熔模精密铸造自动化制壳生产线生产计划优化、调度与控制

南京航空航天大学硕士学位论文熔模精密铸造自动化制壳生产线生产计划优化、调度与控制姓名：胡武茹申请学位级别：硕士专业：机械电子工程指导教师：楼佩煌2011-01南京航空航天大学硕士学位论文I摘要熔模精密铸造是一种近净形成形制造工艺，对产品质量和成品率都有很高要求。产品的质量往往通过改善生产工艺的方式来保证，而产品的成品率，就需要通过关键工艺环节的可重复性来保证。采用自动化生产模式成为熔模精密铸造的必然选择。目前国内的熔模精密铸造自动化生产线全都为进口，价格昂贵。而且，不方便进行工艺的调整。本文在充分研究熔模精密铸造技术国内外研究和应用现状的基础上，对熔模精密铸造制壳工艺进行了分析，并对实际生产中出现的批次分解等问题作了深入的研究，并采用遗传算法提出了加工调度优化的备选技术方案；完成了系统初步设计，并用eM-Plant仿真软件对技术方案进行了仿真分析，获得了满足实际需求的加工调度优化技术方案。在理论分析和仿真实验的基础上，完成了熔模铸造自动化制壳生产线的控制系统的总体设计和详细设计，完成了悬挂输送线、涂料/淋沙机器人控制软件的开发，并采用了OPC和数据库技术完成控制系统上位机控制、管理、调度系统的开发。同时结合制壳工艺，在不断试验的基础上，进行了系统运行参数的优化，有效解决了熔模精密铸造制壳工艺的产品质量问题和生产效率问题。昀后，对本文的研究工作进行了简要的总结，并对熔模精密铸造制壳自动化技术提出了进一步的展望。关键词：熔模铸造，遗传算法，制壳，OPC，数据库熔模铸造生产线生产计划优化、调度与控制IIAbstractInvestmentCastingisanearnetshapeformingmanufacturingprocess,andithashighrequirementforproductqualityandproduce.Thequalityoftheproductscanbeguaranteedbyimprovingproductionprocesses;however,theyieldoftheproductneedstobeensuredbytherepeatabilityofcriticalprocesses.IthasbeenaninevitablechoicetoadoptthisautomatedproductionmodeforInvestmentCasting.Atpresent,theautomaticproductionlinesofInvestmentCastingareallimportedandexpensive.Moreover,itisnotconvenientforprocessadjustment.Inthispaper,onthebasisoffullstudyoftheresearchandapplicationininvestmentCastingTechnologybothathomeandabroad,theshellmakingprocesswasanalyzed,andfurtherstudywasmadeinbatchdecompositionwhichoccursintheactualproduction,meanwhile,byadoptionofgeneticalgorithms,technologyprogramalternativesoftheprocessingscheduleoptimizationhasbeenraised;furthermore,whilepreliminarydesignhasbeencompleted,thispaperthenusedsimulationsoftware——eM-Plantsimulationtomakeanalysiswiththistechnologyprograms,inordertogettingaccesstoprocessingscheduleoptimizationprogramwhichmeettheactualneedsofproduction.Basedonthetheoreticalanalysisandsimulation,thispaperhascompletedthecontrolsystem’ssystemdesignanddetaileddesignofautomaticproductionlineinInvestmentCasting,andalsocompletedcontrolsoftwaredevelopmentofthehangingconveyorlineandpaint/sandshowerrobotsaswell.Meanwhile,bytheuseofOPCanddatabasetechnology,thispaperhascompletedthedevelopmentofcontrol,managementandschedulingsystemsofPCcontrolsystem.Then,withthecombinationofShellTechnology,andonthebasisofcontinuedtesting,theoperatingparametersofsystemhavebeenoptimizedsothattheproblemsofproductqualityandproductionefficiencyofInvestmentCastingShellcanbesolvedeffectively.Finally,thepapermadeabriefsummaryoftheworkuptonow,andmadefurtherprospectsforautomationsystemtechnologyofShellCastingaswell.Keywords:investmentcasting,geneticalgorithm,theshell,OPC,databasesystem南京航空航天大学硕士学位论文V图清单图1.1熔模铸件样品··················································································································1图1.2熔模铸造部分工艺流程··································································································2图2.1遗传算法流程图············································································································12图2.2迭代优化每代昀优曲线图·····························································································16图2.3eM-Plant建模界面·········································································································17图2.4自动化制壳生产线平面布局图······················································································18图2.5仿真系统布局图············································································································20图2.6系统运行中界面············································································································21图2.7加工前工艺数据············································································································22图2.8加工过程数据表············································································································23图2.9编程界面························································································································23图2.10机器人加工效率柱状图·······························································································24图3.1自动模式控制流程········································································································31图3.2系统结构框图················································································································32图3.3控制系统总体方案图·····································································································33图3.4硬件检测························································································································34图3.5Simatic300Station设置界面······················································································35图3.6PC—station配置界面··································································································35图3.7OPC检测界面··············································································································36图3.8PLC主要工作流程图··································································································37图3.9PLC自动模式工作流程图··························································