DYZT-4 Mechanical and Electrical Equipment Installation and Maintenance Comprehensive Training Device

Release time：2024-05-11 13:00viewed：times

1. Product Overview
This tr*ning platform is based on the relevant professional teaching standards of processing and manufacturing secondary vocational schools, closely combined with industry and enterprise needs, operational skills docking with national occupational standards, in line with the actual job ability requirements of enterprises; the platform combines mechanical assembly and electrical control systems Effective integration to meet the teaching content stipulated by the processing and manufacturing related majors in secondary vocational schools involves modern mechanical manufacturing technology, mechanical drawing, mechanical basics, mechanical design basics, electrical and electronic technology, automatic detection technology, PLC and inverter application technology, Knowledge and skill requirements in electromechanical equipment control technology, automatic control system technology, equipment electrical control and m*ntenance technology, sensor technology, low-voltage electrical control technology, electromechanical equipment operation and control technology, etc.; through tr*ning, students can improve their skills in machinery manufacturing enterprises and related Industry front-line process assembly and implementation, installation and debugging of electromechanical equipment, machining quality analysis and control, technology and management work in the field of automatic control systems and production processes, operation of production enterprise computer control systems and equipment, m*ntenance and management of general electromechanical equipment jobs, employability in positions such as technical sales and manufacturing of electromechanical equipment.
2. Technical performance
1. Input power supply: three-phase four-wire (or three-phase five-wire) ~380V±10% 50Hz
2. Working environment: temperature -10℃~+40℃, relative humidity ≤85% (25℃) altitude < 4000m
3. Device capacity: <2.0kVA
4. Overall dimensions: 1400mm×700mm×1415mm ( tr*ning bench )
800mm×600mm×1750mm (electrical control cabinet)
400mm×700mm×1500mm (operating table)
560mm×600mm×1020mm (computer Table)
5. Safety protection: It has current leakage protection and is safe and in line with national standards.
3. System composition and functions
The m*n function of this device is to complete the automatic loading and unloading of processed materials and the precise cold stamping process of multiple molds according to requirements; first, the rotation of the two servo motors is controlled through the touch screen, PLC, sensors, etc. in the electrical control cabinet. The two-dimensional feeding component (cross slide) moves. The two-dimensional feeding component (cross slide) cooperates with the automatic loading and unloading mechanism (warehouse) to realize automatic loading, automatic feeding, automatic positioning and automatic unloading of the processed materials (aluminum plates). function; secondly, according to the processing requirements, the rotation of the stepper motor is used to complete the replacement of the multi-shaped stamping dies in the turret component, and the turret is accurately positioned through the pneumatic positioning system; finally, the joint action of the stamping system and the cold stamping die is used to position the material Perform precision stamping.
This tr*ning device m*nly consists of a tr*ning platform, an electrical control cabinet (including power control module, programmable controller module, inverter module, touch screen module, stepper motor drive module, servo motor drive module, electrical expansion module, etc.), power Source (including AC reduction motor, stepper motor, AC servo motor, etc.), mechanical transmission mechanism , two-dimensional feeding component (cross slide), automatic loading and unloading mechanism (warehouse), turret components, mold, automatic stamping mechanism, operation It consists of a desk, assembly and testing tools, 3D simulation teaching software, profile computer desk, etc.
1. Practical tr*ning platform: It adopts an iron double-layer matte dense texture spray-p*nted structure, including a control area and a mechanical assembly and adjustment area. The control area is m*nly composed of a control panel, power conversion interface, control buttons, etc.; the mechanical installation and adjustment area uses a casting operating table, on which students can install and adjust various mechanical mechanisms.
2. Electrical control cabinet: It adopts iron double-layer matt dense pattern spray-p*nted structure, which is solid in structure. The front door has a transparent design, allowing internal elements to be observed. The structure is divided into three layers. The upper layer is the grid voltage indication, two-position knob switches of each component and operation instructions; the second layer is the Kunlun homomorphic touch screen unit and power output unit; the bottom layer is the mesh tr*ning area, including PLC controller, Electrical expansion units, servo motor controllers, stepper motor controllers, frequency converters, executive component terminal blocks, etc.
