螺旋锥齿轮网络化制造关键技术研究
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摘要
螺旋锥齿轮作为相交或相错轴传动的基础件,因其结构紧凑、承载能力高、传动平稳等优点而被广泛应用于汽车、矿山机械、航空航海等领域中。由于螺旋锥齿轮的齿面几何形状、加工制造技术和啮合安装条件相当复杂,其生产效率和加工精度很难保证。随着我国齿轮制造业的快速发展,如何提高其加工效率和质量是目前螺旋锥齿轮制造所面临的紧迫任务。网络化制造,作为一种制造技术与网络技术相结合的制造模式,能够有效实现制造过程中的资源共享和信息集成,以及制造信息的网络化管理,为螺旋锥齿轮的制造开辟了新的途径。
本文结合螺旋锥齿轮制造的发展需求,从提高加工质量和生产效率出发,综合运用螺旋锥齿轮加工制造技术、网络技术、信息技术与管理技术等多学科领域的研究成果,通过知识借鉴与技术创新,按照“研究相关理论、突破关键技术和解决实际问题”的技术路线,全面、系统地探索和研究了螺旋锥齿轮网络化制造的关键技术问题,初步构建了螺旋锥齿轮网络化制造的理论体系,开发出了螺旋锥齿轮网络化制造集成平台的原型系统。本文主要研究内容如下：
(1)在系统分析螺旋锥齿轮的齿面几何加工特性及其现代制造技术的基础上,提出一种螺旋锥齿轮网络化制造模式,并结合螺旋锥齿轮网络化制造过程,提出了具体实施的关键技术。在此基础上,建立了一种基于工业以太网的螺旋锥齿轮网络化制造数控设备集成控制体系结构模型,通过开发螺旋锥齿轮数控设备集成控制系统,实现了对齿轮数控制造设备的网络化集成控制和螺旋锥齿轮网络化制造的网络构建。
(2)针对螺旋锥齿轮网络化过程中的制造信息集成与共享问题,在分析制造信息集成特性的基础上,提出一种基于XML的螺旋锥齿轮网络化制造信息集成与共享策略,建立了制造信息的集成模型和实现机制,并通过制定制造信息集成标准协议规范,实现了螺旋锥齿轮网络化制造信息的统一描述。在此基础上,通过基于Web服务的应用集成机制,实现了螺旋锥齿轮网络化制造应用系统的松耦合集成,为螺旋锥齿轮的网络化制造提供了信息描述与集成共享基础。
(3)通过对螺旋锥齿轮网络化制造集成平台功能特性与业务模型的深入分析,提出了一种螺旋锥齿轮网络化制造集成平台体系结构和功能结构模型。在此基础上,基于面向服务架构的Web服务技术构建了集成平台的应用集成框架,并利用分层的思想,提出了一种螺旋锥齿轮网络化制造集成平台软件体系结构,进行了螺旋锥齿轮网络化制造集成平台的软件开发和功能实现。
(4)综合运用前文提出的理论与方法,研究并构建了螺旋锥齿轮网络化制造集成平台原型系统,详细阐述了原型系统的实施方案,分析了原型系统的应用集成模式；通过弧齿锥齿轮及准双曲面齿轮网络化制造的集成应用试验、效果分析,以及原型系统的企业应用,验证了本文提出的螺旋锥齿轮网络化制造模式的可行性和实用性,有效提高了螺旋锥齿轮的加工效率和质量。
As a basic component in the driving of intersecting axes and crossed axes, spiral bevel gear has been widely used in the fields of automobile, mining machinery, aviation, navigation and so on due to its performance such as the structure compact, higher bearing capacity, steady transmission, etc. It is rather difficult to ensure the production efficiency and machining accuracy of spiral bevel gear because of its quite a few complexities in tooth surface geometry, processing and manufacturing, and meshing installation conditions. So, with the rapid development manufacturing industry and the wide application of spiral bevel gears, how to improve its manufacturing efficiency and quality has becoming an urgent task for the manufacture of spiral bevel gear. Networked manufacturing, as one manufacturing mode combined with the manufacturing technology and network technology, breaks a new way for the manufacturing of spiral bevel gear. It can effectively realize the resource sharing, information integration, and networked management in the whole manufacturing process.
