微量射出标签机数控系统关键技术的研究
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摘要
微量射出标签即多色塑胶标签,由于多采用微量射出技术生产故称之为微量射出标签。其应用广泛、需求量巨大,但目前的生产还处于原始手工生产的状态,因而开发一种自动化生产设备具有重要意义。采用数控技术可以将手工操作改为自动加工,根据微量射出标签生产的要求,其数控设备应该是低成本、高性能、体积小、易操作的专用数控设备。
本文主要对微量射出标签机数控系统的关键技术进行研究,给出了数控系统的总体架构,提出了一种基于变长度染色体遗传算法的加工路径优化算法,并研制了基于ARM7 S3C44BOX和μC/OS-Ⅱ的嵌入式控制器,这种数控系统有效地满足了微量射出标签生产的要求。主要研究内容包括以下几个方面:
首先,介绍了微量射出标签及其生产现状,提出采用数控技术实现自动化生产的方案,并对数控技术进行了简要介绍,阐述了应用嵌入式技术开发数控系统的优势;
第二,给出了数控系统的总体架构。数控系统采用上位机和多台嵌入式控制器的串行网络架构,主要包括上位机加工代码生成软件、嵌入式控制器、三坐标机床和微流量控制器。控制器采用开环控制方式,执行机构采用步进电机和滚珠丝杠副,这种结构既能满足系统的精度要求又能保证数控设备的经济性;
第三,定义了加工代码生成软件的各功能模块,对软件开发中的关键技术进行了研究。提出一种基于变长度染色体遗传算法的加工路径优化方法,该方法将每个点编码为一个二元组用以表示各种加工要素,其交叉和变异操作能对一些线进行分割和合并,使加工路径能得到更大程度的优化。仿真结果表明,该方法具有良好的优化效果,可以显著地缩短辅助运动路径的长度;
第四,研制了数控系统的嵌入式控制器。该嵌入式控制器硬件平台采用ARM7微处理器S3C44BOX和AT89C52单片机,驱动芯片采用TA8435;软件平台采用μC/OS-Ⅱ实时操作系统,将控制软件划分成几个功能模块,并给出了各功能模块在系统中对应任务的优先级。该嵌入式控制器的软硬件划分及缓冲区的使用较好地满足了微量射出标签加工的实时性要求;
最后,对本文的研究工作进行了总结,提出了系统需要继续完善的地方。
Micro-injection tag,namely,multicolor plastic tag,is so called because it is often produced by micro-injection technique.It is widely applied and in great demand. However,its production is still originally performed by hand.Thus it is significant that developing an automatic production equipment.Using numeric control(NC) technique could realize the automation of micro-injection tag's production.According to the requirements of micro-injection tag's production,the NC system should possess the features of low cost,high performance,small volume and friendly interface.
The key techniques of the NC system was researched in this thesis,the framework of the NC system was given,an approach for machining path optimization based on Variable-Length Genome Genetic Algorithm was presented,and the embedded controller of the NC system based on ARM7 S3C44BOX andμC/OS-Ⅱwas developed,this kind of NC system could meet the requirements of micro-injection tag's production very well.The main work and contributions in this dissertation are as follows.
Firstly,micro-injection tag and the present situation of its production ware introduced,the approach for the tag's automatic production based on NC technique was pointed out,and the NC technique was introduced briefly,then the advantages of the application of embedded technique in NC system was discussed.
Secondly,the framework of the NC system was given,which was a serial network consisted of a host computer and many embedded controllers.The NC system included a NC code generating software installed in the host computer,embedded controllers,machine tools and micro-flow controller.The embedded controller adopted open loop control mode,and the actuating mechanism was consisted of stepper motor and ball screw,this architecture could not only met the precision requirement but also kept the cost of the NC system very low.
Thirdly,every module's function of the NC code generating software was defined, and the key techniques of the software were researched.An approach for machining path optimization based on Variable-Length Genome Genetic Algorithm was presented.In this algorithm,each machining element was represented by some points which were encoded into a combination of an index and its attribute,and some kinds of lines could be cut and spliced by the crossover and mutation operation,thus the machining paths could be further optimized.Simulation results show that this approach is effective for the problem of machining paths optimization,it can dramatically shorten machining paths.
Fourthly,the embedded controller of the NC system was developed.This controller's hardware was consisted of ARM7 S3C44BOX,AT89C52 and TA8435; for the software platform,μC/OS-Ⅱoperating system(OS)was adopted,and the application software was divided into several function models which were assigned different priorities as tasks in the OS.This architecture and the use of buffer could provide perfect real time capabilities which could meet the requirement of micro-injection tag production very well.
Lastly,the research contents of this dissertation were summarized,and what the NC system needs to be improved was pointed out.
