JPRS ID: 9141 USSR REPORT CONSTRUCTION AND EQUIPMENT

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• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000200090027-1
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• Sequence Number: 27
• Content Type: REPORTS

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JPRS L/9141
13 June 1g80
USSR Re ort
p
CONSTRUCTION AND EQUIPMENT
CFOUO 5/80)
FB1~ FOREIGN BROADCAST INFORMATION SERVICE
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JPRS L/9t41
13 June 1980
USSR REPORT
CONSTRUCTION AND E~UIFMENT -
(FOUO 5/80)
CONTENTS
BUILDING MATERIALS
Use of Tiles, Glass in Construction Reviewed
(STEKLO I KERAMIKA, Nos 2, 3 1980) .
1
Ceramic Tiles, by A.A. Farsiants
Use of Glass Grows, by G.M. Matveyev, Kh. G. Yaroker
METALWORKING EQUIPMENT
Supply, Material Savings at Machine-Building Enterprises
(L.M. Striyer; VESTNIK MASHINOSTROYENIYA, Jan 80)...... 10
Machine Tool Industry, Numerically Controlled Machine Tools ~
Examined
(STANKI I INSTRiJMENT, Apr 80) 18
Progress Summarized
Automated Milling Machines, by A.N. Bobrov, Yu.G. Perchenok
Precision Machining on Lathes, by Zh. N. Kadyrov, et al
Simplified Numerical Programming, by Ya. G. Gol'din, et al
Microprocessor Feed Brive, by V.L. Sosonkin, Yu.S. Malyuga
Conference on Computer-Assisted Control, by B.S. Pitskel'
' - a' CaII - USSR ~ 36a FOUA]
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BUILDING MATERIALS
USE OF TILES, GLASS IN CONSTRUCTION REVIEWED
Ceramic Tiles
Moscow STEKLO I KERA~~iIKA in Russian No 2, 1980 pp 2-3
[Article by Chief Manufacturing Engineer A. A. Farsiants of the Ceramics
Industry Administration of USSR Ministry of Construction Materials:
"Raising Production Effectiveness in the Construction-Ceramics Industry"]
[Text] The drive to raise production effectiveness and work quality is =
the main trend in the CPSU's modern economic policy. The following tasks
face our industry at this time: to increase volume of output from exist-
ing capacity, to increase yield from the funds that have been invested, to
, reduce the materials and labor expended per unit of finished product and
to raise product quality. Questions of the integrated mechanization and
automation of production, a reduction in the share of manual labor, mech-
anization and automation of production, and the grading and packing of
products acquire special importan~,e.
Fteequipping with machinery has been going on for the past 10-15 years in
the construction-ceramics industry, especially in the production o~f all
types of ceramic tile. Almost all enterprises have converted from the dry ~
m~thod of preparing the powder press to the slip method, using spray dry-
ers, and at some plants continuous-action mills for breaking up the clay
have been introduced. Kilning of the tiles in tunnel kilns for saggars
has been replaced by kilning~nn conveyor flow lines with roller-hearth
furnaces. Such labor-intensive operations as filter-pressing the slip,
drying clay in drums and repeated manual rearrangement have been preclud- _
ed. The work of NIIstroykeramika [Scientific-Research Institute for Con- �
struction Ceramics], which is used in Giprostroymaterialy [State Institute
for the Design of Building-Materials Enterprises] designs and then is
introduced into the industry, is playing a major role in reequipping the
industry with machinery.
A most important factor in raising production effectiveness and work qual-
ity is growth in labor productivity. Raising labor productivity at con-
struction ceramics enterprises by i percent will yield an inerease of
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300,000 rubles' worth af products aizd will also allow 50-60 people to be
released provisionally per year.
The main resource for an upsurge in labor productivity is acceleration of
scientific and technieal progress. The assimilation of new, highly pro-
ductive machi.nery anii technology will enable more output to be produced
with fewer ~aorkers. The introduction of conveyor flow-line technology
for~ manufacturing ceramic tiles will aid greatly here. At present about
200 such lines are in operation at the enterprises, which a-re producing
more than 40 rtiillion square meters of ceramic tile per year.
The serial productian of conveyor flow lines and of spray dryers has been
mastered at Bologovo's Strommashina ~}lant, Kemerovo's Strommashina plant
of U~SR Minstroydormash (Ministry of Constraction, Road and hlunicipal Ma- -
chine Building], and the Perrn' Machinery Test Plant of USSR Minstroymater-
ialov [Ministry of Construction Materials Industry].
At practically all newly built or rebuilt plants conveyor flow lir_es for
producing all types of ceramic (facing, floor and facade) tiles have been
installed and are in operation. The introduction of these lines enabled
more than 800 persons to be released and about'16 million rubles per year "
to be saved and also permitted the variety of products to be expanded and
- the yuality thereof to be improved.
- Taking i~~L-o consideration the experience gained in,operating the first
lines, wr:i:h had an annual productivity of 250,000 square meters of facing
tile, 2U~),000 squa^e meters of f'loor tile and 100,000 square meters of
_ Pacade t;.le, conveyor flow lines of greater capability--with productivi-
ties, respectively, of
500,000, 400,000 and 300,000 square meters of tile
per year-�-were created. -
- The next step was the creation of lines with an annual capacity of 800,000
square meters of :loor tiles and 700,000 square meters of facing t~les. ~
The first models of these lines were installed at the Khar'kov Tile Plant
and the Si.avyansk Ceramics Combine. Unlike previous designs, these lines
wer~e assembled from unified sections, which is very important during
assembly and operation.
basically new conveyor flow line with a capacity of 100 square meters _
per hour, or more than 800,000 square meters of facing tile per year, is
now being created. This line will include highly productive presses, ver-
tical dryers, an improved glazing installation, and automatic machinery
for grading and packing the finished output.
The country's first conveyor flow line for producing large-dimension
(0.5x1x0.01 meter) Plink plates in accordance with a technology developed .
by NIIstroykeramika is being mastered at the Kuchinovka Ceramic Facing-
~taterials Combine.
hiajor attention has been devoted in recent years to operation of the en-
terprises' large -scale preparation departments; cutting and flinging mills
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for breaking up clayey materials are being used and improved spray dryers
are being introduced, enabling powder output to be about doubled. -
Much is also being done to supply bathroom ceramic products. Almost all
- plants have converted to the production of sanitaryware made of bulk por-
celain with a water absorption of 0.5-1.0 percent. These products are ~
hygienic and are distinguished by high strength, they are not vulnerable
to the effects of aggressive liquids, and ~hey are more durable. While
about 5 million articles were manufactured out of bulk porcelain in 1975,
about 7 million pieces are to be produced in 1980. By the end of the ~
Eleventh Five-Year Plan all sanitaryware will be manufactured from bulk
porcelain.
The national-economic plan for new technology calls for a further increase
in the produczion of colored sanitaryware; in 1980 output thereof will be
350,000 units. Much remains to be done in subsequent years te introduce -
modern designs for colored sanitaryware. NIIstroykeramika, the Institute
of Esthetics and NlIsantekhnika [Scientific-Research Institute for Sani-
tary-Engineering Equipment] are developing bathroom and restroom interiors
of modern design. Much w~~rk on the introduction of new articles is being ~
done at the Kuybyshev and Lobnya plants for construction porcelain. A1-
- most all the large plants that produce sanitaryware are equipped with
glazing conveyors, whose use raises output quality substantially.
Mechanized rigs for the manufacture of lavatories and toilet bowls are now
being created and introduced. The use of such rigs not only eliminates
heavy manual labor but also enables the output of a wide assortment of
articles. The introduction of inechanized rigs combined with swinging-
tray dryers and glazing conveyors will enable the flow-line production of -
sanitaryware to be established. -
Raising production effectiveness is impossible without tY?e rational use of
raw materials and other materials, and fuel and energy. In recent years
the raw-maLerials base has been greatly expanded throagh the discovery of
new deposits (the Fedorov deposit in Rostovskaya Oblast, the Pechora in
Pskovskaya Oblast, the Cambrian in Leningrad, the iankerovskoye in Tselin-
gradskaya Oblast,the Angren in Tashkentskaya Oblast, and other deposits). -
The use of local types of raw materials is of great national economic sig-
nificance. A reduction in the average hauling radius by 100 km will
enable an annual saving of about 1.5 million rubles.
The mechanization and automation of processes in auxiliary departments,
especially for loading and unloading, where the share of poorly productive -
manual labor still is great, are reserves for labor-productivity growth.
The first model of a grading and packing installation far a line with an
anmzal productivity of 800,000 square meters of floor tile that will be
installed at the Khar'kov Tile Plant was manufactured at a NIIstroykeram-
ika test plant during the fourth quarter of 1979 in accordance with that
institute's developments.
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Work to mechanize processes is also being done at a number of plants.
Thus the Voi~onezh and Minsk enterprises have tested a container for pack-
ing and transr~orting ceramic tile, and at Shchekino's Kislotoupor plant
acid-resistant articles are being packed on pallets and bound by a metal ~
strap.
In implementing 25th CPSU Congress decisions, the CPSU Central Committee
and the L`SSR Council of Ministers adopted the decree, "Improvement of'
Planning and Intensification of the Effect~of the Economic Mechanism for
Raising Product'ion Effectiveness and Worl- Quality." This decree is aimed
at fur~ther improving and intensit~ying planning supervision of the econom-
ics activity and at developing democratic principles in management and
crea~ive initiative in laboring collectives.
The decree attributes paramount importance to further improving long-ralge
planning, developing a mutually related system of plans and transformin�
� the five-year plan into the main form of planning for the national
' aconomy.
_ The compilation of annual plans should be started from below {at enter-
prises and associations), based upon a search for the reserves that rxe
uncoverea by socialist competition and counterplans.
Vvhen substantiating the ninistry's draft plans, economic ~uid engineering
calcular,i~~ns wi11 be used, as ~~vell as rating sheet data for each assoc~.a-
tion and ~~nterpr~ise, and sc~ rating sheets are to be made up in 1980.
'I'hcy will. call for information about the existence and level of use of
~
~apaci~y and growth of the shiftwork-utilization factor of the equipment,
as well as measures for specializing production. ~
Tasks for mastering and introducing new equipment should become an organic
part of production and of capital construction. The creation of new
^~terpri.ses and the reconstruction of existing ones should be executed
~-n the basis of highly effective technology and use of the newest equip-
ment tnat ivili provide for the output of pr~oducts that correspond to the
best dom~st;ic and foreign models.
ihc stimulating role of resources of the single fund for developing sci-
_ c.�r.~e and ~ectir.alogy that is established in ministries and agencies
through deductions from profit is to be intensified.
Miav rcviewed the statu~ of and prospects for developing the produc-
tion of const?ruction glass. Our country's glass industry is manufacturing
mare than 300 milliun squarc meters of const�ruction glass each yea~�. The
USS42 ranks first in the woi~ld in output of wind~w glass.
The variety of construction glass is constantly being expanded. The pro-
duction of colored, safety and plate glass, glass section, windaw glass,
devitrified heat-absorbing glass and glued double-glass panes by the mech-
anized ii.~~hod, and of Dletelitsa decorative glass has been mastered. In
the near future it is proposed to orga-~ize the large-scale production of
new solar-protection glass, double glass panes and other glasses in the
near future. The reporter pointed to the importance of experimental con-
struction for checking comprehensively the operati~nal qualities of new
articles, and he noted the necessity for more grecise determination of
construction's requirements for new articles made of glass.
- The report of GIS [State Institute for the Scientific-Research of Glass]
Deputy Director Candidate of F:ngineering Sciences L. L. Orlov was dedicat-
ed mainly to development of the production of facing articles made of
glass: fiooring tiles, marble glass, enamel-coated decorative glass and
~ other glasses.
He dwel~ in detail also on questions of re~ucing losses of window glass
ar~.d oF increasing the litilization effecti~~eness oi glass cut to size. By
` the end o; the ier.ch Five-Year Plar., the annual output. of glass cut to
size is to be a~out 15U million square meters, or al;r.ost nalf of all wind- -
do~ gldss produCTion. However, because of the large nwnber oF standard
:::z~s of glass shee?s called for by existing standards and by standard
C~f:S1~T1$ for wiridows , customers frequently order the sheets in larger
sizes. A~ the construction site this leads later to recuttin~ of glass
that is snipoed bv piants as glass cut to size. Window structure must be
unified, in order to r�aise the utiliza~:ion effectiveness of sheet glass in "
~onsi;ruction.
Deputy bti.nister for the Belorussian SSR Construct~on-Materials Industry
Candidatc of Ln~ineering Sciences S. S. A}:ulich reviewed the prospects for
exnandir~g the pr~uduction and use in the national economy of glass pipe
made o: heat-resistant and borosilicate glass. The use of 1 l~:m of glass
i~;.~~e wi1J. a11u~N n:ore than 7 tons of inetal pipe, inc].uding 3 tons of
st.ainless-steel pipe, to be saved (,taking service li.fe into considera-
tion). During the Nin~h Five-Year P].an the tentative economic benefit
fram introducing glass pipeline was about 450 rnillion rubles. The re-
parter dwelt in detail on choosing an optimal technol.ogy for producing
such pipe.
The report of Deputy Chief of USSR Gosplan's Glavpromstroyproyekt [Main
- Adminis~ration for Zn~ustrial-Construction Design] Candidate of Engineer-
' ing Sciences Ye. G. Kutukhtin was devoted to questions of using glass in
- industrial construction. He noted that window structure influences con-
siderably the economic indicators of buildings, heips to provide the re-
qui.red microclimate and sanitary and hygienic conditions for working and
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personal amenities within a premise, and helps to shape the architectural
appearance of facades and interiors. Designs for window sash are con-
stantly being improved. Hot-rolled steel section used in sash is being
replaced by bent thin-walled tubular sash, which enables metal consump-
~ tion to be reduced by 10-20 kg per square meter of window and the sash's
ioad-carrying capacity to be raised.
I ~
Ye. G. Kutukhtin dwelt in detail on the unification of windcw ~tructure.
