Algorithm for Adaptive Control of Spring Endsprocessing by Plasma Cutting

Abstract

A brief overview and issue general state of the demandand the need for the production of springs for the rolling stock of the RAO Russian Railways are given. Among the existing technological methods, plasma cutting was reasonably chosen and applied as a progressive machining method, as a means to increase the production output. General characteristics of this method as an alter native in the processing of metal products are presented. The existing solution of the plasma cutting method application for spring end processing is described. A new block diagram of automated production control for spring end processing by a set of equipment consisting of: Kawasaki industrial robotic arm, Kjellbreg plasma cutting equipment, auxiliary equipment and tools is presented. A new experimental control system for the spring production is proposed. A well-developed algorithm for adaptive control of large-sized spring end processing by the plasma cutting method is presented, taking into account the individual geometric characteristics of the work pieces being processed. A measuring stand, billet measurement schemes and a program for processing measurement results have been developed. Experimental data of spring machined end surface deviation from the plane perpendicular to the spring axis, under constant parameters of the plasma cutting process are obtained. The factors stipulating the need for individual approach to the processing of spring ends are identified. The requirements for the initial data of processed products are formulated. The valuechangeregularity of technological parameters for plasma cutting due toworkpiece geometric characteristics is presented. A fast tabular method for cutting current calculation as a significant technological parameter is proposed. A software implementation of the algorithm for adaptive control of the machining process in the high-level language Visual Studio C++ has been developed. The analysis of the obtained testing and debugging results is carried out. Conclusion sare for mulated.