3. Mechanical transmission mechanism: It is composed of a variety of mechanical transmission mechanisms and can complete the assembly process and accuracy testing tr*ning of typical mechanical transmission mechanisms such as ch*n drive, belt drive
, and screw drive. 4. Two-dimensional feeding components (cross slide table): It consists of a base plate, a middle plate, a ball screw p*r, a linear guide p*r, a pneumatic clamp, a pneumatic pushing device, etc. It can complete a ball screw p*r, a linear guide p*r, a pneumatic Practical tr*ning on the assembly process and accuracy testing of hand clamps, etc.
5. Multifunctional mold base components: drive the rotation of the mold to realize mold replacement. It is m*nly composed of upper and lower mold plates. It can complete the assembly process and accuracy testing tr*ning between the upper mold plate, the lower mold plate and the upper and lower mold plates. .
6. Mold: Real CNC molds are used to stamp the workpieces, including three types of molds: square hole mold, round hole mold, w*st hole mold, and a set of mold calibration rods.
7. Automatic stamping mechanism: The stamping process of the mold is completed through the action of the gas-liquid boosting cylinder.
8. Operating table: (1) Iron double-layer matt dense spray-p*nted structure, composite table top, the base plate is made of high fiber, the table body structure is made of ≥2 mm steel plate, and the load-bearing capacity is ≥1T.
(2) The countertop is veneered with 50mm polymer composite material and is surrounded by high-strength plastic edging.
(3) The console is equipped with two drawers and adopts central control integrated lock.
9. Drawing hanging frame: The hanging frame is fixed on the operating table. The reference dimensions are 1400mm×150mm×980mm. It adopts a frame structure with an LED energy-saving lamp lighting device above. The back net adopts the design of louver holes under the upper hole. Can hang a variety of boxes, hooks, trays, etc.
10. Assembly and testing tools: configure commonly used assembly tools and testing tools, and master the operating specifications of measuring tools through the use of measuring tools.
11. Virtual simulation teaching system
Mechanical tr*ning safety education virtual simulation software: This software is developed based on unity3d. The software adopts the form of three-dimensional roaming. Movement can be controlled by the keyboard and the lens direction can be controlled by the mouse. It is equipped with mechanical safety distance experiments, mechanical safety protection device experiments, and mechanical safety protection design. For the basic assessment, when the experiment is in progress, the three-dimensional roaming screen uses arrows and footprints to prompt the user to move to the experimental location. The circle around the mechanical object shows the working radius. The experimental process is accompanied by a dialog box reminder of the three-dimensional robot.
A. The content of the mechanical safety distance experiment includes the safety distance experiment to prevent upper and lower limbs from touching the danger zone (divided into two fence heights and opening sizes). After selecting to enter, GB23821-2009 "Mechanical Safety to Prevent Upper and Lower Limbs from Touching the Danger Zone" pops up in front of the camera. "Safe Distance" requirements, error demonstration: The experimental process is that after the human body enters the working radius of the mechanical object and is injured, the red screen and voice prompts that the human body has received mechanical damage, and returns to the original position and conducts the next experiment. The last step is the correct approach.
B. Mechanical safety protection device experiments are divided into safety interlock switches, safety light curt*ns, safety mats, safety laser scanners and other protection device experiments. Optional categories (safety input, safety control, safety output, others), manufacturers, products List (safety interlock switch, safety light curt*n, safety mat, safety laser scanner, safety controller, safety relay, safety guardr*l). There is a blue flashing frame reminder at the installation location. Experimental process: select the safety guardr*l and install it, select the safety interlock switch (or select the safety light curt*n, safety mat, safety laser scanner) and install it, select the safety controller and install it in the electrical control box , select the safety relay and install it in the electrical control box, click the start button on the electrical control box. If you enter a dangerous area, the system will sound an alarm and the mechanical object will stop working. Select the reset button on the electrical control box to stop.
C. The basic assessment of mechanical safety protection design requires the completion of the installation of the mechanical safety system, and the correct installation of safety guardr*ls, safety interlock switches, safety light curt*ns, safety mats, safety laser scanners, safety controllers, safety relays, 24V power supplies, signal lights and Emergency stop button, the assessment is divided into ten assessment points. Some assessment points have 3 options, which are freely chosen by the students. After selecting the final 10 assessment points, submit for confirmation, and the system will automatically obt*n the total score and the score of each assessment point. .