Some 150 standard sizes of glass are now be~_ng used for ind~astrial con-
struction, 25 of them providing 80 percent of the total requirement for
window glass. t'SSR Gosstroy has approved a products mix of windows and
doors made of wood and of steel and aluminum alloys that is unified for
all types of construction. Structure for windows for various types of
buildings, based upon the approved products mix, is being developed that
will enable the number of standard sizes for glass to be reduced
severalfold.
The report devoted major attention to reducing i~e3t loss through translu-
cent barrier structure, including the use of double-pane glass and other
special types of glazing. The reporter pointed out the effectiveness of
introducing sash-free translucent structure, created on the basis of glass
section and glass blocks, into industrial construction, and he also exam-
ined questions of improving the quality and of raising the utilization
effectiveness of these articles in construction.
- Architect V. N. Alekseyev (TsNIIEP zhilishcha [Central Scientific-Research
and Design Institute for the Standard and Experimental Design of Housing]
of USSR Gosgrazhdanstroy [State Committee for Publie Building Construction
and Architecture]) delivered the report, "Effective Articles Made out of
Glass and 'fheir Role in Modern Architecture." He analyzed in detail. the
factors that :estrain the use of new types of glass in construction, name-
ly: the low quality ~f some products, the lack of outfitting materi-
als, unsatisfaci:ory information about new articles made of glass and about -
structure that incorporates them, and the inadequate economic incentives
for producing and using such articles.
Four sections operated at the confernece. The section, "Translucent En-
closure for Buildings," which Ye. I. Kutukhtin headed, examined questions
of the effectiveness of production and the use in construction mainly of
plate glass and of articles made of it.
The reports of candidates of engineering sciences Yu. P. Aleksandrov
(TsNIIpromzdaniy~ and G. I. Khavaldzha (TsNIIEPsel'stroy [Central Scien-
tific-Research and Design Institute for the Design of Standard and Experi-.
mental Rural ConstructionJ analyzed questions of using glass in industrial
and agricultural construction. Yu. P. Aleksandrov dwelt on the advantages
of using skylights for natural illumination of the premises of industrial
and social buildings.
The section's work devoted major attention ta the utilization effective-
ness of various solar-protection glasses. Manager of VNIItekhstroysteklo
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laboratory B. Ye. Romanov told about new types of solar-protection glasses,
_ ihe industrial mastery of which is proposed for the near future at the
Saratov Plant for Engineering Class.
Candidate of Engineering Sciences `!e. I. Semenov (TsNIIEP zhilishcha) re-
ported that the resistance to heat transmissiQn of windows in which one of
the panes has a st,annous-oxide coating is 20 percent higher than of win-
dows made of ordinary ~].ass. According tu the researchers' data, this
_ wil] Enable a substantial economic benefit to be obtained. The reports
of candidates of en~ineering sciences S. I. Belyanovskiy (TsNIIr,P zhili-
shcha), 0. V, Vorob'yev (GIS), S. P. Solov'yev (TsNIIF,P uchebny:sh zdan:y
[Central Scientific-Research and Design Institute for the Standard and F.x-
pei�ir~ental Design of Educational Buildingsj) and physicist T. G. Khalatova ~
(Tbi1ZNZIEP ~Tbilisi ~onaJ. Scientific-Research and Design Institute for
the Standard and EYperimental Design of Housing and Social Buildings])
revealed the utilization effectivenass oi' various solar-protection glasses.
T. G. Khalatova pointed out the high operational qualities of new heat-
absorbing glass developed hy V~,'Iitek.hstroysteklo.
Ca.ndidate of Engineering Sciences A. G. Shab~~i~ov dwelt on the prospects
for organizing the mass production of hardened giass for construction.
The section also discussed questior,s of the strength of glass and the pro--
duction and use of double-pane glass and o(;~er e'.'~ective art.i.cies made of
~lass.
The section, "Faci:ig i.taterials dased on Glass and '~va.trified Giass," re-
vie;,red q,~estions of the producfiioi7 a:id use of both basically r.ew and of
traditional fa~ir.g matez~iais.
Candi.r.a~e of Fngineering Sciences N. Semenov (VNIItekhstroysteklo) re-
ported abuut a method of electrocn~micai tinting of plate glass that his
. ;.~stit:ute developed that can 1~e used as facing material.
The Vladimir PO'1VtCChnical Institute and the Gusev Plant imeni F. F. -
Dierr.hins;c~;~ are doing rror4t i:o raise the decorative qualitzes of glass
s~~:ct.i.on. V. Didenko told about the results of the work.
Sc;ne reports of GIS staff workers were dedi.cated to the perfectio,~ of a
technolog�v f'or producit~g r''oorin~ tiles, marbled glass, decorative glass
~rvmb, enamel-coateci glass and other facing materials. The necessity for
creating new shaping methods and for developing modern highly productive
eyuipment for the manufacture of facing articles ~vas noted. Reports about
the work being conducted by GIS and the Kherson Glass-Products Plant to
- form st;rips of opacifying gl.ass on a one-roll machine provoked great in-
terest. The ;apper part of the strip is formed here under the action of
surface-tension forces, improving product quality considerably.
This same section heard the reports of candidates of engineering sciences
G. V. Rezenko (the Avtosteklo plant) and V. F. Lyasin (the Leninist Glass
Pl.ant) about mastering the production of new articles--marbled and ceramic
glasses--and about raising the quality o~ othar construction articles made
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of glass. Also examined were questions of improving the quality of orna-
mented and safety glass, the share of which in the total output volume of
construction glass is constantly rising.
~ Joint sessions of the: sections on, "Heat Insulated and Heat-Protective Ma-
terials Based upon Glass," and "Glass for Constructional Structure and
Building Materials" were held at the conference. Doctor of Engineering
Sci.ences P. D. Sarkisov headed the work of the sections. During this
~ session much attention was devoted to questions of obtaining foam glass.
In particular, MKhTI [Moscow Engineering-Physics Institute] imeni D. I.
Mendeleyev and NIIavtosteklo [Scientific-Research Institute for Motor-
Vehicle Glass] have done research on the foaming of glass, and NIISM `
[Scientific-Research Institute for Building Materials] has obtained decor-
ative facing glass--decorative and acoustic foamed glasses.
SeWeral reports were dedicated to the use of fiberglass materials such as
reinforcement for glass-cement and the production and use of glass pipe
and products made of artificial stone.
Reports about wcrk being done in the Brest Construction-Engineering Insti-
_ tute on the enameling of construction articles and in the Belorussian In-
dustrial Institute on ~the synthesis of new glasses and devitrified glass
stimulated interest.
The sections adopted recommendations on the basis of which the decision
~ of t;he All-linion conference was worked out.
The conduct of the conference and the realization of its decisions will
help to expand the use in construction of effective articles made of
giass.
COPYRIGHT: Stroyizdat, 1980
11409
CSO: 1.821
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METALWORKING EQUIPMEN~1' UDC 621:658:566
SUPPLY, MATEFIFiL SAVINGS AT MACHINE-BUILDING FNT~RPRISES -
1Koscow VESTNIK MASHTNOSTROYI:NIYA ~.n Russian No 1, Jan 80
~~p 69-?1
[Article by Candidate of ~conomic Sciences L. M.~Striyer]
[Te.xtj One of the co~di~ions for further improvem~nt of savings
in produr.tion by machine-building enter~rises is an efficient
orqan~;~~tion of their supply of materials and equipment. The
_ quali+~y of the st~pply can ~e judged according to the actual
stafi.e c~~ the production stacks of the znterprises. The present
~~~stem af organization of materials and ~quipment for produc-
ti~rz and the level of development of econcmics mean that in
ea~Gh separate case the volt?me (norm) of necessary and suffi- _
ier_~ production stocks can be determined with sufficient ac- `
- curacy for each enterprise according to its physical resources.
Eanc ~~eviation of the amount of production stocks from the ca~-
~u~.ated normative level causes definite losses that reduce the
producta.on efficiency. A direct calculati~n of these losses ~
is imp~ssibl~ be~ause the accounts of the enterprises do not
- have th,E.data characterizing the costs of the supply of mater-
- i~ls and equipment. To construct indicators for the costs of -
� rnaintaining above-standard productive stocks and the losses due
- to a deficit in materials requires that special calculations
' bp performed and the data ir~ the initial accounts be analyzed
ar...d r~arranged.
I -
The losses due t~ the presence of above-norm stocks in ware-
hauses are a part of the cost of maintaining all the produc-
ti~e stocks. The latter combine various expenditures of the
labor, material, and financial assests of the enterprises. De- -

~ pending az how they are reflected in the economic indicators
c~f the operation of the enterprises, they ~ are divided into
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the costs of storing materials and are included in the produc-
tion losses or the costs associated with the immobilization of
working capital in reserves of commodity stocks that are sub-
tracted from the prof its of the enterprises.
The costs of maintaining production stocks are divided into two
- groups for another reason: the indicator for the storage costs
can only ;~e derived by analyzing the initial accounting data,
while the immobil.ization costs can b~ obtained from calcula-
tion.
The costs of storing the production stocks include t3~e expen-
ditures for the labor, materials, and energy involved in the
storage process itself, for maintaining certain conditions in
the storehouses, for guarding and moving the stored materials,
for preserving their qualities, etc., and also the wages of
the supply workers and the packing outlays.
The costs associated with the immobilization of capital inves-
ted in phY~ical reserves are potentiat losses arisinq from the
impossibility of obtaining a certain volume of profits since
the commodity stocks are tied up. This is the so-called mis-
sing profit in ~he economy. From the standpoint of the expen-
ditures by an enterprise for maintaining materials, the specif-
ic costs associated with the presence of stocks in warehouses
are of interest. This includes the charges for working capital
in production stocks and payments to the State Bank for cre~its
used for production stocks.
The total costs of maintaining production stocks are not lim-
ited to the expenditures listed above. Thus, the storage of
raw and finished materials is the reason for budget payments -
to cover the fixed productive capital for storage operations;
many sections in a enterprise - the planning and financial de-
partments, bookkeeping, office workers, personnel section,
etc. - carry out certain functions, whose cost can be assigned
to stock maintenance. These expenses, just as the wages ~f the
supervisors in the supply section, are assigned to nominally ~
constant expenditures that ar~ independent of the volume of the
physical assests being stored. Therefore, if the losses from
the maintenance of above-norm productive stock are to be deter-
mined, only the total of the nominally variable costs must be
calculated.
This model was used to calculate the costs of maintaining the
productive stocks of the Tbilisi enterprises: the Elektrovozo-
stroitel' PO [production association], the Machine Tool Plant
imeni S. M. Kirov, and the Gruzsel'mash Plant.
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E lektrouo- Kirov Gruz-
Tndicators zostroitel' Machine sel'-
Assoc. Tool mash
Plant P1ant
Actual annual average value -
of productive stocks, thous. R 7955 5317 1384 -
Costs of maintaining produc-
_ tive StoCks, thOUS. R 1012,0 762.3 190.4
Costs of maintaining a stock
unit, R/thous. R 127.2 143.4 137.5
.Level of productive stocks as
percent ~f norm 121.6 1.17.3 127.0
Normalized average annual value ~ ~
- of prc~ductive stocks, thous. R 6541 4530 1098 _
CoSts of maintaining normalized
- value af productive stocks, ~
thous. R 832,0 649.6 150.9
Losses due to maintenance of
above-norm productive stock~,
thous, R 180.0 112.7 39.5 -
~
.A direc~~ calculation method can be used to determine ~the losses
_ d~~e above-narm productive stocks in an enterprise. A pre-
limlllc~,~y calculation of the indicator of the costs of maintain-
zng stack unit is performed by dividing the total value of -
t;1e s~ock rnaintenance costs over a certain period by the aver-
aqe s~:ock value. This indicator describes the quality of the
wor3c nf the aupply department and makes it possibl.e to compare
the ar.ganization of the maintenance of raw and finished materi-
a.l~ at different enterprises, In our investigation, it was ~
used to determin~ the loss due to above-norm stocks. For this
purgose, the indicator of the costs of maintaining the actual
v~].ue af the productive stocks was first derived by sampling
t::~~P iniu?al accounting data. Table 1 shows a calculation of
:ne yearly ir.dicator of the costs of maintaining a stock unit;
it was used to dGtermine the calculated value of the costs of
maintaiz~ing the normalized level of productive stocks and, as
the aifferen~e with the total costs of maintaining the actual
va~.ue of the stocks, the addita.onal expenses of an enterprise
in maintaining that part of the productive stocks above the
e~tablis~ed norm.
The ].osG indicators obtained do n~t pretend to be absolutely
accurate: the stock maintenance costs do not necessarily grow
in direct proportion to the increase in the value of the
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production stocks; different product lists of stocks require
different maintenance costs per stock unit. Ne~~ertheless, the
result.s obtained give an idea of the magnitude of the costs as-
sociated with above-norm productive stocks.
Above-norm surpluses of commodity stocks carried over from year
to year indicate constant losses for their maintenance. The
presence of above-norms stocks also suggssts certain economic -
losses because the raw and finished materials cannot be used
by other enterprises. The losses can easily be calculated_by
ueing the efficiency index suggested by the Scientific-Research
Institute of the Economics and Organization of Material and
Technical Supply of the USSR Gosnab for the assets allocated by
enterprisesa On the whole, this coefficient equals 0.21 for
induatry.* This means that each ruble invested in industrial
kopecks per year. As a result, the losses to the economy come
to 210 R for each thousand rubles of above-norm production
stocks per year, i.e., they are more than a factor of 1.5 above
the maintenance costs per stock unit in the enterprises sur-
veyed. Moreover, the raw and finished materials frozen in
warehouses increase the deficit of these types of labor assests
on a country-wide scale.
As the pr~ser~t investigation has shown with regard to the pre-
sence o� a fairly large amount of above-norm productive stocks
in a certain category, the enterprises must still bear heavy
losses due to the lack of other types of physical resources at
the needed moment.
At practically ever~� industrial enterprise, difficulties in
production supply arise periodically due to the lack of produc-
tive stocks required for current consumption at the needed
time. During the investigation, ' there were stoppages in
receiving a number of materials that had a considerable effect
on the fulfillment of the production programs, including pro-
duct assortment.
