R&D Of Variable Diameter Rotary Swaging Machine’s Control System

Variable diameter rotary swaging machine is an important equipment for production of needles, mainly used for machining of needle blanks. Its function is to forge a consistent diameter wire into three sections in order to reduce each diameter. But currently, the rotary swaging machine of the manufacturer has some problems, like low degree of flexibility, low processing efficiency, unstable processing quality and so on. In order to address these practical engineering problems, this paper proposes Design for Quality(DFQ) as a guide and carries on research and development of a new variable diameter rotary swaging machine control system based on PLC, so that the control system can better meet the actual needs of the project and improve the flexibility, processing efficiency and machining quality of the machine.The main research work includes:(1) Combine Design for Quality methods and general control system’s design process, and propose the overall development framework of new variable diameter rotary swaging machine’s control system.(2) Analyse the production process and control requirements of rotary swaging machine, and use Quality Function Deployment(QFD) method to transfer the customer needs into key technical characteristics of the control system, and then on this basis do the overall design of system, design selection and evaluation. After that, the overall control plan is given.(3) According to the general control target, design the hardware and software part of the control system, and optimize the result of the design.(4) Complete the prototype commissioning of control system. Analyse each process factor’s influence on the machining quality of the needle blanks, and design orthogonal experiment to get the best combination of rotary swaging machine’s various process factors. After adjust the machine to the steady status, analyze the stability of control system’s output and the effect of temperature control, and finally by comparing the prototype and the original rotary swaging machine to evaluate the overall performance of the system.