D. The software must be on the same platform as a whole and cannot be displayed as separate resources.
E. At the same time, we provide customers with the VR installation package of this software to facilitate users to expand into VR experiments. VR equipment and software installation and debugging are not required.
Mechanical assembly and fitter assembly virtual simulation software: This software is developed based on unity3d, with optional 6-level image quality. It is equipped with design and virtual disassembly and assembly of reducers and shafting structures, design and simulation of common mechanical mechanisms, mechanism resource library, typical machinery Mechanism (virtual disassembly and assembly of gasoline engine), the software is a whole software and cannot be individual resources.
A. Reducer design and virtual disassembly interface can choose worm gear bevel gear reducer, two-stage expanded cylindrical gear reducer, bevel cylindrical gear reducer, coaxial cylindrical gear reducer, bevel gear reducer, and one-stage cylindrical gear reducer. Gear reducer.
Worm bevel gear reducer: After entering the software, the assembly content is automatically played. Each step in the video has a text description
. Secondary expandable cylindrical gear reducer: After entering the software, the content is played in the form of a video. The video content should include: Part name ( Scan the QR code to see the names of parts), disassembly and assembly demonstration (including disassembly and assembly), virtual disassembly (including overall, low-speed shaft, medium-speed shaft, high-speed shaft, box cover, box seat)
conical cylindrical gear reducer, Coaxial cylindrical gear reducer, bevel gear reducer, first-level cylindrical gear reducer: click to enter and automatically jump to the edrawings interface. The models are all three-dimensional models. By clicking on the parts, the names of the parts are displayed, and the 360° view is av*lable Rotate, zoom in, zoom out, pan, and move parts to disassemble and assemble the entire reducer. At the same time, you can select the home button to return to the original state of the reducer. The bevel gear reducer and the first-stage cylindrical gear reducer have added the function of inserting a cross section, and the cross section can be freely dragged to observe the internal structure of the reducer.
B. Shaft structure design and virtual disassembly and assembly interface optional parts recognition, disassembly and assembly demonstration, and actual operation.
1. Parts recognition: three-dimensional model and part name including helical gear, non-hole end cover, coupling, coupling key, shaft, gear key, hole end cover, shaft sleeve, deep groove ball bearing, any All parts can be rotated 360°
2. Disassembly and assembly demonstration: There are 2 built-in cases. When you move the mouse to the position of a cert*n part (except the base and bearing seat), the part will automatically enlarge and the name of the part will be displayed. It is equipped with disassembly and Assembly button, the function is to automatically complete the disassembly and assembly of the shaft system structure by the software. All three-dimensional scenes can be rotated, enlarged, reduced and translated 360° in all directions.
3. Practical operation: The three-dimensional parts are neatly placed on the table. The students manually select the corresponding parts and move them to the shaft system structure. The parts can be installed only when they are placed in the correct order and in the correct position. There is a restart button to facilitate students to restart. Conduct virtual experiments. When you move the mouse to a cert*n part position (except the base and bearing seat), the part will automatically enlarge and the part name will be displayed.
C. Common mechanical mechanism design and simulation, optional hinge four-bar mechanism design and analysis, I\II type crank rocker mechanism design and analysis, offset crank slider mechanism design and analysis, crank swing guide rod mechanism design and analysis, hinge Four-bar mechanism with integrated trajectory, eccentric linear-acting roller push rod cam , and centering linear-acting flat-bottomed push rod cam.
1. Each mechanism should be able to input corresponding parameters, and the software can automatically calculate the parameters, and can perform motion simulation and automatically draw curves.