Combined with the development demands of spiral bevel gear manufacture, key technologies for spiral bevel gear networked manufacturing are systematically explored and researched in this paper, which aimed to improve the processing quality and production efficiency of spiral bevel gear. The networked manufacturing theory system of spiral bevel gear is preliminarily constructed, and one networked manufacturing integration platform prototype system of spiral bevel gear is developed by comprehensively using the latest research results in the fields of spiral bevel gear manufacturing technology, network technology, information and management technology and so on. In this paper, the thoughts of knowledge reference and technological innovation, and the technical route of "study the relevant theories, break through the key technologies and solve the practical problems" are applied. The main contents are as follows:
(1) Based on systematically analyzed the tooth surface geometrical processing characteristics and the modern manufacturing technologies of spiral bevel gear, one networked manufacturing mode for spiral bevel gear is proposed. The key technologies to implement the spiral bevel gear networked manufacturing are put forward by analyzing its networked manufacturing process. On this basis, a kind of numerical equipment integrated control architecture model based on industrial Ethernet is proposed. And then, the integrated control of gear numerical equipment and the network construction of spiral bevel gear networked manufacturing are realized through the development of numerical equipment integrated control system of spiral bevel gear.
(2) In order to solve the integration and sharing of manufacturing information in the process of spiral bevel gear networked manufacturing, a kind of strategy and mechanism of information integration and sharing for spiral bevel gear networked manufacturing is put forward based on the extensible Markup Language (XML). The integrated mode and realization mechanism of manufacturing information are proposed. The uniform information description of spiral bevel gear networked manufacturing is implemented based on formulating the integrated standard protocol specification of manufacturing information. On this basis, combined with the application integration mechanism of Web services, the loosely-coupled integration of application systems is realized, which lays a information description and integration sharing foundation for the spiral bevel gear networked manufacturing.
(3) One integration platform architecture and functional structure model for spiral bevel gear networked manufacturing are proposed by analyzing its function characteristics and business model. On this basis, the application integration framework of spiral bevel gear networked manufacturing integration platform is constructed based on the service oriented architecture and Web services. Then, a kind of software architecture of spiral bevel gear networked manufacturing integration platform is put forward with the hierarchical thought, and the software function of integration platform is developed.
(4) Combined with the above-mentioned theories and methods in this paper, the prototype system of integrated platform for spiral bevel gear networked manufacturing is constructed, the execute solution of prototype system are elaborated, and the application integration mode of prototype system is analyzed. On this basis, through the networked manufacturing application tests and effect analysis of both spiral bevel gear and hypoid gear, and the enterprise application of prototype system, the feasibility and practicability of the proposed manufacturing mode for spiral bevel gear networked manufacturing are proved, and the processing efficiency and quality of spiral bevel gear are also effectively improved.
本文结合螺旋锥齿轮制造的发展需求,从提高加工质量和生产效率出发,综合运用螺旋锥齿轮加工制造技术、网络技术、信息技术与管理技术等多学科领域的研究成果,通过知识借鉴与技术创新,按照“研究相关理论、突破关键技术和解决实际问题”的技术路线,全面、系统地探索和研究了螺旋锥齿轮网络化制造的关键技术问题,初步构建了螺旋锥齿轮网络化制造的理论体系,开发出了螺旋锥齿轮网络化制造集成平台的原型系统。本文主要研究内容如下：
(1)在系统分析螺旋锥齿轮的齿面几何加工特性及其现代制造技术的基础上,提出一种螺旋锥齿轮网络化制造模式,并结合螺旋锥齿轮网络化制造过程,提出了具体实施的关键技术。在此基础上,建立了一种基于工业以太网的螺旋锥齿轮网络化制造数控设备集成控制体系结构模型,通过开发螺旋锥齿轮数控设备集成控制系统,实现了对齿轮数控制造设备的网络化集成控制和螺旋锥齿轮网络化制造的网络构建。
(2)针对螺旋锥齿轮网络化过程中的制造信息集成与共享问题,在分析制造信息集成特性的基础上,提出一种基于XML的螺旋锥齿轮网络化制造信息集成与共享策略,建立了制造信息的集成模型和实现机制,并通过制定制造信息集成标准协议规范,实现了螺旋锥齿轮网络化制造信息的统一描述。在此基础上,通过基于Web服务的应用集成机制,实现了螺旋锥齿轮网络化制造应用系统的松耦合集成,为螺旋锥齿轮的网络化制造提供了信息描述与集成共享基础。
(3)通过对螺旋锥齿轮网络化制造集成平台功能特性与业务模型的深入分析,提出了一种螺旋锥齿轮网络化制造集成平台体系结构和功能结构模型。在此基础上,基于面向服务架构的Web服务技术构建了集成平台的应用集成框架,并利用分层的思想,提出了一种螺旋锥齿轮网络化制造集成平台软件体系结构,进行了螺旋锥齿轮网络化制造集成平台的软件开发和功能实现。
(4)综合运用前文提出的理论与方法,研究并构建了螺旋锥齿轮网络化制造集成平台原型系统,详细阐述了原型系统的实施方案,分析了原型系统的应用集成模式；通过弧齿锥齿轮及准双曲面齿轮网络化制造的集成应用试验、效果分析,以及原型系统的企业应用,验证了本文提出的螺旋锥齿轮网络化制造模式的可行性和实用性,有效提高了螺旋锥齿轮的加工效率和质量。