The continuation of productive output under shortage conditions
involves the carrying out of unplanned measures requiring addi-
tional expenditures, which are losses for the enterprises,
since they would not occur if the productive stocks of raw and
finished materials were present in the required.amount and
*Standard sampling technique for direct shipment or storage of
products used for industrial or technical purposes by the in-
dustrial enterprises. Moscow, NIIMS, 1967, p. 16
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v~riety. T:ie measures include the e.fforts of the supply work-
ers to find additional sources of productive stocks and to or-
ganize an accelerated input of the insufficient materia'ls,
where thE losses appear in the form of additional out-of-town,
telepr~Une and telegraph, and transportation expenditures for
accelerated shipment of the critical goods. Other measures aim
at continued manufacture o~ products by replacing the missing
mat~rials with substitute materials or by large-scale purchases
of av~ilable ma~erials, In this case there are losses associ-
ated with the carry-over of materials and the wages of workerG
processing the extra volume of mater.ials, purely material los-
ses ciue to tne use oi more expensive brands in production, and
the I~sses o~ labor resources a~sociated with design c;~anges in
_ the speci~ied products. In cases where substitution is not
possibl~, L-he planning targets are sometimes ignored, and the
autpu~c consi.sts of products planned for a lafteY~ time. As a _
r~sul.L-~ some of the efpected profits are not received, and
, th~~re ~r.e iosses due to payment oF penalties for late shipment
of gocas.
An~ up~~ations designed to eliminate the shortages cause finan-
c:ial c:_.ses to the consumer enterpra.se. These additional ex-
iJ~Il!'~it~::~�e are recorded in the primary accounts of th~ enter-
~r~:~t~;- C~ses cf substitution. for missing product assortments
Gx~e .r~: ~-;-de~ on decumer_ts , supplemental payments to the oper-
atinr; ~ms anc3. ap~raisals are recorded ~.n special supplemen-
:.ary ~~~~;_�,>t~~ent do~uments and orders, the difference in costs be-
tw~:~zY ~~.;~r_elerated and normal shipments can be determined from
th~ ap~~ropr3.ate accompanying documents, and, finally, the ad-
d:i.tioraal. mail, ~el.egraph, and out-of-town expEnditures can be
~ a~~ermined f.~:om the accounts. It turned out that for only one
~lLa.:~ clze ~1~:'�:tro~~ozostroitel' PO incurred losses on the order
c:~i` ~6t),OUO xZ c:ue to material shortages; losses for the Kirov
w~~d Gru.zel`nash plants were 172,000 and 82,000 R, respectively.
E�r.,~aendit;ares to repla~e missing ~roducti~n stocks pr_edominate ~
~:'r~~ s~ruc.'clt~~ af the losses due to material shortages at all
enterprises. Over the course of a year, the enterprises
- m~.de ac+~ive use of available materials for missing ones. The
~~roductiori tempo was not of~en interrupted because of an arti-
~ici.a].ly or~~duced shortage in the nex~ year. '~lanned produc-
t:ion can continue because the source of the additional mater-
i%~.ls is the above-norm surplus of physical resources that is
a~rai7.ai~1_e at every entErprise. The subsequent ~uildup of the
pi~oduc~i.~~~ stocks, which often occurs ~-,'zen the acute need for
t.hem haa passed, again brings the above-norm surpluses to the
previous ievel.
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The significant excess of materials carry-over (322,000 R) com-
pared to wage carry-over (4,000 R) at the ElektrovozostroitPl'
PO is due to the frequent replacement of materials by more ex-
pensive grades, which usually did not require additional labor
input. The wage losses due to shortages are largely associated
with the manuf acture of parts from the large-scale stocks,
_ Therefore, it is not accidental that at the Kirov Machine Too1
Plant, where ferrous metals are 80~ of the produc~ion input,
- the wage carry-over due to shortages (6.96 thous. R) is the
- largest among the enterprises investigated, both absolutely and
relativ~ to the total losses.
Unplanned transportation and procurement expenses due to the
search for addition sppply sources and the organization of ac-
clerated shipment of materials are fairly large at all the en-
terprises (30,000 to 56,000 R). This reason is the frequent
use of external measures to eliminate the deficit. Thus, the
shortage of ferrous metals at the Elektrovozostroitel' PO was
three-fourths covered by shipments from various sources, and
during the entire year the Gruzsel'mash plant experienced dif-
ficulties in obtaining parts for complete sets. During the
period investigated, all the enterprises paid the buyers of
their production considerably higher penalties then they re-
ceived from ~Eheir suppliers. However, the uncompensated part
of the fines is many times lower than the losses the enterpris-
es would bear if the planned production.were attempted without
the required materials.
The total amount of financial losses due to shortages at a11
the enterprises does not contain the losses associated with
that part of the profit not received from the unfinished and
thus unrealized production which was suspended because of a
shortage of required materials. These losses are compensated
by the shipment of products of diff erent description, often
with a much higher profitability. In this manrier the plan for
profits was filled and overfilled. The present monetary sanc-
tions do not seriously affect the economic interest of the man-
ufacturers. Thus, the Elektrovozostroitel' association paid a
year's fines worth 6$ of its balance-sheet profits, the Gruz-
sel'mash paid 2$, and the Kirc~v plant paid l.l~. These figures
indicate the low efficiency of the claims work done under the
present statute on production shipments. Therefore, such los-
ses due to shortages are either not present a~ industrial en- _
terprises at all or are quite insignificant. The consumer en-
terprises, as a result, must bear additional expenditures, '
_ which, as we saw in the enterprises analyzed above, are many
times larger than the total fines.
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Elektrovo- Kirov Gruz- -
Indicators zostroitel' Machine sel'
Assoc. Tool mash
Plant Plant
Actual production co~t of the
commodity pr~ducts, thous. R 36,121 23,735 I1,378
including:
losses for storage of above-
norm stocks 83.38 49.98 19.00
material losses for substi-
tut.es due to shortages 322.84 56.88 35.48
wage losses due to shortages 4.00 6.96 2.13
losses due to shortages in
general plant expenditures 34.90 56.82 30.2_l
To~.al losses 445.12 170.64 86.82
Actual balance sheet profits,
thous, R 4627 5769 3472 -
Reduc~iun in profits as a re-
sult of Zosses, thous. R:
- from sales 445.12 170.64 86.82
due zo immobilization of
aboue-norrn stocks 96.62 62.67 20.50
fin~~s for physical shortages 98.68 52.58 14.66 .
Tota1 _i.asses 640.42 285.94 121.98
Losses due to an insuffica.ently efficient organization of the
supply of materials and equipment affect most of the indicators
of the enterprises' operation. A quantitative estimate o~
these losses is possible because of the ultimate reflection in
the mast important cost indicators - production cost and pro-
fit.
The presence of above-norm stocks in the enterprises affects ~
the production costs through the general plant expenditures, in
which the maintenance costs are reflected. A deficit of cer-
tain production stocks leads to additional expenditures by the
enterprises in order to continue produ~tion when the resources
are insufficient, and they either increase the proauction cost
of the entire production or part of it, depending on the type
of ineasures undertaken to eliminate the shortage. In particu-
lar, the replacement of missing stocks leads to a carry-over of
materia]_s and wages, and this is reflected in an increase in
the production cost of those parts whose manufacture required
the missing materials. Thus, the losses due to substitutions
for shortaqes are similar in nature to direct exFenditures for
production, including the production cost. The un~lanned
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.
_ expenditures by supply sections in the enterprises in order to
organize rush shipments ot needed materials are indirECt costs.
They are included in the general plant expenses and increase
. the production cost of all the products. Table 2 shows the ef-
fect of individual items of expenditure for maintaining above-
- norm productive stocks and losses due to a shortage of materi-
als on the production cost of all the commodities praduced dur-
- ing the period under study.
Inefficient organization of th~ supply of industria~ enterpris- _
~ es that increases the producti~n cost reduces the profit from
its realization, which is the princi~al item in the balance-
sheet profi~. Therefore, the losses from the deviation of the
stocks from the norm, which are reflected in the prodi~ction
cost, affect the amount of the balance-sheet profit. In addi-
tion, part of the costs of maintaining the production stocks
and certain losses due to shortages are directly subtracted
from the balance-sheet profit of enterprises operating under
the conditions for planning and economic incentives. This ap-
plies to payments to the budget for working capital to put in
commodity stocks and a percentage payment for credits for pro-
duction stocks, and also the imminent penalty payments for
- late, low-quality, and incomplete shipments of products that
occur because of a shortage of raw and finished materials.
Part of the costs of immobilization of assets in productive
stocks that ref lects the above-norm portion and the fines paid
for violation of contrac~ obligations are losses to the enter-
prises due to the deviation o~ the stock from the norm, which
are not included in the production costs. The effect that los-
- ses of material and equipment supply have on the balance-sheet
profit is shown in Table 2.
Thus, the presence of above-norm surpluses of physical assests
and the simultaneous shortage of certain stocks of raw and fin-
ished materials cause appreciable material ~osses. These los-
- ses not only increase the cost of production but also have a
substantial effect on the most important indicators for thE op-
eration of the interprises. They can be reduced and then elim-
inated by improving the organization of the supply of materials
and equipment and by making the practical application of scien-
tific methods of controlling productive stocks a primary goal
COPYRIGHT: Izdatel'stvo Mashinostroyeniye, VESTNIK ~
MASHINOSTROYENIYA, I980
9370
CSO: 1821
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METALWORKING EQUIPMENT
MACHINE TOOL INDUSTRY, NUMERICAI,LY CONTROLLED MACHINE TOOLS EXAMINED
Progress Summarized ~
Moacow STANKI I INSTRUMENT in Russian No 4, Apr 80 pp 1-2
/Article: "Machine Tool Builders by the 110th Anriiversary of the Birth of
V. I. Lenin"/
/Text/ The workers of the machine tool and tool building industry, like all
the Soviet people, are greeting the 110th anniversary of the birth of V. T.
Lenin with new labor achievements.
Guided bg the decisions of the November (1979) CPSU Central Committee
?lenum an~ the decree of the CPSU Central Commitr_ee, "On the 110th Anniver-
sary of t~a Birth of Vladimir Il'ich Lenin," the collectives of the produc-
tion and ecientific production associations, enterprises and organizations
af the sector have assumed sacialist obligations which are aimed at the in-
crease of efficiency and work quality, the in~rease of labor productivity,
the quickest possible introduction of the results of scientific and techni-
cal progress in production, the improvement of planning and the tightening
_ up of organization and discipline.
The Moscow Machine Tool Building Plant imeni Sergo Ordzhonikidze, the Lenin-
grad Machine Tool Building Froduction Association imeni Ya. M. Sverdlov, the
Ryazan' Machine Tool. Building Production Association and other leading enter-
~~ses of the Ministry of the Machiiie Tool and Tool Building Industry were
the initiators of the anniversary socialist competition in the sector.
The socialist obligations for 1980 provide for the following main measures:
the sale of products in excess of the plan worth 15 million rubles; the pro-
duction for the national economy in excess of the plan of 300 ~achine tools
(inc:luding 140 machine tools with numerical program control), metal-cutting ~
tools (including diamond tools) worth 1.5 million rubles, reducers and
standardized items wnrth 700,000 rubles; the attainment in 1980 of an over-
all increase of production at operating enterprises by~the increase of labor
_ productivity without increasing the nuuiber of.workers.
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Stepped-up obligations on the acceleration of the rate of scientific and
technical progress and the imp:ovement of the structure of tHe equipment be- '
_ ing produced, the most important of whi~h are cited below, have been adopted
for 1980.
By the 63d anniversary of Great October to produce 3,415 test models of ~ew
types of highly efficient equipment and items, to assimilate 3,120 ad~ust-
ment aeries.
To ensure the early development and assimilation of machine tools, machines, "
equipment, instruments anr~ automation equipment with a productivity not less
than 1.5-fold to 2-fold greater as compared with the 1975 level. '
To increase as compared ~,rlth 1979 the output of test models and ad~ustment
aeriea of new highly efficient machine toola with numerical program control
by 12.4 percent, machine tools of especially high preciaion by 12.6 percent
and automs.tic and aemi-automatic machines of all technological groups by
6 percent.
To increase the output of machine tools with numerical program control in
1980 to 6,000 units, including machine tools with the automatic changing of -
tool to 2,800 units.
To produce and perform the ad~ustment and testing of tw~ automated sections -
of models ASV-22 and ASK-11 from machi,ne tools with numerical program con-
trol, which are controlled by computer.
The assimilate the output of the ad~ustment series of 35 models of automatic -
� and semi-sutomatic forge and press tnachines of all technological groups,
5 models of forge and press machines and units with program control, 20
models of forge and press machines and units for obtaining precision blanks
and 7 models of heavy-duty and unique forge and press machines.
To produce ahead of tim~ quickly read~uatable automatic linea with numerical
program control (two unite), which consiat of semi-automatic lathes of model
1B732F3 and automatic manipulators with program control; a unit consisting
of three automated, lines (for assembling tr.actor engines), the use of which
will increase the. productivity of assembling 2.6-fold; a unit consisting of
five automatic lines, the use of which for the machining of parts of motox
vehicles wi11 make it possible to release 134 general-purpose machine tools
and about 270 workers. .
By the 110th anniversary of the birth of V. I. Lenin to produce the test
models of milling machines (made by the Odessa Plant of Milling Machines
imeni S. M. Kirov, the Vil'nyus Komunaras Machine Tool Plant and the Dmi-
trov Plant of Milling Machines) with amall devices for numerical program
control on the basis of microcomputers, which ensure the preparation of the
control programs at the workplace.
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To produce the test models (the Sterlitamak Machine Tool Plant imeni V. I.
Lenin, the Gomzl' Machine Tool Plant imeni S. M. :Cirov, the Molodechno Ma-
chine xool Plant) and the adjustment series (the Odessa Plant of Precision
~ Machine 'lools imeni XXV s"yezda KPSS, the Vil'nyus Zhal'giris Machine Tool
Plant) of multitool machine tools with numerical program control, which are
built according to the standard-unit principle from standardized assemblies
and ensur~ an increase of productivity by 2-fold to 3.5-fold.