D. The mechanism resource library includes 11 types of planar link mechanisms, 5 types of cam mechanisms, 6 types of gear mechanisms, 8 types of transmission mechanisms, 11 types of tightening mechanisms, 6 types of gear tr*n mechanisms, and 8 types of other mechanisms (mechanical equipment simulation)
E , virtual disassembly and assembly of gasoline engines, optional crankcase assembly and disassembly demonstration, crankcase virtual assembly, valve tr*n assembly and disassembly demonstration, valve tr*n virtual assembly
1. Crankcase assembly and disassembly demonstration and valve tr*n assembly and disassembly demonstration both have disassembly button, assembly button, restart, and decomposition observation button. When the mouse is moved to a cert*n part position, the part will automatically enlarge and the part name will be displayed. The software automatically completes the disassembly and assembly of the shaft system structure. When using the decomposition observation button, the 3D model of the crankcase or gas distribution system automatically displays an exploded view, which can be rotated, enlarged, reduced, and translated 360°.
2. The 3D parts of the crankcase virtual assembly and the gas distribution system virtual assembly are neatly arranged When placed on the desktop, students manually select the corresponding parts and move them to the mechanism. The parts can be installed only when they are placed in the correct order and in the correct position. There is a restart button to facilitate students to re-perform the virtual experiment. When you move the mouse to cert*n part locations, the part names are automatically displayed.
8. Microcontroller and plc programmable design and control virtual simulation software
This software is developed based on unity3d. It has built-in task books and experimental prompts. It adopts the form of three-dimensional roaming. Movement can be controlled by the keyboard, the mouse controls the direction of the lens, and the mouse wheel controls the distance of the picture. It can rotate 360 degrees. There are electrical diagrams p*nted on the three-dimensional wall.
1. Equipment component assembly: Follow the highlighted prompts to find the component control rack. You can drag components from the component library according to the electrical component layout diagram and place them on the component control rack. The component library is equipped with control panels, switching power supplies, micro relays, and PLCs. , frequency converter, stepper motor, AC motor, servo motor, servo driver, stepper driver, interface board, operation panel, circuit breaker, servo motor interface, digital display voltmeter, there will be a prompt when the selection is wrong.
2. Technical indicator measurement: Select the multimeter to check the servo motor connection cable and the servo driver with BOP panel. Adjust the left and right buttons to the ohm level, drag the black and red test leads and insert them into the R, S, T, U, V, W and ground phases respectively for testing. For resistance value, according to the highlighted prompt, find the power switch in the scene, drag the pen or multimeter to measure whether the power is on.
3) Electrical component connection: According to the electrical wiring diagram, connect the power line and control line, highlight the interface, connect the driver, interface board, power line, servo motor, encoder, PLC, and relay in order, and turn on the m*n power supply After turning on the switch, servo power switch, and faulty circuit switch, a fault code will be prompted, and you can select the cause of the fault from three items.
4) Parameter adjustment test: Turn on the power to adjust the speed, set the driver parameters according to the requirements of the mission statement, perform inching control/analog speed adjustment/multi-stage speed control, and observe the three-dimensional servo motor motion control. Select any of the 6 PLC programs and then adjust the servo drive analog speed. The PLC parameters are adjustable. Set the drive parameters and enter the three-dimensional servo motor motion control interface and electrical display interface. The operation panel is equipped with servo start, low speed, medium Speed, high speed, servo stop, torque limit, abnormal reset, forward/reverse rotation selection, 0-10 sliding control (the electrical panel displays the value in real time).
5) Inspect the three-dimensional virtual simulation machine of the servo system mask machine, observe its structure, inject fault points, select multiple fault causes, and locate faults. Connect the fault causes with the corresponding detection and positioning methods, and troubleshoot after selecting the correct ones. Connect the cause of the f*lure with the corresponding solution.
6) Control process plan, optional single machine mode and online mode of inching control/analog speed regulation/multi-stage speed regulation control, call up the control panel, display the operation of 3 production lines, perform real-time control, optional inching, low and medium High speed, start and stop control, adjustable speed. According to the control plan, the system automatically determines the performance of the production line and submits a disclosure record.