As a basic component in the driving of intersecting axes and crossed axes, spiral bevel gear has been widely used in the fields of automobile, mining machinery, aviation, navigation and so on due to its performance such as the structure compact, higher bearing capacity, steady transmission, etc. It is rather difficult to ensure the production efficiency and machining accuracy of spiral bevel gear because of its quite a few complexities in tooth surface geometry, processing and manufacturing, and meshing installation conditions. So, with the rapid development manufacturing industry and the wide application of spiral bevel gears, how to improve its manufacturing efficiency and quality has becoming an urgent task for the manufacture of spiral bevel gear. Networked manufacturing, as one manufacturing mode combined with the manufacturing technology and network technology, breaks a new way for the manufacturing of spiral bevel gear. It can effectively realize the resource sharing, information integration, and networked management in the whole manufacturing process.
Combined with the development demands of spiral bevel gear manufacture, key technologies for spiral bevel gear networked manufacturing are systematically explored and researched in this paper, which aimed to improve the processing quality and production efficiency of spiral bevel gear. The networked manufacturing theory system of spiral bevel gear is preliminarily constructed, and one networked manufacturing integration platform prototype system of spiral bevel gear is developed by comprehensively using the latest research results in the fields of spiral bevel gear manufacturing technology, network technology, information and management technology and so on. In this paper, the thoughts of knowledge reference and technological innovation, and the technical route of "study the relevant theories, break through the key technologies and solve the practical problems" are applied. The main contents are as follows:
(1) Based on systematically analyzed the tooth surface geometrical processing characteristics and the modern manufacturing technologies of spiral bevel gear, one networked manufacturing mode for spiral bevel gear is proposed. The key technologies to implement the spiral bevel gear networked manufacturing are put forward by analyzing its networked manufacturing process. On this basis, a kind of numerical equipment integrated control architecture model based on industrial Ethernet is proposed. And then, the integrated control of gear numerical equipment and the network construction of spiral bevel gear networked manufacturing are realized through the development of numerical equipment integrated control system of spiral bevel gear.
(2) In order to solve the integration and sharing of manufacturing information in the process of spiral bevel gear networked manufacturing, a kind of strategy and mechanism of information integration and sharing for spiral bevel gear networked manufacturing is put forward based on the extensible Markup Language (XML). The integrated mode and realization mechanism of manufacturing information are proposed. The uniform information description of spiral bevel gear networked manufacturing is implemented based on formulating the integrated standard protocol specification of manufacturing information. On this basis, combined with the application integration mechanism of Web services, the loosely-coupled integration of application systems is realized, which lays a information description and integration sharing foundation for the spiral bevel gear networked manufacturing.
(3) One integration platform architecture and functional structure model for spiral bevel gear networked manufacturing are proposed by analyzing its function characteristics and business model. On this basis, the application integration framework of spiral bevel gear networked manufacturing integration platform is constructed based on the service oriented architecture and Web services. Then, a kind of software architecture of spiral bevel gear networked manufacturing integration platform is put forward with the hierarchical thought, and the software function of integration platform is developed.
(4) Combined with the above-mentioned theories and methods in this paper, the prototype system of integrated platform for spiral bevel gear networked manufacturing is constructed, the execute solution of prototype system are elaborated, and the application integration mode of prototype system is analyzed. On this basis, through the networked manufacturing application tests and effect analysis of both spiral bevel gear and hypoid gear, and the enterprise application of prototype system, the feasibility and practicability of the proposed manufacturing mode for spiral bevel gear networked manufacturing are proved, and the processing efficiency and quality of spiral bevel gear are also effectively improved.
引文
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