- T~~ prodtice the adjust~ment series of new lathes (the Srednevolzhskiy Machine
Tool Plant of Kuybysh~v, the Moscow Kr~snyy proletariy Machine Tool Plant
- imeni A. I. Yefremov) and the test model of a lathe (the Ryazan' Machine
To~l Bu?lding Production Association),with small devices for numerical pro-
gram control on.the basis of microcomputer.s~. At the Moscow Plant of Jig-
Boring Mschines to.produce a high-precision,~ig-boring machine with a tool
box and a device for numerical program control on the basis of mierocom-
puters. .
At the G'oronexh Production association ior the~~0utput of Heavy-Duty Power
Pressea to produce crank shears (five units) for`the precision cutting ~f
blanks; the use oi the shears will provide a saving of inetal of up to 10
percent and ~rill increaae the productivity of machining 1.8-fold.
P,*_ tne T=.i~;~nrog Plan~ of Forge and Press Equipment to produce an automatic
:.~ain-cr2.,~.~-. atamping macnime, which ensures an increase of labor productiv-
ity by :.~1n`old. ~
Tre furt,:-~c increase of labor productivity is the most important ~ondition
of the auc~e~sful fulfillment of the socialist obligations, adopted for 1980.
Tak_tug tr,is into account, a set of target and additional measures on the
nechanizatian and automation of production processes, the reduction of the
pr~por.t~on of manual labor, the improvement of the use of working time, the -
increase ox the skil~.s of worke-rs and engineering and technical personnel,
the int~.ouuction of advanced know-how and others have been drawn up in the
Mia:j.a~ry of the ~fachine Tool and Tool Building Industry. Of the indicated
meaEUres the main ones are cited below.
1, The introduction in production of not less than 1,000 machine tools with
~ irp=ical progrzm control, which will make it possible to release 3,000 work-
ers and 1,380 general-purpose machine tools.
2. The early installat:ton, ad~ustment and placement into operation of 14
_ automatic and 100 mechanized flow lines; 1,360 units of highly productive
- aquipm~nt {~utomatic machines, standard-unit and special machine tools);
69't conv~yers, transporters and other materials-handling machinery; 56 mech-
anized warehouses.
3. The reduction of the labor-output ratio of machining by 330,000 norm-
hours by using tools made from synthetic superhard materials.
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4. The early fulfillment of the five-year plan on the introduction of ad-
vanced technology, the mechanization and automation of production processes
according to the main indicators by 7 October 1980.
5. The increase of the output of casting by the completely mechanized meth-
od to 998,000 tons, ingots by the method of continuous casting to 25,000
tons, casting with the use of self-hardening mixtures to 830,000 tons, in-
gots made from pig iron obtained in induction furnaces ta 101,300 tons and
the receipt as a result of this of a considerable saving of inetal and other
materials.
6. The introduction at the Bogotol Plant of Fitter's Installation Tools of
two mechanized flow lines for the production of stamped parts with a capaci-
ty of 2,000 tons a year.
7. The assimilation at the Shilute Gidroprivod Plant and the Nikolayevskiy
Pilot Plant of Lubrication Systems of the production of highly stressed
parts made from aluminum allows by chill casting and in~ection molding,
which will make it possible to save 150 tons of rolled aluminum and to re-
duce to ten-seventeenth the labor-output ratio of machining.
8. The introduction at the Kalinin Tsentrosvar Plant of Wel.ded Components
of a set of automated flow lines for the purpose of increasing the output of
welded components in 1980 to 22,000 tons. -
9. The early (by 1 December 1980) placement into industrial operation of
the sectorial automated control system (consisting of 14 subsystems).
- The machine tool and tool building industry in four years of the lOth Five-
Year Plan increased the production volume of commodity products 1.41-fold
as compared with 1975. The national economy received during this period
about 455,000 machine tools, 151,000 forge and press machines, more than
1,000 automatic and semi-automatic lines for metalworking, as well as much
other equipment and tools. ,
In the work on further expediting economic growth it is necessary to use
more extensively the experience of innovators and production leaders. To
assimilate it everywhere, to adopt all the best things born of the initia-
tive of the masses means to put into effect the great internal production
potential. It is necessary to develop more extensive the socialist competi-
tion, which is aimed at the increase of production efficiency and work qual-
ity, to step up the movement for a comraunist attitude toward labor, to in--
culcate in every worker, engineering and technical worker and employee a
genuinely practical attitude toward his job.
Socialist competition is a proven method of achieving high production indi-
cators. Practice has confirmed that competition is an effective lever of
the increase of production, ensures high technical and economic indicators
and plays a leading role in the communiat education of the workers. The
21 ~
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year of 1980--che year of the 11�Oth anniversary of tne birth of V. I. Lenin--
should become a year of shock labor, a year of work in the Leninist way.
The consistent implementation of the economic strategy of the CPSU is in-
separably connected with the increase of produc~ion efficiency and work qual-
ity. TYee drive for efficiency and work quality is making new demands on the
management of the economy of each sector and each enterprise.
The decrea of the CPSU Central Committee and the USSR Council o� Ministers,
"On Inproving Planning and Strengthening the Influence of the Economic Mech-
- snism on Increasing Production Efficiency and Work Quality," affords labor
collectives new opportunities to seek rational methc~ds of management and to
display creative in~tiative. The responsibility o� managers and each work-
er for the fulfillnent of the plan assignments and the adopted socialist ob-
ligations is increas~.ng.
:n the systzm of ineasures on the improvement of the management of the social-
ist ec.:onomy breat importance is attached to the skillful use of economic
levers--cost accounting, the profit, the price, the bonus. Cost accounting
is a n~ethr,d of the planned management of production-,~ which is aimed at the
dchievement of the greatest national economic results and at the increase
of work a~:ficiency and the quality of the products being produced. Cost ac-
counting iaakes it passible to combin_e cpntralized planning and the creative
activity oY the masses, unites the interests of the state, the enterprise
~~nd eac4~ wc~r.~.t~r ari~ promotes the quickest possible solution of social problems.
'f',~e der_rei~ of the CPSU Central Cormnittee, "On the Further Improvement of
Ideoiogica:?. and Political Educational Work," is of enormous importance in
the matter of the communist education of the workers and the furthEr in-
cresse of the creative activeness and consciousness of each Soviet individ-
~a:l. 'The practical implementation of this decree is the primary task of the
party oYganizations of each enterprise and association of the sector. The
- duty o.f the managers of al.l levels is to improve the style and methods of
caork, ta tighten up labor, planning and production discipline and to step
i~?~ the monitorin~ of trie .fulfillment of the plan assignments and the deci~
sions r~~hicr have been made.
1'he workPrs, engineering and technical personnel and employees of the ma-
cl:ins tool and tool bui.Iding industry should apply all their knowledge and
cre~tive energ}~ for the unconditional fulfillment of the adopted socialist
ubligations and the plan assignments of 1980--the year of the 110th anni-
versar~ of the hirth of V. I. Lenin.
CO?YRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980
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UDC 621.914.3-52
Automated Milling Machines
Moecow STANKI I INSTRUMENT in Russian No 4, Apr 80 pp 3-7
/Article by A..N. Bobrov and Yu. G. Perchenok: "Automated Milling Machines'
for the Three-Dimensional Machining of Parts"/
/Text/ The Leningrad Machine Tool Building Production Association imeni
Ya. M~ Sverdlov produces (according to the plans of the Leningrad Special
Design Bureau of Machine Tools) a range of automated milling machines for
the three-dimensional machining of ;~arts of complex form. General-purpose
and special machine tools (for machining items like press molds, propellers
and so forth) are produced.
Depending on the method of setting the tra~ectory of the movement of the
cutter with respect to the part being machined the machine tools are divided _
into two types: profile-milling and milling machines with numerical program -
control. Both types of general-purpose machine tools are produced on the
basis of standardized machine blocks.
The machining of items on automated milling machines is carried out by spe-
cial cylindrical or conical cutters with a spherical tip, which are produced
from high-speed steel or a hard alloy. There are three methods of working
complicated surfaced: the seam, contour and three-dimensional methods.
The technical characteristics of the base models of general-purpose auto-
mated milling machines (with the horizontal positioning of the spindle) are
cited in the table. The following modified versions of machine tools are
produced on the hasis of the base models: with increased movements (vertical
and horizontal); with mirror duplication; paired machine tools and so on.
The production of special five-coordinate machine tools on the basis of -
general-purpose three-coordinate machine tools (see the table) is envisaged
for the machining of especially complicated parts (like propellers, blade
wheels and so forth). In this case a unit with revolving tables is in-
stalled on the table of the base machine tool.
Descriptions of the designs of general-purp~se and special automated milling
machines are cited below.
Milling machine model 6B443GF3 (Figure 1) with numerical program control is
produced on a common base with profile-milling machine model 6B443G and con-
sists of a fixed stand and a moving horizontal table. The base of the
- stand is rigidly connected to the bed. The main working units of the ma-
- chine tool move in the horizontal (the table with the item being mac~iined),
vertical (the cross piece with the headstock seated on it) and axial (the
headstock) directions.
. 23 _
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24
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. ~
>E;
'y ::Cj
_ ~;':1'::.
~te~;` g;
t~ ~
~ h , J~f }j ~r ,
~ry~ ~
d k'' ~ � s ~yy~.' ~ a ~ .'t.
g:,)~,h y~ i
F . ? ~S�::r.
~N.. ,~i .+.,4 +A.r.4�.II~ ' 2 . . v .
Figure 1. Milling Machine Model 6B443GF3 With Numerical Program Coi:trol
- The circulatory lubrication of the combined (sliding and rolling) guides is
accomplished centrally. Telescopic devices are envisaged to prevent cut-
tings and cutting fluid from getting into the guides. The drive of the main
_ movement is derived from an AC motor. The spindle is mounted on precision
roller bearings in the tail spindle and has ad~ustable movement, which is
accomplished manually.
The electromechanical drives of the feeds of the working units are fitted
with quick-response electric motors like t:.e GTG-1, reducers with the mini-
mal clearances and ball-type worm gears. Machine tools with drives of the
~eeds from high-torque motors, which ar.e cc:nnected directly to the lead
screws through special clutches, are also prod~iced. The balancing of the
vertically moving masses (the cross pieces with the headstock) is accomp-
lished hydraulically. A special hydr~ulic clutch has been installed on the
lower end of the vertical lead scre*;r in order to prevent the spontaneous
downward movement of the cross pie~~e with the headstock seated on it (when
the machine tool is shut off and in emergency situations).
The machine tool is equipped wit:i a system for cooling the cutting tool, a
conveyer for removing the cutti*.igs and cutting fluid, as well as a device
which protects the cutting tool from overloads.
The sqstem of numerical program control like the N552 is equipped with dig-
ital display. Inductosins are used as sensors of feedback on the positiAn.
Control of the machine tool is carried out from a panel located on the head-
stock or from the panel of numerical program control.
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Profile-milling machine model 6B444 (Fig~lre 2~hotograph not reproduced7) _
is designed for profiling various items of complicated form, including ~
mirror-synnnetr~.cal items. The machine tool has an original portal arrange- ~
ment with two vertically positions tables. The stand of the machine tool is
set in a base, which is fixed rigidly to the bed. The stand of the master
form, which in the upper portion is connected by a beam with the main
stand, is mounted on the upper surface of the bed. Thus, the chassis parts
�orm a portal, owing to which the machine tool acquires additional rigidity.
Th.e main operating units of the machine tool move in the horizontal (the
t-able with the article being machined and the table of the master form),
vertical (the cross piece with the headstock seated on it) and the axial
(the headstock) directions. The tables of the article and the master form
can move together (in direct duplication) or toward e.sch other (in mirror
duplication). The movEment of the table of the master form is accomplished -
by means of a special rack mechanism.
The profiling instrument is fastened in a special chuck, whictc is mounted
on the headstock, and can be.moved in the horizontal, vertical and axial
directione.
The roller guides of all the operating units of the machine tool, which are
fitted with hardened cover plates, are protected from cuttings and cutting
fluid by telescopic devices. The headstock, the drives of the f.eeds, the
balancing mechanism and the accessory mechanisms are analogous in design to
the correspon~ing units of machine tool model 6B443GF3.
The control of the machine tool is carried out from a special work ~t~ridge,
cahich is equipped with a table, a tool stand, a stand for blueprints, a ;
swivel seat and a partition.
Profile-millin~ machine model 6A445 (see the first page of the cover ~hoto-
graph not reproduced/) is arranged so that during the machining the head-
stock with the tool moves, while the article remains fixed. The main oper-
~ ating units of the machine tool move in the horizontal (the sled with the
stand), vertical (the cross piece with the headstock seated on it) and ;
axial (the headstock) directions. The profiling instrument is mounted on I
thP headstock. The article and the master form are attached to the stands, !
which have been mounted to the table which is rigidly attached to the seat.
The stands have ~oint adjustable movements in the horizontal and axiai di-
rections (moreover, the top stands can be moved with reference to the bottom
stands); all the movements of the stands are mechanized. '
i
The machine tool is equipped with guides with hydrostatic lubrication (for
the movement of the sled of the stand) and with sliding guides (for the
- movement of the cross piece and the headstock). The drive of the main move-
ment is derived from an AC motor. In order to move the headstock and the ~
~ cross piece a ball-type worm gear is used as the output unit of the feed ~
gear, while in order to move the sled of the stand a special screw-rack
sliding gear with a choice of clearance is used.
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Differential reduction gears are used in the feed drivesof the cross piece
and the sled of the stand. The accelerated movement of these units is ac-
complished from an induction motor, while the working feed is accomplished
from a quick-response DC motor like the PGT-2. The machine tool is equip-
ped with an automatic profiling system, a conveyer for the removal of cut-
- tings and cutting fluid, as well as other accessories.
Profile-milling machine model 6446 (Figure 3~hotograph not reproduced/)
has an original arrangement (the horizontal positioning of the spindle and
the vertical positioning of the profiling instrument), which considerably
simplifies the mounting of the article and the master form and ensures the
machining of mirror symmetrical (with respect to the master form) parts.
The main operating units of the machine tool m?;~~e in the horizontal (the
sled with the stand), vertical (the cross piece with the headstock seated
on it) and axial (the headstock) directions.
