Precision automation and CNC machining: their coordination and application

Precision automatics and CNC machining are complementary to each other. Precision automatics realize the automation and intelligence of the CNC machining production process through precise motion control and efficient operation. CNC machining, with its high flexibility and precision, meets the processing requirements of complex parts of precision automatics. The two complement each other, like a dual-wheel drive, and jointly promote the development of the manufacturing industry to a higher level. This article will explore the relevant knowledge about precision automatics and CNC machining.

⏩ Overview of precision automatics

Importance

Precision automatics play an increasingly important role in modern industry. With the advancement of science and technology and the improvement of industrial automation, precision automatics have become an indispensable part of the manufacturing industry. These devices, with their high precision and high efficiency, have greatly improved the automation and intelligence level of the production process. In modern production, precision automatic devices not only improve product quality and production efficiency, but also reduce production costs and manpower requirements. For example, in the fields of automobile manufacturing, electronic product assembly, and precision instrument processing, the application of precision automatic devices makes the production process more precise and reliable, thus ensuring the consistency and high quality of products.

Development trend

With the continuous development of new technologies such as artificial intelligence, machine learning, and the Internet of Things, precision automatic devices are gradually evolving towards intelligence and networking. In the future, these devices will pay more attention to real-time data analysis and self-adjustment capabilities to adapt to more complex and changing production environments. For example, by integrating advanced sensors and data analysis technologies, precision automatic devices can monitor various parameters in the production process in real time, and self-adjust and optimize according to the results of data analysis, thereby improving production efficiency and product quality.

⏩ What is the relationship between precision automatics and CNC machining?

There is a close relationship between precision automatics and CNC machining, which is mainly reflected in the following aspects:

Precision automatics serve CNC machining:

Precision automatics, such as fixtures, are an indispensable part of CNC machining. They are used to fix and position workpieces to ensure that the workpieces can maintain a stable position during machining on CNC machine tools, thereby ensuring machining accuracy.

Automation improves CNC machining efficiency:

Precision automatics usually include electronic control, hydraulic components, pneumatic components, etc. The automated control function of these devices can significantly improve the efficiency and accuracy of CNC machining.

CNC technology is the basis of automation:

CNC technology is the technical basis for modern manufacturing to achieve automated, flexible and integrated production. Precision automatics often rely on CNC technology to realize their automation functions.

Complementary relationship:

CNC machining requires the support of precision automatics to achieve high-efficiency and high-precision machining, while precision automatics require the control of CNC technology to realize their automation functions.

In summary, there is a complementary and interdependent relationship between precision automatics and CNC machining, which jointly promotes the development of modern manufacturing.

⏩ The embodiment of precision automatic devices in the field of CNC machining

Let’s take a look at what aspects of precision automatic devices are reflected in CNC machining and how they play a role in machining? The following will focus on four types of precision automatic devices.

Servo drive system: performing cutting tasks

CNC machine tools can accurately cut and grind materials, which is inseparable from the control of servo drive systems. The servo drive system can accurately control the various axes of the machine tool, such as the movement of the X-axis, Y-axis, and Z-axis through high-precision motors and encoders.

The execution principle of the system is as follows: When the machine tool receives the processing instruction, the servo system acts as the brain of the machine tool, quickly and accurately performing the cutting action, while ensuring that the tool is in the correct position, at the correct speed and force for processing. For example, it can accurately process high-precision holes in precision instrument parts.

Automatic measurement and detection

During the processing process, how to ensure that each part meets the standard? At this time, it is necessary to rely on automatic measurement and detection systems. The measurement and detection principle of this system is as follows: through sensors, cameras and other equipment, the size, surface roughness and even tool wear of the parts in real time are monitored.

For example, when processing a part, the system will automatically scan the shape of the part with a laser. If the size deviation exceeds the preset range, it will immediately send an alarm to the machine control system to adjust the processing parameters or stop processing.

Automatic tool exchange system

In traditional processing, workers need to manually change tools according to different processes, which is time-consuming and error-prone. The automatic tool exchange system (ATC) of CNC machine tools can realize automatic tool change between different processes.

The principle of the system is as follows: It is equipped with a “tool magazine” that stores various types of tools, such as drills, milling cutters, boring tools, turning tools, etc. When a tool change is required, the robot will automatically take out the appropriate tool from the tool magazine and accurately install it on the spindle. The whole process may only take a few seconds.

Automatic material handling and loading and unloading

This system usually includes manipulators, conveyor belts, automatic warehouses and other equipment. Its operating principle is as follows: On a precision aerospace parts production line, the raw materials will be automatically transported to the machine tool processing position. After the processing is completed, the manipulator will take out the finished product, put it on the testing equipment for testing, and finally send it to the warehouse.

⏩ Production and processing technology of precision automatics

The production and processing of precision automatics not only requires high precision, but also needs to ensure high efficiency, stability and reliability. The following will introduce its production and processing technology in detail.

(1) Raw material selection and processing

1) Raw material selection:

The performance of precision automatics depends largely on the selected materials. Commonly used materials include high-strength alloy steel, titanium alloy, engineering plastics, etc. When selecting materials, the strength, hardness, wear resistance and processing performance of the materials should be considered.

2) Material processing:

After the raw materials enter the workshop, they need to be pre-processed, such as cleaning, rust removal, stress relief, etc., to ensure the purity and stability of the materials and lay a good foundation for subsequent processing.

(2) Design and modeling

1) CAD design:

Use computer-aided design (CAD) software to perform three-dimensional modeling of precision automatic devices and design the precise size and shape of each component. When designing, the performance requirements, assembly relationships and processing feasibility of the device should be considered.

2) CAE analysis:

Through computer-aided engineering (CAE) simulation analysis, verify the rationality and reliability of the design, including strength analysis, modal analysis, thermal analysis, etc., to avoid design defects in the later stage.

