嵌入式数控工具磨削系统的六轴联动建模及控制算法研究
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摘要
为了精简、优化数控系统的软、硬件结构,提高实时响应、控制性能和可靠性,实现六轴联动控制,本文基于嵌入式技术,研究分布式六轴数控工具磨削系统的体系结构,研究六坐标空间中的复杂工具型面的六轴联动数学建模及控制算法,开展了如下内容的研究。
(1)研究并设计了分布式六轴数控工具磨削系统体系结构。基于ARM9微控制器的嵌入式系统、FPGA电路和CAN现场总线技术,以及嵌入式LINUX系统,设计了上、下位机结构的嵌入式六轴联动数控工具磨削系统。
(2)研究并建立了六坐标空间复杂曲面位置关系的数学模型。基于所设计的嵌入式六轴数控工具磨削结构,针对复杂工具型面,如锥刃刀具和球刃刀具,设计并建立了其前刃面、后刃面及球刃面的多轴联动关系的数学模型。
(3)提出了对数曲线插补算法。设计并推导出满足锥刃和球刃刀具磨削加工所需要的对数曲线的多轴联动奇偶步插补算法,算法运算快速,能实现在嵌入式数控系统中的实时应用,在此基础上,进一步设计出对数曲线奇偶步三次逼近插补算法,提高了控制精度。
(4)提出了六轴联动控制算法。该控制算法能实现六坐标空间内通用的复杂空间曲线的六轴联动进给控制。将对数曲线奇偶步插补算法结合到该算法中,能实现包括锥刃及球刃等复杂工具型面六轴联动的实时控制。
(5)对所提出的对数曲线奇偶步插补算法、三次逼近插补算法及六轴联动控制算法,在MATLAB环境下进行仿真,验证了算法的有效性,取得很高的控制精度。
(6)研制出嵌入式数控工具磨床样机,并对所设计的控制算法进行了实际测试。通过对锥刃刀具前、后刀面的磨削加工测试,得出结果验证了嵌入式数控工具磨削系统与控制算法的实用效果。
最后针对所设计的控制算法,分析了其特性、控制精度和效率,并探讨了进一步研究工作的方向。
Aiming to optimize the software- and hardware-structures and improve real-time response, control performance and reliability, a distributive architecture of CNC tool grinding system with 6-axis was studied in this dissertation based on embedded technology. The mathematical model and the control algorithm for complex cutters'curves in 6-coordinate space are researched to feed the axes simultaneously. Under contents are included.
(1) A distributive structure for CNC tool grinding system with 6-axis was designed. Based on embedded technology of ARM9 MCU (Micro-Controller Unit), FPGA (Field Programmable Gate Array) circuit, CAN (Controller Area Network) field bus, and embedded LINUX system, an embedded CNC tool grinding system in 6-axis feed with upper- and lower-controller structures was developed.
(2) The mathematical models for position relationship of the complex curves in 6-coordinate space were researched and built. Based on the embedded CNC tool grinding structure with 6 axes, the multi-axis feed mathematical models for grinding the complex cutters with rake and clearance of the conical and ball-nose were designed and established.
(3) The interpolation algorithms for logarithmic curve were proposed. The odd-even steps interpolation algorithm was designed and inferred to control the logarithmic relationships between the axes feed when grinding the conical and ball-nose cutters. It is featured with quick in computation and suitable for real-time application in embedded CNC system. Furthermore, a novel odd-even steps third order approach interpolation algorithm was presented so as to raise the control accuracy for interpolating the logarithmic curve.
(4) A 6-coordinate feed control algorithm was newly designed. It was proposed to control the 6-axis feed for any complex space curve with 6-coordinate. Combining with the proposed odd-even steps interpolation algorithm for logarithmic curve, it realizes real-time control in the grinding process for complex cutters with conical and ball-nose.
(5) The proposed logarithmic curve's interpolation algorithms and the 6-coordinate feed control algorithm for grinding the conical cutters were simulated by MATLAB software and got satisfied with high accuracy and effectiveness from validation.
(6) An embedded CNC tool grinding prototype machine was built and the proposed control algorithms were tested in practice. Results from field grinding the rake and clearance of conical cutter proved the practical applications of both the embedded CNC system and the control algorithms.
