction, and even lead to the failure or damage of the system control unit; see Figure 1 for noise emission and interference, and Figure 2 for the transmission of interference signals. Therefore, improving power quality and enhancing grid quality are also important factors in effectively solving the "bottleneck" of CNC machine tool reliability.
To ensure that the transmission control system is protected from or has reduced interference in the industrial electromagnetic environment, interference suppression measures must be taken; cutting off or attenuating interference propagation paths and coupling channels, and reducing the system's sensitivity to interference signals are necessary to ensure the system's electromagnetic compatibility and operational reliability. Currently, the following measures are being taken: (1) Isolation/Filtering: Isolation separates the interference source from the susceptible parts, preventing them from having electrical connections. Filtering suppresses conducted interference, typically using isolation transformers or filters. (2) Adaptive Reactors: These can reduce harmonic pollution of the power grid. (3) Stabilized Power Supplies: These can improve power grid quality and reduce power fluctuations. Specific measures need to be determined based on the enterprise's power grid conditions and CNC machine tool system configuration. When conditions permit, the enterprise can consult with the machine tool manufacturer to consider the above configurations based on the original design configuration; this is the most ideal approach.
III. Conclusion
In today's era of rapid development in CNC technology, the "bottleneck" in the application of CNC machine tools may be a topic that people do not pay much attention to or often overlook. However, the research and development and application of CNC machine tools is a systematic and complex project. Only by continuously improving the comprehensive application capabilities of CNC machine tools and giving full attention to and effectively solving the "bottleneck" in the application field can my country's CNC machine tools develop along a healthy track.
About the author: Yan Engang (1960-), male, engineer at Tianshui Xinghuo Machine Tool Co., Ltd., No. 41, Shetang East Road, Maiji District, Tianshui City, Postcode: 741024.
Main research areas: CNC machine tool product design and technical support/consulting; 6 published papers.