The profiling instrument is fastened in a special chuck on the carrier and
has horizontal and vertical movement. The vertical movement of the head-
stock is coordinated (by a flexible connector) with the horizontal movement
of the carrier. The flexible connector is made in the form of a steel
belt, which derives motion from the cross piece and t:ansfers it to the
carrier. A mode of direct or mirror duplication is realized depending on
which run of the belt (the top or bottom) the carrier is connected to.
The axial displacement of the headstock kinematically is rigidly connected
with the vertical displacement of the duplicating instrument, which also
has. additional manual adjustable displacements which are necessary for the
ad~ustment of its position with respect to the master form before the start
of the machining. The master form is mounted on a ta~le which is situated
on the seat. The article is attached to stands which have mechanized ad-
~ustable movements.
The main drive, the feed gears and the accessories are analogous to the de-
sign of the corresponding units of machine tool model 6A445.
Tiie control of the ma.chine tool is carried out from a special elevator
bridge, which has independent vertical movement, which considerably facili-
tates the handling of the machine tool and improves the field of view of
the work zone.
Special profile-milling machine model LR266 (Figure 4~hotograph not re-
produced7) is designed for the machining of press molds of large tires ac-
cording to a master form which reproduces one (repetitive) sector of the
press mold; direct and mirror duplication are possible. The adjustment of
the master mold to the initial position (at the start of the cycle of ma-
chining of the next part of the profile of the press mold) is carried out
automatically.
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The machine tool is made from two separate parts, which are mounted on a
single seat. The article being machined is ~~ttached to the faceplate, while
the master for;n is attached to the rotating section located above the arti-
cle. The faceplate and the section have a kinematic connector and derive
motion from a cotmnon drive. The headstock is mounted on a cross sled and
has two mutually perpendicular movements: axial and cross. The angular
orientation of the cutter with respect to the profile being machined is
ensured by ttirning the sled about the guides of the curved stand. The du-
plicating instrument is mounted on the headstock. The control of the ma-
chine tool is carried out from the caork bridge, which is kept from turning
by a pantographic device.
Specifications .
Diameter of the faceplate, mm . . . . . . . . . . . . . . . . . . . 3200
Greatest displacement (axial and cross) of the headstock, mn 1200
- Greatest angle of rotation of the headstock, degr.ees 90
Rating of thP main drive, kW . . . . . . . . . . . . . . . . . . . 6.1/7.3
P.ate of rotation of the spindle, rpm . . . . . . . . . . . . . . . 125-1600
Speed of working feed (axial and cross), mm!min. . . . . . . . . . 12.5~500
Speed of rapid ad~ustment movements (axial and cross), mm/min. 20Q0 -
- Dimensions of machine tool (length ~ width X height), mm...8000 X 7900 X4750
~,'ei~ht , toYis . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
;~pecial >>:~;~j.le-milling machine modeZ LR323 (Figure 5~hotograph not repro-
dr.~ccd/) l.s _installed on ths table of macl~ine tool model 6A445 and is de-
sj_~ied i:c~r che machining of the parts of the press molds of end windings of
't~ydraulic ~enerators. The machine tool has two faceplates (for the article
and the naaster form), wYiich turn together around the vertical axis and syn-
chronously arour~d the horizontal aaes. A special mechanism with the auto-
r~:~a~ic choice of clearances is used for the kinematic connection of the face-
i;iates. The readtng of the angles of rotation is made by round inductosins
ccmbir.ation with a digital disp].ay.
Lhe m~~chi_ne tool makes iL- passible to machine an article by the productive
c~~ntour method of. dupll.cation (instead of the seam method), whicYi also in-
creases the prPcision of the milling. In the process of machining the part -
r.he maving iznits of the machine tool are made fast by hydromechanical
U1-;:nps. The control of the machine tool is carried out by means of a de-
tached panel.
Specifications
- Diameter of the faceplate (of the article and the master form), mm. 1200
Distance from the horizontal axis of the faceplate of the article
to the table, mm . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 _
Distance between the horizontal axes of the faceplates of the
article and the master form, mm . . . . . . . . . . . . . . . . . . 1320
Angle of rotation of the faceplates around the vertical axis,
degr.ees . . . . . . . . . . . . . . . . . . . . . . . . . . . . +90 to -30
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Specifications (continued)
Rate of rotation of the faceplates around the vertical and
horizontal axes, rpm . . . . . . . . . . . . . . . . . . . . . . 0.0005-2.5
Dimenaions of machine tool (length X width X height), mm. . 2100 X 1600 X 3000
Weight, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . 9000
Special milling machine model LR336F3 (Figure 6) with numerical grogram con-
trol is intended for the machining of articles of complicated form (cams,
propeliers, power wheels and so forth) and is designed on the basis of
aeries-produced machine tool model 6B444F3. A special unit, which ensures
_ the rotation of the stock of the article with respect to the vertical axis
and the faceplate with the article with respect to the horizontal axis, is
- mounted on the three-coordinate table of machine tool model 6B444F3. Re-
duction gears with devices for the selection of clearances and the creation
of preliminary tension are used in the rotation gears. The machine tool is
equipped with a system of numerical program control like the N552M. Linear
and round inductosins are used as sensors of the feedback on the position. ~
.
~y
.4,.~..~~ , .
Figure 6. Special Milling Machine Model LR336F3 With Numerical Program
Control
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Specifications
Distance from the horizontal axis of the faceplate to the table, mm. 800
Angle of rotation of the head of the article, degrees. 45-135
- Rate of rotation of the table, rpm . . . . . . . . . . . . . . 0.0016-1.25
Rate of roCation of the head of the article, rpm 0.00125-0.4
Greatest diameter of the part being machined, mm 1000
Greatest weight of the part being machined, kg . . . . . . . . . . . 1000
Design of the Main Units. When machining items on automated milling ma-
chines the duty of the drive of the main motion changes relatively infre-
quently, which makes it possible to use AC electric motors. The gear boxes
are built into the housing of the headstock; the hardness of the working
surface of the teeth of the gears is HRC 45-60. The adjustment of Che
spur gears, which is made according to a special system %
1/, incr~~ases the -
durability of the gears of the drives of the main movement and the feeds.
A flexible nonlinear clutch / 2/(which protects the kinematic circuit
against overloada) and an electromagnetic friction clutch (for slowing) are
_ mounted on the shaft of the motor of the drive of the main movement. The
lubrication of the gear box is accomplished centrally from a pumping station.
The spindle units of the machine tools are made (as a rule) to be twin=
supporting, on roller bearings. The taper of the spiiidic ;7: 24) facili-
tates the changing of the tool and makes it possible to use its mechanized
clamp. Normally closed clamps with disk springs and hydraulic drive for the
release of the tool /-3 / are mounted on machine tools of models 6B443 and
6B444. The spindle is mounted in the tail spindle, which has"manual ad- _
3ustable movement.
Various types of guides are used for moving the units. The combined guides ~
(F'igure 7) of the table of machine tool model 6B443GF3 are rectangular,
- closed, with pretension. The weight of the unit with the part and the ver-
r_ical component of the cutting force are absorbed by.the roller bearinga.
The pretension of the roller bearings is accomplished by ad~uatment devices
with wedges. The horizontal components of the cutting force and the tilting
moments are absorbed by the sliding guides.
Clamps, which clamp the table to the base surface of the mounted guides, are
uaed for the selection of the clearances in the sliding guides during fin-
ishing. During rough finishing the clearances are not selected and the unit
can be moved to the point of contact with the wedges. The latter are
mounted with a clearance not exceeding 0.03 mm. In Figure 7 tY~e wedges are
located in the area of the right-hand mounted guide, one of the surfaces of
which is the base surface. A filled fluoroplastof brand F4K15M5 in combina-
tion with hardened steel is used ae an antifriction material.
Hydrostatic guidea, which are equipped with an automatic lubrication control
system %4 are used for moving units oi great weight. The deaign of the
hydrostatic guides of the table of machine tool model 6A445 is described in
work %5 The guides, as a rule, are protected from cuttings and cutting
fluid by telescopic devices.
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f t
.
Figure 7. Combined Guides of the Table of Milling Machine Model 6B443GF3
The feed drives are electromechanical. Ball-type worm gears (for movement
of up to 2 m), as well as.rack or screw-rack gears (for greater movementa)
are used as the output units for movements of the units. T'he kine~atic
diagrams of the feed drives are made, as a rule, with the compulsory selec-
tion of the clearances /5 and 6/, the standard diagram of which is cited
in 'r~'gure 8. This diagram is used in the drives of the advances of the
units, which are achieved by means of rack gears, and in the drive of rota-
tion.
t ~
11 ~2
~ 3
% x
. ~ II
~1 11 x x 11
x x
~ X II 1
~ 11 ~i
~ 11
x x
Figure 8. Standard Diagram of the Choice of Clearances in the Kinematic
Circuit of the Feed Drive
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The power conr.act of the kinematic circuit is made by the axial displacement
of the shaft 3 of the rPduction gear under the influence of the spring 2
(or hydraulic cylinder). Pretension is created in the circuit owing to the
spiral gears which are rigidly fixed for the shaft 3(with the same angles
of inclination of the opposite direction). The di.agram from work / 7 7 is
used ii it is necessary to choose the clearance in the drive which comes di-
rectly from the:moto'r 1: Some other means of selecting the clearances are
also described~~ in' work / 5/.
The lead screws are fitted with sets of thrust bearings, which absorb the
axial forces and are mounted, as a rule, on two sides (to increase the ri-
gidity of the feed drive).
Automatic Control Systems. The~rofile-milling machines are equipped with
automatic duplicating systems / 8/, which operate in the contour mode (with
an unlimited angle of duplication and compensation of the influencs of the
actual angle) and the seam mode (with an angle of duplication of f'90~, with-
out co~tpensation). The tracing block is constructed according to the prin-
r_iple of phase control; a proportionate-integral regulator is used to in-
crease the precision of duplication. The feed drive is thyristor, servo
and re~ulated. Motors of series PGT with an unslotted armature are used as
the servo motors, ta~hogenerators buiit into rhese motors are used as sEn-
sors of .feedback on the speed. The dr'.ve can also operate with high-torque
mntors.
The expz~-i,ence of using machine tools, which are equipped with the described
d~splica~~ng systems, has shown the simplicity and convenience of the con-
struction af the systems, as well as their great stability and reliability.
The precision of the tracing is characterized bq the following indicators
/ 8/: t}~e steady-state error with a tracing speed of not more than
- 2~0 mm/min is �0.03 mm in the seam mode and �0.02 mm in the contour mode;
ti:e transient dynamic error during a"point-blank approach" on a laboratory
bench is 0.08 mm(the tracing speed is 1,000 mm/min). The real value of
tn~ dy~iamic error depends on the parameters of the servo motors oi the
machine tool equipped with this system /S
Milling machines are equipped with systems of numerical program control
?ike the N552. Inductosins mounted directly on the servo device are used
as the sensors of feedback on the position. The program is recorded on a
standard perforated tape (25.4 mm wlde) in the ISO coding system and is fed
in from the panel of the system of numerical program control. The discrete-
ness of the assignment of inrormation is O.OI mm.
Without changin~ the control program, it is possible to perform the follow-
ing operations on the machine tools: mirror machining (male and female dies);
production on a reduced scale (1 :2; 1: 1.5; 1: 10); the mounting of a tool
of a different length and diameter; the change of the allowance for the next
machining. The system of numerical program control is equipped with a
digital display.
32
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The Precision of Machining. Since automated milling machines are intended
for the machining of complicated surfaces, the precision of the reproduction
of the form, which is characterized by the sum of the maximum deviations of
the real surface of the part from the ideal surface, which is identical to
the set shape, is decisive for them. The precision of machine tools changes
subject to the type and mode of machining, the dimensions and shape of the -
item and the rate of feeding.
The extreme indicators of precision are conventionally called the static and
dynamic error / 5/. The static error (the steady-state error wlth the mini-
mum rate of feeding and a large radius of the equidistance to the set shape)
characterizes the maximum attainable precision of the machine tool. The dy-
namic error (the transient dynamic error with the maximum rate of feeding
and the greatest d:ty, which corresponds to the circumvention of the inter-
nal right angle) characterizes the guaranteed precision with the maximuu~
productivity of the machine tool. For any other conditions the error of the
machining is within the indicated boundaries.
The static precision of profile-milling machines is �(0.02-0.10) mm, and with _
~ the contour method of machining it is, as a rule, higher than with the seam
method. The dynamic precision of profile-milling machines is governed by
the parameters of the mechanisms of the machine tool and is, for example,
for machine tools of models 6B443F and 6B444 0.4-0.5 mm with a tracing
speed of 1,000 mm/min. In mirror duplication the precision of machining
decreases. The static precision of milling machines with numerical program
~ control is �(0.02-0.05) mn, while the dynamic precision does not exceed
O.T From the cited data it ie evident that the static precision in ma-
chining on profile-miiling machines and milling machines with numerical
program control is approximately identical, while the dynamic precision is
considerably higher in machining on milling mactiines with numerical program
control.
BIBLIOGRAPHY
~ l. El.'yasberg, M. Ye.; Vil'fson, I. I.; Gidaspov, I. A., and Perchenok,
Yu. G., "The System of Ad~ustment of Straight-Toothed Gears," STANKI I
INSTRUMENT, No 10, 1971, pp 6-8.
2. Patent No 238962 (USSR). -
3. Bobrov, A. N.; Varlamov, M. K.; Nizhnik, Ye. G., and Perchenok, Yu. G.,
"The Mechanized Clamp of a Tool," STANKI I INSTRUMENT, No 4, 1973,
PP 28-29.
4. A~ranovskiy, S. N., and Zvonarev, N. M., "Automatic Control Systems of
Hydrostatic Lubrication," S'PANKI I INSTRUMENT, No 7, 1976, pp 12-14.
5. Bobrov, A. N., and Perchenok, Yu. G., "Avtomatizirovannyye frezernyye
stanki dlya ob"yemno~ obrabotki" /Automated Milling Machines for Three-
Dimensional Machinin~/, Leningrad, Machinostroyeniye, 1979, 231 pages.