4. Basic configuration list

serial number	name		Specification	quantity	unit	Remark
1	Tr*ning platform		Iron double-layer matt dense spray-p*nted structure, 40mm thick casting flat countertop, storage cabinet under the table, and 2 drawers above the cabinet	1	tower
2	Electrical control cabinet	Power control module	It consists of three-phase power m*n switch (with leakage and short-circuit protection), three-phase fuse, AC contactor, intermediate relay, switching power supply, key switch, emergency stop button, stop-start button (red, green), system control knob switch and It is composed of indicator lights, etc., which can provide system power supply (AC 380V, AC 220V, DC 24V), expandable power supply (one set of AC 220V, three sets of DC 24V)	1	set
3		programmable controller module	Adopts Mitsubishi's third generation 3U series host, FX3U-48MT, 24 input points/24 transistor outputs, plus digital expansion module FX2N16EX, 16 inputs	1	set
4		touch screen module	Beijing Kunlun touch screen, 10.2-inch LCD, power supply DC24V, with network interface, USB interface, serial port, etc.	1	set
5		Motor and motor drive module	The servo motor driver uses TECO JSDEP-15A, which has torque, speed, position, point-to-point positioning and mixed mode switching functions, 220V level. The servo motor uses TECO 400W TSB07301C-2NT3-1, equipped with 2500ppr encoder; stepper motor The driver adopts Les* M series, two phases, current: 1.0-4.2; voltage: DC (18-48); subdivision: 2-128; suitable for 57 and 86 motors, the stepper motor uses 57H500Q30, reduction ratio 1:30; The inverter adopts Mitsubishi D700 series 0.4KW inverter, three-phase AC380V, built-in filter, V/F open loop control, adjustment mode PAM control, the AC reduction motor adopts Xiamen Jingyan 400W 80YS25GY22 motor, and is equipped with 80GK60H reducer	1	set
6		Electrical expansion module	DC24V red and green indicator lights, 1 buzzer each, 1 two-position knob switch, 2 buttons (without lights)	1	set
7		Sensor part	M*nly composed of proximity switch (LE4-1K, GKB-M0524NA), infrared photoelectric switch (SA005-1K), gas-liquid booster cylinder magnetic switch, compact cylinder magnetic switch, fixed cylinder magnetic switch, pen-shaped cylinder magnetic switch, etc.
8	Mechanical equipment parts	transmission mechanism	It mnly includes typical transmission mechanisms such as synchronous belt drive (synchronous wheel is XL050BF series, synchronous belt is XL050 series), chn drive (08B single row ch*n), etc.	1	set
9		Two-dimensional feeding components (cross slide)	It mnly consists of ball screw nut pr (lengths are 508mm, 605mm respectively; nominal diameter 20mm; lead 5mm; right-hand rotation), linear guide rls and slide blocks (length 470mm, width 15mm, length 550mm, width 23mm), Work table (bottom plate, middle sliding plate, upper sliding seat), bearings (angular contact bearing 7202AC, deep groove ball bearing 6202-2RZ), bearing seat (in order to ensure that the height of the screw rod is adjustable, there are two center heights of the bearing seat), end It consists of cover, contour block, pad block, guide rl pressing block, guide r*l positioning block, etc.; in order to ensure the stability of the equipment, the work surface and bearing seat are all milled with precision CNC milling machines.	1	set
10		Multifunctional formwork components	It mnly consists of the upper and lower mold plate positioning pins, the lower mold plate blanking hole, (08B), chn (08B single row ch*n), upper mold plate, lower mold plate, transmission shaft, elastic coupling, tapered roller bearing (32004, 32907, 32909), support, end cover, etc.	1	set
11		Mold	M*nly composed of upper mold assembly, upper mold guide bushing, lower mold positioning block (2 pieces), lower mold, mold calibration rod, etc.	3	set
12		Automatic stamping mechanism	It is m*nly composed of an automatic punching machine bed, a gas-liquid boosting cylinder (APTC-50-20-1T-F plus magnet), etc. To ensure the stability of the equipment, the punching cylinder bed is processed by precision CNC milling.	1	set
13		Pneumatic module	It mnly consists of electric control valve base plate, electric control valve (4V11006B 5 pieces), pneumatic triple joint, hand slide valve, multi-position fixed cylinder, compact cylinder, pencil cylinder, gas-liquid booster cylinder, tee, four-way, PU r pipe , quick-change joints, *r pump (ESW-24), etc.	1	set