本文主要对微量射出标签机数控系统的关键技术进行研究,给出了数控系统的总体架构,提出了一种基于变长度染色体遗传算法的加工路径优化算法,并研制了基于ARM7 S3C44BOX和μC/OS-Ⅱ的嵌入式控制器,这种数控系统有效地满足了微量射出标签生产的要求。主要研究内容包括以下几个方面:
首先,介绍了微量射出标签及其生产现状,提出采用数控技术实现自动化生产的方案,并对数控技术进行了简要介绍,阐述了应用嵌入式技术开发数控系统的优势;
第二,给出了数控系统的总体架构。数控系统采用上位机和多台嵌入式控制器的串行网络架构,主要包括上位机加工代码生成软件、嵌入式控制器、三坐标机床和微流量控制器。控制器采用开环控制方式,执行机构采用步进电机和滚珠丝杠副,这种结构既能满足系统的精度要求又能保证数控设备的经济性;
第三,定义了加工代码生成软件的各功能模块,对软件开发中的关键技术进行了研究。提出一种基于变长度染色体遗传算法的加工路径优化方法,该方法将每个点编码为一个二元组用以表示各种加工要素,其交叉和变异操作能对一些线进行分割和合并,使加工路径能得到更大程度的优化。仿真结果表明,该方法具有良好的优化效果,可以显著地缩短辅助运动路径的长度;
第四,研制了数控系统的嵌入式控制器。该嵌入式控制器硬件平台采用ARM7微处理器S3C44BOX和AT89C52单片机,驱动芯片采用TA8435;软件平台采用μC/OS-Ⅱ实时操作系统,将控制软件划分成几个功能模块,并给出了各功能模块在系统中对应任务的优先级。该嵌入式控制器的软硬件划分及缓冲区的使用较好地满足了微量射出标签加工的实时性要求;
最后,对本文的研究工作进行了总结,提出了系统需要继续完善的地方。
Micro-injection tag,namely,multicolor plastic tag,is so called because it is often produced by micro-injection technique.It is widely applied and in great demand. However,its production is still originally performed by hand.Thus it is significant that developing an automatic production equipment.Using numeric control(NC) technique could realize the automation of micro-injection tag's production.According to the requirements of micro-injection tag's production,the NC system should possess the features of low cost,high performance,small volume and friendly interface.
The key techniques of the NC system was researched in this thesis,the framework of the NC system was given,an approach for machining path optimization based on Variable-Length Genome Genetic Algorithm was presented,and the embedded controller of the NC system based on ARM7 S3C44BOX andμC/OS-Ⅱwas developed,this kind of NC system could meet the requirements of micro-injection tag's production very well.The main work and contributions in this dissertation are as follows.
Firstly,micro-injection tag and the present situation of its production ware introduced,the approach for the tag's automatic production based on NC technique was pointed out,and the NC technique was introduced briefly,then the advantages of the application of embedded technique in NC system was discussed.
Secondly,the framework of the NC system was given,which was a serial network consisted of a host computer and many embedded controllers.The NC system included a NC code generating software installed in the host computer,embedded controllers,machine tools and micro-flow controller.The embedded controller adopted open loop control mode,and the actuating mechanism was consisted of stepper motor and ball screw,this architecture could not only met the precision requirement but also kept the cost of the NC system very low.
Thirdly,every module's function of the NC code generating software was defined, and the key techniques of the software were researched.An approach for machining path optimization based on Variable-Length Genome Genetic Algorithm was presented.In this algorithm,each machining element was represented by some points which were encoded into a combination of an index and its attribute,and some kinds of lines could be cut and spliced by the crossover and mutation operation,thus the machining paths could be further optimized.Simulation results show that this approach is effective for the problem of machining paths optimization,it can dramatically shorten machining paths.
Fourthly,the embedded controller of the NC system was developed.This controller's hardware was consisted of ARM7 S3C44BOX,AT89C52 and TA8435; for the software platform,μC/OS-Ⅱoperating system(OS)was adopted,and the application software was divided into several function models which were assigned different priorities as tasks in the OS.This architecture and the use of buffer could provide perfect real time capabilities which could meet the requirement of micro-injection tag production very well.
Lastly,the research contents of this dissertation were summarized,and what the NC system needs to be improved was pointed out.
引文
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[18]杨伟东,檀润华,颜永年等.遗传算法在快速成形轮廓路径规划中的应用.计算机辅助设计与图形学学报,2005,17(10):2179-2183
[19]王霄,刘会霞.PCB数控钻孔最佳走刀路线的建模与求解.计算机辅助设计与图形学学报,2001,13(7):591-593
[20]梁吉元,郁鼎文,张玉峰等.CAM系统中孔加工路径的优化处理.计算机集成制造系统,2000,6(1):74-76.
[21]程森林,李松强,郝满炉.印制板打孔最短路径的遗传算法实现.计算机工程与应用,2006,30:180-182
[22]邢文训,谢金星.现代优化计算方法.第2版.北京:清华大学出版社,2005
[23]Chatterjee S,Carrera C,Lynchl A.Genetic algorithms and traveling salesman problems.European Journal of Operational Research,1996,93(3):490-510.
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