33
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6. Avdushev, S. A.; Gidaspov, I. A.; Demidov, S. V., and Perchenok, Yu. G.,
"Ispolnitel'nyye mekhanizmy bystrodeystwyushchikh sledyashchikh sistem
stankov" /Servo rlotors of High-Speed Servosystems of Machine Tools/,
Leningrad, LDNTP, 1975, 40 pages.
7. Patent No 574565 (USSR). -
8. Avdushev,' S. A.; Go1'dshmid, S. F., and Demidov, S. V., "Avtomati-
cheskiye kopiroval'nyye sistemy stankov" /Automatic Duplicating Systems
- of Machine Tools/, Leningrad, LDNTP, 1974, 36 pages.
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980
UDC 621.9.06-529-583.6
Precision Machining on Lathes
Moscow STANKI I INSTRUMENT in Russian No 4, Apr 80 pp 11-12
/Article by Zh. N. Kadyrov, E. L. Zhukov and K. P. Dolgov: "Increasing the
Precision of Machining on Lathes With Numerical Program'Control"/
/Text/ ~xperiments conducted at the Special.Design Bureau of Machine Tools
(Leningrad) established that when working with a lathe of model 16K20F3 with
the lubrication of the guides of the saddle with industrial oil the preci-
sian of the production of parts is within the range of quality 9-10. A spe-
cial device (Figure 1) was developed for increasing (as required) the pre-
cision oi machining by dimensional deviation control.
3 a_a
~
- - _ :
c- ; ~ s
. ,
.
i
- Z ~
, X
; -f- -H -4- ,
� a s ~v
. ~
Q
- r -~~t
f~
~ ~ ra n ~s s
Figure Special Device for the Adaptation of Tools
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The tool holder 1 by means of flat springs 2, 3, 4 and 5, which are mounted
on its facing surfaces, is attached to the housing 10 of the device. A
double-arm lever 19 with the rollers 20 located at its ends is mounted on
the tool holder. This lever forms with the cams 18 and 12 (they have a dif-
ferent characteristic slope and direction of the contours) a differential _
cam gear.
Cam 18 is rigidly attached to drive shaft 7, while cam 12 is connected with
it by means of a controllable clutch. Half-coupling 15 is realized on the
face of cam 18. Plungers 11, which are connected with half-coupling 14 and
brake disk 9, are fitted in the openings of cam 12. Springs 13 are posi-
tioned on the plungers 11. The pistons 16 of the pneumatic drive of the
clutch are mounted in the openings of cam 18. These pistons make contact
with the half-coupling 14 through ball bearings 17. The described device
is mounted in the tool holder 6 of the machine tool instead of a cutter.
During ad3ustment rough displacements (over a wide range) of the tool hold-
er 1 with respect to the housing 10 of the device are made by rotating the
cam 18. Here the cam 12 is checked by the brake disk 9, for which compress-
ed air is fed through a connecting pipe into the working chamber of the
pneumatic drive of the clutch. The pistons 16 act on the half-coupling 14 ~
through the ball bearings, disengaging it from the half-coupling 15 and
pressing the brake disk 9 against the facing surface of the cover 8.
When the feeding of compressed air is halted, under the influence of the
springs 13, the brake disk loses contact with the face of the cover 8,
while the half-coupling 18 couples with the half-coupling 15. The simultan-
eous rotation of came 18 and 12 causes displacements of the rollers 20
(which are different in magnitude and direction). Here precision displace-
ments, which are determined by the displacements of the rollers 20, are im--
parted to the tool holder 1 through the double-arm lever 19. The drive
shaft 7 is turned by means of a step-by-step motor.
The differential cam gear has ranges of displacements of 4 mm, which are
sufficient to eliminate the inaccuracies in bringing the cutter up to the
required set-up size (rough displacements, a discreteness of 0.005 mm) and
to further offset the initial errors of machining (fine displacements, a
diecreteness of 0.0025 mm). This makes it possible to increase the preci-
sion of machining to quality 7-8. The making of the flat springs 2 5 differ-
ent in rigidity increased the resistance of the device to vibration, as a
result of which the roughness of the surface being machined decreased.
Such a device is used for machine tools with a single-position cutter head.
For machine tools with multiposition cutter heads it is advisable to carry
out the ad~ustment of the cutter by moving the carrier, if in this case
sufficient precision and stability of the bringing to the required position
are ensured. This is achieved by the reduction of the friction in the
guides, for example, with the use of shock-proof plastics which are based
35
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on fluoroplastlas the material of the mounted guides. It has been ~stab-
lished that filled fluoroplast F4K15M5 has the most favorable iric:tion char-
acteristics. Thus, its coefficient of friction sub~ect to the slip velocity
almost does not change, while when working in combination with pig iron the
coefficients of the friction of starting and movement are practically the
same and do;npt exceed 0.08-0.09. ~
8 9 .
t
7
s,
10
~ 6 S k 3
Figure 2. Stand for Determining the Precision of the Displacement o� the
Carrier
The precision of the displacement of the carrier with the mounted guided
r,,~de fro~r~ filled fluoropl3st F4K15M5 was studied on a stand (Figure 2), which
was assembled on the basis of the saddle of the machine tool. The carrier 1,
which under the action of the spring 8 makes contact with the slanted
slide 6 through the point bearing 5, was displaced by this slide by means
of the screw 3. A measuring head 7 was used for the precise recording of
tha displacement of the slide. The slanted slide with the screw and the
measuring head were mounted on a plate 4, which was rigidly attached to the
saddle 2 of the machine tool. The force of the spring 8 was regulated by
a acrew 9. During the study they assigned various values of the displace-
mPnts (from 0.01 to 2 mm) of the carrier of the machine tool and for each
va.l.ue repeated the experiment 10 times. The actual positions of the car-
*i~=r when it reached the checking point ;,~ere recorded according to the read-
ing of the spring measuring head 10 (the scale division is 0.2 �m).
The deviations x of the actual positions of the carrier of the machine tool
from the set positions were regarded as random values. The precision of the
ad~ustment was estimated by the cumulative deviation A(which was calculated
according to the algebraic difference of the extreme arithmetic means ~ and
1. K. P. Dolgov, M. K. Varlamov, "Metodicheskiye rekomendatsii po prime-
neniyu ftorlona v kachestve nakladnykh napravlyayushchikh" %Methods
Recommendations on the Use of Fluorlon as Mounted Guides/, Leningrad,
Special Design Bureau of Machine Tools, I977, 28 pages.
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the standard deviation The plots of the precision of the ad~ustment
of the carrier of the machine tool with mounted guides made from filled
fluoroplast F4K15M5 are cited in Figure 3. As is evident, tha use of the
~ mounted guides makes it possible owing to the increase of the precision of
ad~ustment of the tool to produce parts with a precision quality of 7-8.
Here the smoothness of the displacement of the carrier and the reduction
of the force of Che feed drive are noted.
x, Mm
6
t
~ ~
~
2
~ ~ i.. ?
~ ~ ? ~
- .
0 -
.Z 1
.y 1 -
�
z ~ 6 Q ~ r
_ Figure 3. Precision of the Ad~ustment of the Carrier of a Machine Tool With
Conventional (Solid Line) and Mounted Guides Made From Filled Fluoroplast
F4K15M5 (Broken Line); N is the number of the checking point; the middle
lines are the change of the values of x, the outside lines are the bound-
aries of the intervals '~3 0'.
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980
- UDC 621.9.06-529
Simplified Numerical Programming
Moacow STANKI I INSTRIIMENT in Russian No 4, Apr 80 pp 12-13
/Article by Ya. G. Gol'din, A. Yu. Mal'chik and L. N. Faynshteyn: "A Simpli-
. fied Device for the Numerical ~ontrol of a Machine Tool According to Fixed
Programs"/
/Text/ The device being described is designe~ for implementing fixed cycles
of the operation of a machine tool, which cr,ntain as components of che path
af the tool segments of lines, ares of circumferences and other curves.
The minimum amount of variable numerical information ia required for setting
thesP cycles. The following can serve as examples of such cycles.
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~
. / R� ;
:
R
; / , b> .
a ,
j~ , -
R~ -
/ � %
C) d~
~'igure 1. Exampl.es of Cycles is the radius of the cntter): a--the ma-
chining of a circumference by milling; b--the milling of a rectangular area;
c--th~~ milling of a rectangular bed; d--positioning for the machining nf
- six hol?s.'
The machining of a circumference by milling (Figure la); the path of the
tool consists of semicixcumferences o.f the contact and wi*_hdrawal of the
cutter and the compl:ete'circumference of the working motion. One number~--
the radi~~s of the equ~distance to the circumferen~�e bei.ng machined--is r~-
qu~red to set the cycle. ~ ~
The machining of a rectangular area by milling (Figure lb) with the setting
oz three parameters: the ler?gth of the pass, the feed per pass and the num-
~ ber of passes.
~ The mdchining of a rectangular bed by milling (Figure lc). The path con- =
sists of four interlinking ares and two pairs of segments and is set by
three garametera: the radius of the equidistant ares and the lengths of the
s~~ments. -
~ositioning for the machining of regularly spaced holes (Figure ld), particu-
i~irly four, six or eight mounting holes lying on one circumference, for which
it is necessary to ser two parameters--the radius of the circumference and
the number of holes.
The threading, for which tne pitch of the thread and the depth of the cut-
ting are set.
It is advisable to use simplified devices of numerical control according ta
fixed prograa~s, ~ahich implement one of the cycles, for special and special-
ized machine tools.which are used for producing parts of a single configura-
t{.on. The form of the path of the tool and its numerical characteristics
are constant and are enr_ered in a permanent memory (II3Y) during its produc- -
tion. Only the correction for the size of the tool is variable information.
38 -
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The devices in question can also be used for general-purpose machine tools
as autonomous devices which implement a set of cycles. Such devices in-
crease the productivity ofthe machine tool (automatic positioning for the
machining of regularly spaced holes, the milling of beds and areas), make it
possible, moreover, to reduce the expenditures and to shorten the period of
preproduction (for example, owing to the reduction of the nomenclature of
tool chucks when replacing the boring of holes ~y milling), as well as to
simpl~,fy the design and to reduce the labor-output ratio of the production
of the machine tool.
The simplified devices, first of all, are characterized by a small amount
of input (variable) data and a limited number of modes of operation; they
control, as a rule, no more than two coordinates simultaneously. This makes
it posaible to discard all types of digital display and input devices with
- a program carrier and to reduce the control panel. The mentioned circum-
stances make it possible to design the simplified device (including the
power supply system) in the form of a block with a volume of up to 25 dm3,
by using only widespread electronic components. Such a block can be in-
stalled in the electrical box of the machine tool.
In a number of instances the simplified device of numerical program control
proves to be preferable to the operational and productive systemsl of pro-
_ gram control. First, such a device does not require an increase of the
area taken up by the electrical equipment of the machine tool. Second, the
atandby block of the simplified device can be included in the set of the
delivery of the machine tool, which considerably facilitates repair in case
of the breakdown of the device. Thus, the simplified d~vice in practice
does not worsen the maintainability of the machine tool (as compared with a
machine tool without numerical program control) and does not increase the
- idle time during repairs. Finally, the cost of the simplified device is
considerably lesa than for any traditional devtce of numerical program
control.
A simplifed device of numerical program control for milling machines, which
are intended for the machining of the parts of a tractor according to the
outer contour, was designed at the Special Design Bureau of Machine Tools.
These machine tools can be incorporated in an auton?atic line.
_ The device is a part of the electrical equipment of the machine tool. It
operatea according to a rigid program which specifies the preliminary cal-
culations, which are connected with the consideration of the real radius of
the cutter, the formation of all the segments of the path of the center of
_ the cutter and the control of the rate of its movement during machining. -
The manual control of the movements of the units of the machine tool is also
carried out by means of this device.
1. V. S. Vasil'yev, A. G. Rozinov, "Prospects of the Development of Systems
of Numerical Program Control of Machine Tools," STANKI I INSTRUMENT,
No 9, 1978, pp 3-5.
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~
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Y , '1
3 ~ Q
- ~ R ..d' ~~,a
- �1 ~
o ~ fn
9~ a^ B ~
X
Figure 'L. Diagram of Che Machining of an Item: I--initial position of the
_ cuCter; IJ--the path of its center; III--the contour being machined; 5-14--
the camponPncs of the program; A--the distance from the contour of the item
to the c~ater of the cutter in the initial position; B, C, RR -the dimen-
' 9~ORS ~f the iteni; D--the rated allowance.
The contour of the part being machined and the path of movement of the cut-
ter, whir_h is broken down into segments, are shown in Figur~ 2. The rigid
program consists of 14 components (see the table). The dimensions A, B, C _
and RA are constant for the part being machined and its positioning on the
machine toal and are entered in the permanent memory of the device. The di-
mension D, which characterizes the allowance for machining, is also con-
tained in the permanent memory, but can be recalled for a batch of blanks
over the range of 9-20 mm (with a spacing of 1.28 mm).
The device ensures four different settings of the contour speed: on the
:iinear and curved segments of the equidistance, during the cutting in, as
well as in the approach to the item (and return to the initial position).
The operatienal ad~ustment of the contour speed from the panel of the ma-
chine tool is also possible.
The structural diagram of the device (Figure 3) contains the main units
which are typical of the standard device of numerical program control. The
processor B, which performs the preliminary calculations, the linear and
cixcular interpretar_ion arid transfers by compoiients of the program, is cen-
tral in the strucziire. The arithmetic unit AY along with the sources of
data (03Y1, 03Y2, lI3i' and the input switch R~) performs the algebraic sum-
mation in binary code sequentially by tetrads.
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Contponent of
program Purpose of the component of the program
1 Clearing of the memory
2 Conversion of the value of the radius R~ from binary-
decimal code into binary code
3 Calculation of the radius of the equidistance of the
curved segments R~ + RA
4 Calculation of the distance from the tool to the item
A - R~
5 Di~placement in the negative direction of the Y axis by
the distance A- R~. Change in the speed at the distance D
from the item
6 Displacement in the negative direction of the X axis by
the djstance B
7 Displacement along the arc in the second quadrant
8 Displacement in the negative direction of the Y axis by
the distance C
9 Displacement along the arc in the third quadrant ~
10 Displacement in the positive direction of the X axis by
the distance B
11 Displacement ?long the arc in the fourth quadrant
12 Displacement in the positive direction of the Y axis by
the distance C
13 Displacement along the arc in the first quadrant
14 Ret~rn to the initial position by movement in the positive
direction of the Y axis
- Note: S+~e the dimensions I~, A, D, B, C in Figure 2.