14	tool	electrician tool kit	Includes digital multimeter, wire strippers, needle nose pliers, diagonal pliers, screwdriver (flat, cross, large, medium and small), hex wrench (15-1), tweezers, scissors, soldering iron (digital), soldering iron stand , solder wire, rosin, insulating rubber pads, desk lamps.	1	set
15		Copper rod	One end is φ18, one end is φ14, and one end is φ30.	2	root
16		Rama	150	1	pieces
17		Slotted screwdriver	10" through core slotted screwdriver	1	Bundle
18		Rubber hammer, hammer	1 round hammer (1.5 pounds), 1 fitter hammer (500g), and 1 rubber hammer each	1	set
19		Wrench assembly	9-piece set of hexagonal wrenches; 1 set of 150mm and 250mm adjustable wrenches; 1 set of 14-17 and 7-opening spanners; 1 set of ratchet ring wrenches with 17-19 openings; 1 set of M14, M18, and M22 round nut wrenches	1	set
20		ch*n cutter	420～530	1	Bundle
twenty one		Bearing assembly sleeve		2	indivual
twenty two		file	Assorted files, medium flat files	1	set
twenty three		movable handle	The thread is M8	1	set
twenty four	Measuring tools	scribed tablet	300mm×300mm	1	piece
25		Vernier caliper	Measuring range: 0~300mm, graduation value: 0.02mm	1	Bundle
26		Depth Vernier Caliper	Measuring range: 0～200mm, graduation value: 0.02mm	1	Bundle
27		square ruler	200×130×12.5mm	3	Bundle
28		Debugging mandrel	Length 70mm, diameter 35mm	2	Bundle
29		lever dial indicator	0～0.8mm, graduation value: 0.01mm; including adapter and magnetic base	1	indivual
30		Dial indicator	0～10mm; including adapter and magnetic watch base	1	indivual
31		micrometer	0～25mm	1	Bundle
32		Steel ruler	500mm	1	Bundle
33		feeler gauge	Measuring range: 0.02～1.00mm	1	Bundle
34	console		The countertop is veneered with 50mm polymer composite material, which is acid, acid and alkali resistant, wear-resistant, and oil-resistant. The base plate is made of high-fiber fiber and has good impact resistance. It is surrounded by high-strength plastic edging to prevent it from being damaged by impact. The operating table is equipped with two drawers with central integrated locks, which can place parts, accessories, etc.	1	tower
35	Suspension rack		The paper hanging frame is fixed on the operating table and adopts a frame structure. There is an LED energy-saving lamp lighting device on the top. The back net adopts the design of the upper hole and the lower louver hole, which can hang a variety of material boxes and hooks.	1	tower
36	Accessories		Hooks, parts boxes, programming cables, product supporting CDs (software, user manuals, programs, etc.)	1	set
37	Profile computer desk		Used to place the computer, with four universal wheels with brakes installed below, size: 560mm×600mm×1020mm	1	tower
38	computer		M*nstream brands	1	tower	Prepared by user

5. Practical tr*ning projects
Project 1. Mechanical drawing recognition and preparation of assembly processes
Based on the partial assembly drawings and general assembly drawings, understand the working principles, assembly relationships and technical requirements of mechanical equipment, and write the assembly processes.
Project 2. Assembly and adjustment of the automatic loading and unloading mechanism (warehouse).
According to the functional requirements of the department assembly drawings, general assembly drawings and mechanical equipment, and in accordance with the correct assembly process requirements, complete the assembly and adjustment of the guide r*ls, ch*n transmission, synchronous belt transmission, etc. And adjust the sensor position to ensure cooperation with the two-dimensional feeding components.
Project 3. Assembly and adjustment of the two-dimensional feeding components (cross slide table).
According to the functional requirements of the departmental assembly drawings, general assembly drawings and mechanical equipment, and in accordance with the correct assembly process requirements, complete the linear guide r*l p*r, ball screw p*r, bearings, and bearings. Assembly and adjustment of seats, pneumatic positioning clamps, etc., and completion of the overall control process debugging of the two-dimensional feeding component (cross slide).
Project 4. Assembly and adjustment of the turret stamping mechanism.
According to the functional requirements of the departmental assembly drawings, general assembly drawings and mechanical equipment, and in accordance with the correct assembly process requirements, complete the assembly and adjustment of the upper and lower mold plates, and adjust the upper and lower mold plates. coaxiality.

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