(3) Processing and manufacturing

1) CNC machining:

Use CNC machine tools (CNC) for high-precision machining. CNC machining can achieve efficient and high-precision machining of complex shapes and is a key link in the production of precision automatic devices. Common processing methods include turning, milling, drilling, tapping, etc.

2) Special processing:

For some complex structures or high-hardness materials that are difficult to achieve with traditional processing methods, special processing technologies such as electrospark machining (EDM), wire cutting machining (WEDM), laser processing, etc. are required.

3) Surface treatment:

In order to improve the surface hardness, wear resistance, corrosion resistance, etc. of parts, surface treatment such as heat treatment, surface coating, nickel plating, anodizing, etc. is required.

(4) Assembly and debugging

1) Parts cleaning:

Before assembly, the parts need to be thoroughly cleaned to remove surface oil, impurities, etc. to ensure the cleanliness of the assembly environment.

2) Precision assembly:

According to the design requirements, the various parts are accurately assembled together. During the assembly process, high-precision measuring tools need to be used for real-time monitoring to ensure assembly accuracy.

3) Debugging and testing:

After assembly, debugging and testing are required to ensure that the performance indicators of the device meet the design requirements. Commonly used inspection methods include dimension inspection, form and position tolerance inspection, and functional testing.

(5) Quality inspection and control

1) Quality inspection:

Strict quality inspection is required throughout the production process, including raw material inspection, process inspection, and finished product inspection, to ensure that every link meets quality requirements.

2) Quality control:

Establish a complete quality control system, use statistical process control (SPC) and other methods to monitor and analyze the production process, and promptly discover and correct quality problems.

⏩ Technical characteristics of precision automatics

High precision and high efficiency

Precision automatic devices can achieve micron or even nanometer processing accuracy by integrating high-precision mechanical components and advanced control systems. This high precision ensures extremely high consistency in product size and shape, meeting the needs of high-end manufacturing. At the same time, these devices significantly improve production efficiency and reduce production time and cost through optimized design and automated processes.

Automation and intelligence

Modern precision automatic devices widely use automation technology, which reduces dependence on manual operation and improves production stability and safety. The introduction of intelligent technologies, such as machine learning and artificial intelligence, enables these devices to make complex decisions and operations, further improving the flexibility and adaptability of the equipment. In addition, intelligent technologies also enable precision automatic devices to achieve predictive maintenance, reducing equipment downtime and maintenance costs by monitoring equipment status in real time and predicting potential failures.

⏩ Key technologies and components of precision automatics

Sensor technology

Sensors are an indispensable component of precision automatics. They can monitor equipment operating status and environmental changes in real time and provide key data support. Modern sensor technology is developing towards higher accuracy, faster response speed and stronger adaptability.

For example, in automated production lines, sensors are used to detect the position, size and surface quality of products to ensure that each production link can meet the predetermined standards. In addition, sensors are also widely used in environmental monitoring and equipment status monitoring, providing important data support for the real-time control and optimization of precision automatics.

Control system

The control system of a precision automatic device is its core part, responsible for receiving sensor data and making decisions and operations according to preset programs. Advanced control systems use complex algorithms and logic to ensure the accuracy and consistency of equipment operations.

For example, in CNC machine tools, control systems control the movement of machine tools according to the processing program to ensure that each processing step can be accurately executed. In addition, control systems are also widely used in automated production lines and robotic systems to improve production efficiency and product quality through real-time control and optimization.

Actuators

Actuators are the components that actually perform operations in precision automatic devices, such as motors, hydraulic systems, and manipulators. These components require high precision and reliability to ensure the overall performance of the equipment.

For example, in automated assembly lines, manipulators accurately grab and place parts according to the instructions of the control system to ensure the accuracy and efficiency of the assembly process. In addition, actuators are also widely used in precision processing equipment and testing equipment to ensure high performance and efficiency of the equipment through highly precise and reliable operations.

⏩ Application areas of precision automatics

Petrochemical industry

In the petrochemical industry, precision automatics are used to control chemical reaction processes to ensure production safety and product quality. These devices can handle extreme environments of high temperature and high pressure and are the key to modern refining and chemical production.

For example, in oil refineries, precision automatics are used to control the temperature and pressure of reactors to ensure the accuracy and safety of chemical reactions. In addition, precision automatics are also widely used in the automation control and optimization of chemical production lines, improving production efficiency and product quality by real-time monitoring and controlling the production process.

Automobile manufacturing industry

The automobile manufacturing industry is one of the important application areas of precision automatic devices. Automated production lines and robotics have greatly improved the efficiency of automobile assembly and production, while ensuring high-precision processing and consistency of parts.

For example, on automobile assembly lines, robots accurately complete welding, painting and assembly processes according to the instructions of the control system, ensuring the quality and production efficiency of each part. In addition, precision automatic devices are also widely used in the processing and testing of automobile parts, ensuring the quality and performance of parts through high-precision processing and testing.

Electronic information industry

In the electronic information industry, precision automatics are used for high-precision electronic component manufacturing and assembly. As electronic products develop towards miniaturization and high integration, the role of these devices in maintaining accuracy and efficiency has become particularly important.

For example, in semiconductor manufacturing, precision automatics are used for chip processing and testing to ensure the quality and performance of each chip. In addition, it is also widely used in the assembly and testing of electronic products, ensuring the quality and reliability of electronic products through high-precision assembly and testing.

⏩ Summary

Precision automatics achieve precise control of the production process through complex mechanical structures and intelligent control systems; while CNC machining relies on advanced computer technology to transform design blueprints into high-precision actual products. The close combination of the two not only greatly improves production efficiency and product quality, but also promotes the automation and intelligence of the manufacturing industry.