To represent the number with a sign 16 digits are used, which with a dis-
creteness of 0.01 mm makes it possible to obtain the radius of the arc and
- the length of the segment of up to 310 mm. The time of an opzration on one
tetrad is 2~ts, which ensures a~,rate of the aperations on the numbers of
125 kHz and an output frequency of the unary code of diaplacements of up to
30 kHz. In the device being described in conformity with the technological
requirements the output frequency does not exceed 3 kHz.
Before the start of the movement preliminary operations on the transforma-
tion of the code and preliminary cal~ulations are performed in components
1-4 of the program (see the table). 'rhe value of the radiua of the cutter
in binary-decimal code is transmitted from the awitches via the t+lock of
optrons and relays BOP to the input of the multiplexer MII and is transformed
into a value in binary code. The transformation is carried out according to
a standard algorithm, which contains the tenfold summation of the function ~
of the preceding decades of the code of R~ and the addition of the result
with the value of the subsequent decade. The total time of the preliminary
operations is not more than 1 ms.
~ 41
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~.1 l_.._. . .
I ' n3~ Mn A9 .~v .
Rm I
~ I I
~ Q7.Y1 0J9? C9!( Y1/ �
l~. . _
~ f
I .
Y ~
~ 93C 3KN ,
_ JCN
:K, - Ur
L. N.vn .
n
en er2 '
.
~
Figure 3. Structural Diagram of tne Device: BOP--block of optrons and re-
J.ays; 3CH--setting of the speed and direction of displacements; IdYIt--unit
of. the msasurement and control of the drive; II3Y--permanent memory; MII--
niultipl.exer; YCO--device for comparing the operands; 03Y1 and 03Y2--main
memories; C9L(--recorder of the components of the program; YY--control unit;
~'3C--speed setting device; 3KH--device for setting the coordinate and the
direction; I3T1 and BT2--rotating transformers; Rip--radius of cutter; v--con-
tour speed; tx and ty--commands for displacements; OX and Oy--signals on the
l~cating of the cutter in the initial position; UX and Uy--voltage of the
control of the drive.
tdith ~ displacement along the coordinate axes in components 6 and 8 of the
program the value of the actual coordinate is stored in 03Y2 until it coin-
cides with the dimension requested from the II3Y. Similar displacements in
componentg 5, 10 and 12 are made until the cumulative value returns to zero.
The l.ast displacement (component 14) is accomplished in the mode of the re-
~~urn to the initial position, which is recorded by the sign "0 step" after
the tripping of the terminal switch of the selection of the zero step.
For the circular interpolation in components 7, 9, 11 and 13 of the program
the method of the evaluation function is employed with the use of the func-
tions F~,+1= Fi+xi+l for a step along the X axis and Fi+l� Fi-yi for a step
along the Y axis, where Fi and Fi+l are the values of the evaluation func-
tions before and after the step, and Fp=O; xi and yi are the values of the
actual coordinates with respect to the center of the arc. The values of Fi
_ are contained in 03Y1, while those of xi and yi are contained in 03Y2. The
achievement of a zero value of the diminishing coordinate is an indication
of the completion of the curved se~ment. ~
42
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The identification of the coincidences with the constants or with zero is
accomplished in the device for comparing the operands (YCO) and leads to the
awitching of the recorder of the components of the program. The control
unit of the processor (YY) organizes the performance of the operation by
tetrads, controls the selection of the numbers from the 03Y and II3Y and the
setting of the axis and direction of diaplacement in conformity raith the
number of the component of the programe
03Y1 and 03Y2 are each made on the basis of a K155PU2 integrated circuit.
The two lower-order digits of the address of the 03Y are used for the selec-
tion of the tetrad, while the two higher-order digits are used for the selec-
tion of the number. The rate of movement during manual control or the ad-
~ustment of the speed during the running of the cycle is set by the magni-
tude of the voltage coming from the control panel of the machine tool.
The speed setting device (Y3C) carries out the transformation of the magni-
tude of this voltage into the frequency of the pu.ises in conformity with
the component of the program, ensuring the uniformity of the speed on the
curved segments. The device for setting the coordinate and the direction
, (3KH) forma the unary codes of displacement on the commands tx, �y from the
~ panel in the case of manual control and on the commands of the processor
when running the cycle.
The unit of the measurement and control of the drive (I3YII) carries out the
power supply of the rotating transformers, which perform the functions of
sensors of the position of the units of the machine tool, forms (on the sig-
nals of the sensors and according to the assignment of displacement) the
voltages UX and Uy of the control of the drive, the signals OX and Oy on the
locating af the units in the initial position, as well as the signal II on
the exceeding of the permissible error. This device has a universal struc-
ture; the sensors are used in the phase mode with the maintenance of a di-
rect voltage.
The block of optrons and relays ensures a high noise immunity of the device
of numerical program control as a result of the separation of the integrated
- circuits by galvanization with all the peripheral units (the units for set-
ing R~ and controlling the machine tool, the sensors of the position, the
�~ed drives and the components of the automatic electrical equipment).
Suecifications
P7umber of controllable coordinates . . . . . . . . . . . . . . . . . 2
~iscreteness of the setting of dimensions, mm . . . . . . . . . 0.01
l~.aximum linear displacement and maximum radius of arc, mm . 320
Li~its of speed regulation, mm/min . . . . . . . . . . . . . . . . . 5-1000
riaxi~num assignable radius of the cutter, cran . . . . . . . . . . . . 99.99
Ge~r ratio from the working unit to the sensor, rmn/revolution 20
Dimension of device, including power pack (length X width X height),
"~II. . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 X 320 X 235
Rate3 input, W . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980
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UDC 621.9.06-529-531.3:681.325-181-48
Microprocessor Feed Drive -
,~~Ioacow STANKI I INSTRUMENT in Russian No 4, Apr 80 pp 18-20
- /Artic~e by V. L. Sosonkin and Yu. S. Malyuga: "A Microprocessor Feed Drive
for Machine Tools With Numerical Program Control"/
/TextJ The use of a microprocessor in the control s~~:si~.em of the feed servo-
drive makes it possible to increase the reliability and quality of the opera-
tion of the machine tool, to improve the dynamic properties of the drive, '
to obtain additional infortnation on the inaccuracy of the shape (by calcula-
tions with allowance made for the actual errors in conjunction with the
operating drives) and others.
_ We atudied the microprocessor electrohydraulic control system of the feed
servodrive for machine tools with numerical program control. The features
of the developed system (Figure 1) are the lack of electronic devices of
analogous functioning; the control of the positioning and speed from one
pulae photoelectric sensor of feedback on the position (the frequency of the
pulses of the sensor characterize the speed, while each individual pulse
characterizes the displacement / 1/); the use of a single-stage servo con-
trol unit (which was built on the basis of a standard E32G18 unitized step~
by-step d-~;ve), which r~ceives discrete control signals.
6cf ' 6CT
/ilf3 UN ~9 M
. OC
Figure 1. Structure of the Control System of the Microprocessor Servodrive:
fiCi and EC2--comparison blocks;IIK3--sequential correction unit; L(~i--digital
ir.tegrator; PY--servo control unit; M--motor; ,qOCII--sensor of feedback on
r.hc posit~.on.
Let us assume that both step-by-step motors in the single-step servo control
unit (Figure 2) rotate in the same direction. The right-hand step-by-step
mctor th-rough the screw gauge nut displaces the central rod and the slide
valve distributor in the axial direction. The left-hand step-by-step motor
rotates the central rod and through the screw of the screw gauge displaces
it along with the slide valve distributor in the opposite direction. From
this it follows that program action can be applied to one step-by-step motor
Qf the servo control unit, while action through the feedback channel can be
applied to the other.
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. ,
_ _ ~',~j.
.
�
' ~
i
Figure 2. Design of the Single-Step Servo Control Unit, Which Is Built on
the Basis of the E32G18 Unitized Step-by-Step Drive ,
In the struc.tural diagram (see Figure 1) the comparison block BC1 and the
sequential correction unit IIK3 are realized by software, while the digital
integrator I~I~I, which forms a signal proportionate to the set speed, belongs
to the hardware. This made it possible to organize the operation of BCl in
the mode of a constant carrier frequency: initially within each period the
relative code increments of the signals of the program and the feedback are
compared, then computation operations in conformity with the correction al-
gorithm are performed on the result of the comparison and, finally, a multi-
digit code enters the input of the I(I3, which controls the contour of speed
control, which is locked in comparison block BC2.
- An Elektronika NTs-03 microcomputer was used for modeling SC1 and II3K; it
was regarded as the basis for building the processor of the device of numer-
ical program control, which can solve problems of controlling the drive.
Such an approach does not rule out the use of a special microprocessor,
which operates in conformity with the ad3usted algorithm in the servodrive.
The blocks of the microcomputer (Figure 3a) include: a 16-digit processor
IIP (it.has eight levels ofpriority of interrupt, high speed in the perform-
ance of operations of addition like "register-register" with a"short" ad-
dressing of not less than 100,000 operations/second and in the transmisaion
of the manipulated variable with a"short" addressing of the storage cells
- of not less than 70,000 operations/second, a capacity of the main memory of
8K words); an arbitrator-timer AT (it carries out the distribution of the
signal$ of the external unified main circuit BYM and the main data transmis-
sion circuits MIII-i of the microcomputer by levels of priority); an adapter of
the main circuits AM (it realizes the logical connective and the electrical
' conformity of the levels of the signals of the microcomputer and the peri-
pheral units). The interaction between all the blocks, as well as between
the microcomputer and the peripheral units is asynchronous; it is governed
by the sequence of the control signals: 3II ("record"), B,I~I~ ("master"), B,I~hI
("dependent") and others. In all instances the signal of the, receiver appears ~
in reaponse to the signal of the source, while the signal of the source is
released in response to the signal of the receiver.
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M6 ~ Q'JN ~
i ~
e
M ~ ~ a I ~E?u 6pn ~
a~ ~ ~
A~ ~ A AI
lli AM ~ ddlll i M6 Lf 1 biOC
OJ9 V ~ EQM i "
~ ~nv
.y ~ ny
~ 3~H I NQ
6? ~ t P3P f~0 . ,
/!D 0
AT g~ `3n b~
rigure 3. Structure of the Con.*.rol Microcomputer (a) and the Connections of
the Interface Block I~ With the Microcomputer and the Servodrive (b): IIP-~- -
processor; 03Y--main memory; IfY--control console; BII--power supply unit;
AT--arbitrator-tim~r; NIlI~i--main data transmission circuit; AM--adapter of
main circuits; BYM--external unified main circuit; A--address line; A--
general data line; B~--master signal; B~I--dependent signal; 3IIP--inquiry;
iTT3-~confirmation of inquiry; 3AH--busy; P3P--permission; IIPEP--interrupt;
3II--record; FIII--interrupt pulse; KII--interrupt code; I'TII--interrupt timer;
sPII and BPOC--buffer registers of the program and feedback; A1 and A2--ad-
dress lin~s of. sPII and BPOC; ,~BX--input data line; ,i~b~--output data line.
The j.nterf~ce block I~iB (Figure 3b) serves as the buffer block between the
microcomputer and the servodrive. In the proceas of operating the BYM is
captured by the block. The capture request, which is initiated by the inter-
rupt timer I'TII, ~nters the I3S and then goes to the AT, which transfers con-
tcol to the HS in conformity with its level of priority (the fifth) in the
sequence: the signal of the fifth level of priority on the line of 3IIP
("inquiry"); the receipt of the signal of P3P ("permission"); the setting
Qi the signal of iTT3 ("confirmation of inquiry"); resetting of the signal
of. 3IIP; generation of the signal of 3AH ("busy"). From the moment of the `
setting of the signal on the line of 3AH the main circuit of BYM belongs to
the HF (the exchange of data begins). .
The process of exchanging data consists of the operations of interrupt,
rt~ad (the receipt of the contents of the feedback channel) and record (the
transmission of the control signal). In the interrupt operation the I~iE and
C'TII are master, while the microcomputer is dependent. In the operations of
the reading and recording of the data the microcomputer becomes master,
whi].e the Nfi along with the buffer registers of the program SPII and of the
feedback BPOC become dependent.
Interrupt begins with the setting by the interface block of the signal of
IIPF~E' ("interrupt") and its transmission to the microcomputer through the
input data line ~X. The processor records the interrupt signal in the
register of the buffer of interrupts and uses it for the evaluation of.the
address of the start of the running of the interrupt program. Further, the
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arbitrator-timer sets the address of the register of the buffer of inter-
rupts in the aadress ~ine A, as well as the signals 3II and B,~(; the proces-
sor receives the interrupt signal and forms the signal B,I�~I; the I~S resets
the signal IIPEP, while the AT resets the signals B,I~q, 3II and address; then
the I~iB removes the signal BJ.~NI.
During the reading the address BPOC is set in line A(in feedback line A2)
and the signal B,I~I1( is set in the corresponding channel. After this the con-
tenta of BPOC are tranamitred to the general data line A, while the tag
"dependent" (which sPOC is) appears in the channel of the signal B,I~i. On
the signal B~I the microcomputer receives the data, then resets the signal
B~�q and ceases the transmission of the address over the line A. The depend-
ent register (SPOC) waits for the resetting of the signal B,I~q and resets
B~I. With this the reading of BPOC is completed.
When recording the address of BPII is transmitted to line A(output data line
A1), the control code is transmitted to line ,q, while the signals 3II and B,~q
are tr.ansmitted to the corresponding channels. The interface block receives
the data from line A, transmits it over line ,i~x to BPII and generates the
signal B,I�I. After receiving the signal, the mi~rocomputer resets the sig-
nals B,t~tq and 3II, as well as the address from line A, after which the I-iS re-
moves the signal B,t~M. With this the receipt of the control signal in the
BPII is completed.
