Development And Realization Of Two Axes Linkage PLC Control System Of Helical Gear Electrochemical Machining

Micro-segment helical internal gear is a new type and high-performance gear, whichhave higher transmissionefficiency, tensile, and lower temperature rise than involutegear.Its tooth profile curve which consists of micro-segments is like grading arc tooth profile.Because it is difficult to machine, there is no mature process now. ECM（electrochemical machining) is controllable and could be applied to the process ofcomplex part., therefore ECM has outstanding advantages in the process ofmicro-segment helical internal gear. In this background, this issue develops a PLCcontrol system of two-axis linkage for the processing of micro-segment helical internalgear according to the process requirement of ECM.Based on analyzing the ECM technology of micro-segment helical internal gearsynthetically, the issue establishes the overall design of the control system. According tothe requirements of the control process, the issue accomplishes the selection ofhardware, design of hardware system, and fabrication and installation of hardwaremodules. Combining the principle of PLC motioncontrol with the interpolation idea ofNC machining helical gear helix, the issue develops PLC controlalgorithm of two-axislinkage of electrochemical machining micro-segment helical internal gear. By MD（modulardesign）method，the issue designs the PLC program and touch screen. By thefield debugging, the software and hardware designing of the control system are furtheroptimized. At last, the issue chooses the appropriate processing parameters for theexperiment of electrochemical machining. The results show that the control algorithmcan fulfill the machine of micro-segment helical internal gear, and the control system isstable and reliable.The control system of two-axis linkage has many functions, like single axismachining, linkage machining and they are easy to switch. Achievement of PLC linkagecontrol makes full use of the floating point arithmetic of PLC and pulse output ability.The development of the control system reduces the production cost of micro-segmenthelical internal gear which has great significance for the small and medium-sizedmanufacturing enterprises and the development of economical NC system.