The characteristics, control accuracy and the efficiency of the proposed control algorithms were analyzed at the end part of the dissertation, and future work was also outlined.
(1)研究并设计了分布式六轴数控工具磨削系统体系结构。基于ARM9微控制器的嵌入式系统、FPGA电路和CAN现场总线技术,以及嵌入式LINUX系统,设计了上、下位机结构的嵌入式六轴联动数控工具磨削系统。
(2)研究并建立了六坐标空间复杂曲面位置关系的数学模型。基于所设计的嵌入式六轴数控工具磨削结构,针对复杂工具型面,如锥刃刀具和球刃刀具,设计并建立了其前刃面、后刃面及球刃面的多轴联动关系的数学模型。
(3)提出了对数曲线插补算法。设计并推导出满足锥刃和球刃刀具磨削加工所需要的对数曲线的多轴联动奇偶步插补算法,算法运算快速,能实现在嵌入式数控系统中的实时应用,在此基础上,进一步设计出对数曲线奇偶步三次逼近插补算法,提高了控制精度。
(4)提出了六轴联动控制算法。该控制算法能实现六坐标空间内通用的复杂空间曲线的六轴联动进给控制。将对数曲线奇偶步插补算法结合到该算法中,能实现包括锥刃及球刃等复杂工具型面六轴联动的实时控制。
(5)对所提出的对数曲线奇偶步插补算法、三次逼近插补算法及六轴联动控制算法,在MATLAB环境下进行仿真,验证了算法的有效性,取得很高的控制精度。
(6)研制出嵌入式数控工具磨床样机,并对所设计的控制算法进行了实际测试。通过对锥刃刀具前、后刀面的磨削加工测试,得出结果验证了嵌入式数控工具磨削系统与控制算法的实用效果。
最后针对所设计的控制算法,分析了其特性、控制精度和效率,并探讨了进一步研究工作的方向。
Aiming to optimize the software- and hardware-structures and improve real-time response, control performance and reliability, a distributive architecture of CNC tool grinding system with 6-axis was studied in this dissertation based on embedded technology. The mathematical model and the control algorithm for complex cutters'curves in 6-coordinate space are researched to feed the axes simultaneously. Under contents are included.
(1) A distributive structure for CNC tool grinding system with 6-axis was designed. Based on embedded technology of ARM9 MCU (Micro-Controller Unit), FPGA (Field Programmable Gate Array) circuit, CAN (Controller Area Network) field bus, and embedded LINUX system, an embedded CNC tool grinding system in 6-axis feed with upper- and lower-controller structures was developed.
(2) The mathematical models for position relationship of the complex curves in 6-coordinate space were researched and built. Based on the embedded CNC tool grinding structure with 6 axes, the multi-axis feed mathematical models for grinding the complex cutters with rake and clearance of the conical and ball-nose were designed and established.
(3) The interpolation algorithms for logarithmic curve were proposed. The odd-even steps interpolation algorithm was designed and inferred to control the logarithmic relationships between the axes feed when grinding the conical and ball-nose cutters. It is featured with quick in computation and suitable for real-time application in embedded CNC system. Furthermore, a novel odd-even steps third order approach interpolation algorithm was presented so as to raise the control accuracy for interpolating the logarithmic curve.
(4) A 6-coordinate feed control algorithm was newly designed. It was proposed to control the 6-axis feed for any complex space curve with 6-coordinate. Combining with the proposed odd-even steps interpolation algorithm for logarithmic curve, it realizes real-time control in the grinding process for complex cutters with conical and ball-nose.
(5) The proposed logarithmic curve's interpolation algorithms and the 6-coordinate feed control algorithm for grinding the conical cutters were simulated by MATLAB software and got satisfied with high accuracy and effectiveness from validation.
(6) An embedded CNC tool grinding prototype machine was built and the proposed control algorithms were tested in practice. Results from field grinding the rake and clearance of conical cutter proved the practical applications of both the embedded CNC system and the control algorithms.
The characteristics, control accuracy and the efficiency of the proposed control algorithms were analyzed at the end part of the dissertation, and future work was also outlined.
引文
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