It is possible to generalize the functions of the interface block: 1) the
transformation of the two-way data line of BYM into one-way input and output
lines; 2) the decoding of the address generated by the microcomputer and its
transmission to the peripheral unit; 3) the organization of the interrupt
process at the request of the peripheral unit; 4) the generation and re-
ceipt of the signals necessary for the exchange of data.
The equipment portion of the microprocessor servodrive is shown in Figure 4.
The mode of operation at a constant carrier frequency of 500 Hz, which the
I'TII generates, is a peculiarity of the main algorithm of the operation of
the servodrive. Owing to this mode of operation the microcomputer has a
considerable reserve of time for calculation operations 3nd procedures of
communication with the drive, and this reserve does not depend on the speed
set for the drive by the program / 2/. The routine pulse from the I'TIl, -
which initiates the period of the constant carrier frequency, is a request
for the interruption of the operation of the microcomputer. The processor
of the microcomputer begins the implementation of the program of the run-
- ning of the interruption, which contains the memory of the operating re-
- gisters of the microcomputer, the evaluation and correction of the control
signal and its transmission to the dr3ve, the reading of the BPOC, in which
the data on what was performed during the preceding period of displacement
is stored (it is received from the accumulator, which sums the pulses of the
AOCII within the period), the formation of auxiliary control signals. ~
The microcomputer, after evaluating the control signal according to the pro-
gxam, transmits the code of this signal to the digital integrator i~I through
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the BPII. At the output of the I.~I a signal is formed, which is represented
_ by a unary cor:e, the frequency of the pulses of which is proportionate to
the code of the EPII. The coefficient of proportionality is the coefficient
of the increase of the servodrive in speed.
_......-~!6`----~--~
t
rrn 6c ~
~ ~ r_..~~-
i ~ r /1!'y i
y ~ 6Pl! ((H ~ ~ 3Nl yf , /~1Q1 ~
~ ~ i _s
~ ~ i
~ N6 i
o ~ 6N ' ~9
o , i ~ J/~y
.
~ 6POC n ~ 3HZ 'J2 UlQ2 ~
~ ~ i
. + 1 L____~^_^ ~__.._J
1 ~
i H CCC OC p1 '
L_..._____________J
k'igure 4. Structure of the Equipment PorCion of the Microprocessor Servo-
drive: AE--equipment block; H--accumulator; BC--synchronizing block; EH--
guidance ~loc'r.; COC--feedback system; III'Y--servo control unit; 3K1 and 3K2--
- electronic switches; Y] and Y2--power amplifiers; [l~l and IIIA2--step-by-step
motors; K-~-channel of feedback on~speed; see the other symbols in Figures 1
and 3.
The direction of the movement of the motor M(the hydraulic cylinder or the
hydraulic motor) is selected in the guidance block BH on the comanand from
the microcomputer. If a positive direction of movement is specified, the _
~equence of pulses from the L~i is fed into electronic switch 3Kl of step-by-
sr_ep motor [11~1, while the sequence of pulses from the AOCII is fed into
electronic switch 3K2 of step-by-step motor IIIA2. If a negative direction of
movement is specified, the sequence of pulses of I~i and AOCII changes.
The general algorithm of the the interaction of the microcomputer and the
_ t~quipment portion of the drive is shown in Figure 5. The supervisory pro- '
gram t carries out the preparation of the microcomputer and the drive for
- joint operation. Upon completion of the evaluation of the control signal
the microcomputer restores ttie initial state of the operating registers and
waits for the next interrupt pulse, with the arrival of which the evaluation
is repeated. .
tdith the presence in the main program of the operation of accelerated dis-
placement the channel K(see Figure 4) of feedback on the speed is blocked;
here under the influence of the sequence of signals from the I~i the slide
valve distributor of the servo control unit is displaced to the arresting
device in the extreme position and remains there until the completion of the
mode of accelerated displacement. Thus, the speed of accelerated
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displacement is governed by the maximum capacity of the pumping station (in
practice the speed of accelerated displacement of the servo unit was up to
10 m/min).
i Figure 5. Algorithm of the Interaction
of the Microcomputer and the Equipment
2 Portion of the Servodrive; 1--super-
visory program; 2--resetting of the
' signals of the SPII and BPOC; 3--start
of the I'TII, BC and I~i; 4--beginning of
4+ the running of the interrupt program,
recall of the operating modes; 5--read-
5 ing of the SPOC; 6--evaluation and cor-
rection of the control signal; 7--posi- -
s tive direction of displacenent; 8--
es ? No signal "forward" in the BH; 9--signal
"back" in the BH; 10--there is an
s operation of accelerated displacement;
11--blocking of channel K; 12--record
9 in SPII; 13--restoration of the initial
, state of the operating registers, end
Yes ~o No of the running of the interrupt pro-
gram
~r
12
~J
The main working program of the evaluation of the control signal takes up
_ 60 cella o� the memory 03Y, the aupervisory program takes up 25 cells (the
time of ita operation is not included in the cycle of evaluation of the con-
tral signal) plus 20 cells for the constants, the input and intermediate
data.
When building a drive according to the proposed structure (see Figure 4) at �
a maximum frequency of interruption of 500 Hz (the output of codes of con-
trol data at a frequency in excess of 500 Hz is not required) the
Elektronika-NTs-03'microcomputer controls three drives. The time of a cycle -
of th~ evaluation of the control data according to the proposed algorithm
(aee Figure 5) for one drive is 0.5 ms, the time reserve is 0.5 ms. At a
frequenc�y of the output of the codes of control data, which is equal to
200 Hz, the time reserve in the case of three-coordinate control is 3.5 ms
(the apeed of the microcomputer is not less than 90,000 operations per
second).
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In additional to a single-step servo control unit a high-torque DC motor
can be uaed as the servomotor.
The Cests of the microprocessor servodrive confirmed its efficiency and ac- -
ceptable precision (the coefficient of the increase in speed in a stable
~ mode was set at up to 100 s-1)., The duration of the transient response in
the experi.mental system., in which a G15-2 hydraulic motor was used as the
servomotor, was 6-7 ms. ~ , . - , , �
, - .
_ BIBLIOGRAPHY
1. Patent No 641397 (USSR).
2. Sosonkin, V. L., "The Principle of Organizing the Software of Interpola-
tion in the Case of the Numerical Program Control of Technological
Equipment From Small Computers," VESTNIK MASHINOSTROYENIYA, No 12,
1976, pp 58-61..
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980
UDC 061.3:681.51:621
Conference.on Computer-Assistad Control
Moscow S3AI~TKI I I13STRUP4ENT in Russian No 4, Apr 80 p 37
lArticle vy B. S. Pitskel': "The All-Union Scientific and Technical Confer-
ence 'The Development of IntegLrated Computer-Assisted Control Systems at
Machine Bui.lding Enterprises
/Text% The conference, which was organized by the Central and Umskaya
Oblast Scientific aad Technical Society of the Machine Building Industry,
the USSR State Committee for Science and Technology and the machine building
~niriistries, was held in Omsk from 12 to 14 September 1979. At the plenary
sesaions the most important reports were heard and the decision of the con-
ierence was adopted; the other reports were delivered at the meetings of the
six sections ("Systemwide Questions of the Development and Operation of
fl~itomate~i Control Systems," "Computer Complexes and the Collective Use of
t;omputers," "Automated Control Systems of Technological Processes~" "The
Use of Computer Hardware in the Control of Machine Tools and Units," "The
Automati.on of Instruction at the Higher Educational Institution on the
Basis of Computers").
First Secretary of the Omsk City Committee of the CPSU Ye. A. Norka deliv-
ered the opening address to the participants. He told about the intrc?duc-
tion at enterpri~es of Omsk and Omskaya Oblast of integrated automated con-
trol systems, which cover questions of planning, diapatching and the control
of technological equipment from computers.
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The reports at the pleaary meetings were devoted to /modern equipment/ /in
boldface/, which ensures the development of automated control systems.
Thus, K. V. Peselev (Moscow) told about new computers of series YeS and SM;
V. A. Ratmirov (Moscow) acquainted the participants with the new generation
of devicea of numerical program control, which are built on the basis of
small computers, and with the problems which arise when developing the sec-
tions of machine tools with several levels of the hierarchy. Moreover, a -
number of reports were devoted to /the increase of production efficiency/
/in boldface/ owing to the use of automated control systems of technologi-
cal processes.
The reports on /the experience of operating, already existing automated con-
trol systems of technological processes/ /in boldface/ aroused the greatest
interest of the conference participants. The speakers touched upon the im-
portant question of the need to determine the dependences of the main indi-
cators of product quality on the technological parameters for the drawing
up of scientific and technical documente which are used in dPVeloping auto-
mated control systems. Thus, the report of V. I. Bulgakovi (Kuybyshev),
which wae devoted to the experience of operating an automa.ted control sys-
tem of the technological processes of the molding of microcable, which is
designed for~the overall control of proiiuction and for immediately control-
- ling the process of molding, told about the identification of the main tech-
nological parameters of the process of molding, which influence the product
quality. The .report of V. T. Zaborovskiy (Kishinev) was devoted to a de-
acription of the hierarchical structure of the automated control system of
the technological processes of molding microcable.
The /experience of developing automated control systems for machine building
enterprises/ %in boldface/ (V. A. Malakhovski.y, Omsk) and the development of
automated control systems of the bench tests of engines, clutches and
brakes (N. Yu. Batin, Khar'kov) were told about at the canference. A set
of equipment for gathering and preparing data (KSPD-1), which is a system
with the remote gathering of data which includes terminal equipment con-
trolled by a general-purpose small computer, was also described (Ts. N.
Perel'shteyn, Kazan').
Many reports were devoted to /machine tools and units with numerical program
control/ %~.n boldface/. Thus, in his report A. G. Rozinov (Moscow) reported
on the building of control systems of automatic lines on the basis of pro-
gramming equipment, particularly on single-processor programmable command
equipment. A. S. Chubukov (Moscow) delivered a report on one algorithm
which is used for controlling a grinder. I. R. Podzolov (Odessa) reported
on an automated control system of milling machines on the basis of an
S5-12 small computer.
1. Here and below only the firsti author of the report is indicated.
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The report of V. ^T. Borovik (Kiev) on /the software of the system of dynam-
ic contr.oi of ;i section of machine tools with numerical program comtrol/
/in boldface/ aroused great interest. This system has been introduced and
is in operation at several enterprises. During the discussion of this re-
port the speakers directed attention to the fact that the computer, which
controls the section, can be used fo~ translating the general,language into
the mnemonic codes of each machine tool. This makes it possible to use the
comput=~ for the controi of machine tools with numerical program;control,
which have ciifferent programming codes (ISO, BTsK-5 and so on) and different
program carriers (perforated tape or magnetic tape).
A considerable portion of the reports were devoted to /algorithms of the -
optimizatian af technological processes and problems of the software o�
- uutor.iated control systems of technological processes/ iin boldface/. Thus,
the problem of linear progranming with a large number nf zeroes in the matrix
of coefftcients in the presence of unknowns was examined in the report of
Ye. A. Karagodava (Kiev) on the algorithm of the formatioYi of a productian
program f~r enterprises of the discrete type. The report of V. D. Diptan
~ (Kiev) told about the solution of r.he problem of circumventing the points _
of drilling of plates by the shortest path by means of the algorithm of the
_ cotnputer designing of programs of the control of drilling on machine tools
with numerica7. program control. -
~ev~ral ~f~~orts were devoted to /s_mulation models of automated control ~ys-
te~es/ /in ~oldface/. At times the model is a queuing system, while the solu- _
= tion is o'~i~ained b_y analytical methods (Ye. F. Babushkin, Riga~ . Hoc~ever,
- as the discussion at the conference showed, more often an attempt is made
' to study the system not by analytical methods, but by means of computer-
assisCed ~a3eling. Here the GPSS/360 modeling system (a packag~ of applied -
prograris) is used, as, for example, ir. the study of the productj.vity of auto-
r.~atic lines (Xe. I. Korovyanskaya, Moscow), in the solution of the problem
;;f sctleduling for the machine building enterprise (V. G. Mogila, Kurgan),
in tl:e study of the characteristics af the use of equipment in automated
carjlplexes made up of machine tools with numerical program control, which
are cont ralled from a computer (A. V. Zav'yalov, Mo~cow).
_ In maay reports, which were devoted to /the mathematical modeling of auto-
m~:r.ed control systems/ /in boldface/ or some aspects of it (economic, infor-
mation, reliability), they examined in addition, on the basis of what data
H ane model or another should be built.
Much attenti.on was devoted to /systems of the automated designing of auto-
:nated control systems/ /in boldface/. In particular, they told about the _
multist.age model of the synthesis of autamated control systems on the basis
of collective-iise computer equipment (Ye. M. Kalganov, Omsk), the automated
designing of the technal~gical processes oi asser~bling (V. V. Pavlov,
~Ioscow), *_he automation of the modeling of nonlinear systems of automatic
control (V. G. Ivanenko, Moscaw) and othsrs.
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The conference participants familiariz~d themselves with the work of a num- ~
ber of industrial enterprises of Omsk. In the decision of the conference
the mos.r_ important direct3ons in the development of the software and hard-
- ware of automatQd control systems were indicated and specific reco~nenda-
tions on the use of the results of the performed developments were given.
COPYRIGHT: Izdatel'stvo "Mashinostroyeniye", "Stanki i instrument", 1980 �
7807.
CSO: 1821 -
. END
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- ~ , SELECTIVE LIST OF JPRS SERIAL REPORTS
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USSR REPORT: Engineering and ~quipment
USSR REPORT: Earth Sciences
USSR REPORT: Space ,
USSR REPORT: Materials Science and Metallurgy
USSR REPORT: Physics and Mathematics -
USSR REPORT: SPACE BIOLOGY AND AEROSPACE MEDICINE*
~ ~ WORLDWIDE SERIAL REPORTS
WORI~AWIDE REPORT: Environmental Quality _
WORLDWIDE REPORT: Epidemiology �
WORLDWIDE REPORT: Law of the Sea
WORLDWIDE REPORT: Nuclear Development and Proliferation
WORLDWIDE REPORT: Telecommunicat:tons Policy, Research and Developmant
*Cover-to-cover "
~
APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200090027-1