This paper briefly introduces the control technology of fine automatic compensation, which has been successfully applied in modern automobile manufacturing industry. Taking engine cylinder hole processing as an example, according to the investigation of the actual application situation of domestic mainstream automobile engine factory, this paper analyzes the enterprise planning Different process choices made during the process. The article also introduces a typical compensation mode with examples.

1 fine automatic compensation technology

(1 Overview

Fine automatic compensation is a mature technology that has been born for many years. It is a very important and representative one of the control technologies called “automatic compensation” in modern machinery manufacturing. It has been widely used in the machining of main parts of engines such as cylinders and connecting rods. Taking cylinder machining as an example, the fineness of the cylinder bore is one of the most important processes, and the dimensional accuracy and shape error involved will directly affect the quality of the engine. The actual use effect shows that if the automatic compensation link is added in the fine boring process, the operation quality of the process can be significantly improved, which is mainly reflected in the following aspects:

1 Since the automatic compensation system can compensate for the influence of tool wear and temperature and other unstable factors, and the compensation amount of the cutting edge can reach 1μm, the effect of improving and improving the workpiece quality is obvious.

2 can reduce the number of adjustments and improve the efficiency of the process (especially when combining semi-precision and fine boring in the same process).

3 By upgrading the machine tool performance, ordinary machine tools can be upgraded to precision machine tools.

(2) Realization of fine automatic compensation function

The automatic compensation system consists of three parts: random detection, (signal) feedback compensation and boring with fine-tuning function. In the main parts of the engine, in addition to the outside of the cylinder, there are many automatic tapping compensation systems in the connecting rod processing, but the compensation principle and system composition are exactly the same. The working cycle is as follows: the boring tool exits after machining the hole, and the workpiece is measured by the electronic plug gauge (probe); then the probe exits, the detection information is sent to the measuring instrument, and is sent to the compensation control after amplification and A/D conversion. The unit, after performing the calculation, makes corresponding judgments. If compensation is needed, the corresponding command is issued to the compensation actuator; the compensation actuator can have different forms, and the servo motor is shown in Fig. 1. The coupling is converted into the axial movement of the tie rod, and sometimes it needs to be equipped with a coolant supply device; finally, the displacement is generated by the tie rod, and the diameter of the cutting edge (blade) of the file is caused by the boring head (knife) with fine adjustment function. Displacement, thus completing the automatic compensation of the tool during the boring process.

Among the three elements that make up the system, the random detection part consisting of the probe/electronic plug gauge and the measuring instrument is actually the same as the commonly used off-line detecting device. In the controller, the execution unit and the auxiliary components of the composition (signal) feedback compensation system, the controller has been commercialized, and is generally provided by a supplier of random detection. When a servo motor or a stepping motor is used as the actuator, To configure the drive power. The famous measuring instrument company MARPOSS cooperates with the machine tool factory in this way to meet the needs of users. Therefore, in the process selection of the automatic compensation of the cylinder bore precision made by the engine plant planner, in addition to the execution mode of the compensation, the last element of the three elements of the system - the selection of the hoe (knife) with the fine adjustment function is particularly important. It must be pointed out that in recent years, the measuring instrument and the compensation control unit in the above system have been integrated and replaced by a general-purpose computer-aided measuring system based on an industrial computer (such as MARPOSS' E9066 product).

So far, in the fine compensation system, the proportion of the fine adjustment boring tool using the wedge mechanism is still the largest, although the actual application of the tool will have some differences in the specific structure, and even the driving method of the tie rod is completely different, but the basic The working principle is the same. Such a sickle is shown in Figure 2. As can be seen from the figure, the front end of the pull rod has a small angle wedge, and in close contact with the wedge is a short column at the upper portion of the lever, and the fine blade is mounted at the front end of the lower portion of the lever. Thus, when the drawbar moves back and forth, it causes a slight radial displacement of the tip. Based on the known angle of the wedge and the lever ratio, the mathematical relationship between the axial displacement of the tie rod and the radial displacement of the tool tip can be established to achieve a quantitative tool fine adjustment.

(3) Compensation mode for fine automatic compensation

However, how is the measurement information outputted after random detection converted into the corresponding compensation command and the radial displacement of the tool tip is determined? This is achieved by the control unit (compensation controller) calculating and processing the detection result, and making a corresponding judgment and then issuing an instruction to the driving device. Only the mode of operation and processing (that is, the mathematical model for performing compensation) must be determined by the user's process department and quality department according to their own situation.

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