数控系统运动平稳性和轮廓精度控制技术研究
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摘要
随着虚拟技术、云计算、物联网、云制造等新型技术以及高速切削和精密加工技术的迅速发展，先进制造技术对数控系统提出更高要求。为了满足先进制造技术的需求，本文综合运用多种交叉学科的先进理论和方法，围绕数控系统运动平稳性和轮廓精度控制等问题，主要从连续短线段轮廓加工技术、数控伺服控制系统模型辨识与建模技术、独立轴位置伺服控制技术和多轴联动位置伺服控制技术等方面展开研究。论文主要研究工作及取得的成果如下：
（1）为减小数控系统连续短线轮廓加工过程中速度较大的波动，研究一种三次参数样条曲线局部平滑过渡方法，设计内接过渡法和外接过渡法两种过渡类型，在转接点附近插入两段或三段三次参数样条曲线进行局部处理，实现转接速度高平稳过渡；为解决嵌入式数控系统柔性加减速速度规划的实时性问题，提出一种简化快速的S形速度规划算法，实现连续短线段高平稳运动。通过仿真和加工实验，验证所提出的方法有效地提高连续短线段轮廓加工的运动平稳性和加工效率。
（2）为提高系统模型的建模精度，综合运用支持向量机、粒度计算、系统辨识、免疫算法、微粒群算法等多种交叉学科的先进理论和方法，对数控伺服控制系统模型辨识与建模进行研究。采用二维搜索算法和支持向量机相结合的思想对数控伺服控制系统的模型结构进行辨识；为提高模型辨识精度，研究一种基于信息粒度支持向量机的辨识方法，对数控伺服控制系统的模型参数进行辨识；提出基于交叉变异功能的免疫微粒群优化算法对信息粒度支持向量机的参数进行优化，改善辨识效果。实验结果表明，所提出的方法可有效地提高系统的辨识精度。
（3）为提高独立轴运动平稳性和运动精度，综合运用广义预测控制和模糊控制等理论方法，研究一种改进型广义预测控制和非线性自适应模糊控制相结合的复合模式控制策略。为减小独立轴运动速度波动、加速度波动和跟踪误差，改进广义预测控制的性能优化指标；提出一种自适应调整改进型广义预测控制参数的方法，提高系统的控制性能；为满足控制系统的实时性要求，提出一种简化计算模型求解控制输入量；为提高系统的抗干扰能力，提出一种自适应变结构参数的模糊控制算法。实验表明，所提出的创新性方法可有效提高数控系统独立轴运动平稳性和运动精度。
（4）为提高多轴联动数控系统的运动平稳性和轮廓加工精度，研究一种多轴参数模型预测控制和非线性自适应模糊PID控制的复合模式控制方法，采用多轴参数模型预测控制方法对系统的线性模型进行控制，采用非线性自适应模糊PID控制对系统的非线性模型进行误差补偿控制。为提高模型计算效率，构建一种轮廓误差模型、速度误差模型和加速度误差模型；为提高多轴伺服控制系统的控制性能，提出一种性能优化指标，使系统的跟踪误差、轮廓误差、速度误差和加速度误差最小；为满足控制系统的实时性，设计一种简化的计算模型求解多轴参数模型预测控制增量；为提高多轴联动数控系统鲁棒性，提出一种非线性自适应模糊PID控制方法。实验结果表明，所提出的创新性成果可有效地提高多轴联动数控系统的运动平稳性和轮廓精度。
（5）以数控雕铣机为机械平台，自主设计和研发相应的数控系统，并对本文所提出的连续短线段三次参数样条曲线过渡算法、简化快速的S形速度规划算法、数控伺服控制系统模型辨识与建模方法、独立轴位置伺服控制和多轴联动位置伺服控制方法等进行工程验证。实验结果表明，所提出的创新性方法具有良好的可行性和有效性。
With the development of virtual technology, cloud computing, the internet of things, cloudmanufacturing, high speed cutting, and precision machining technology, the advanced manufacturingtechnology puts higher request on CNC system. For meeting the requirement of the advancedmanufacturing technology, various interdisciplinary theories and methods are applied synthetically.By centering on motional smoothness and contouring error control of CNC system, the paperresearches about continuous micro line contour machining technology, model identification andmodeling technology of the servo control system, independent-axis position servo control technology,and multi-axis position servo control technology. The main research work and results of this paper areas follows:
(1) For the issue of continuous micro line contour machining, the traditional method takes eachprogram segment of micro line as a unit to deal with the problems, which leads to lower turningvelocity of the connective points, causes losing motional smoothness, influences processing efficiency,and machining quality. To improve turning velocity, the transition method of cubic parametric splinecurve is presented. Two type of approach about inscribed transition and external transition aredesigned according to the characteristics of the transitional line, and realizes high smooth transition ofturning velocity according to gradual change characteristics of the parameters spline curve tangent.The calculation of traditional S-curve velocity planning algorithm is so complex, that cannot meetreal-time requirement of the embedded CNC system. To solve this problem, a simplified fast S-curveplanning algorithm is proposed, which realizes high smooth machining. The simulative andexperimental results verify the feasibility and validity of the proposed approach.
(2) In order to improve the system modeling accuracy, various theories and methods ofinterdisciplinary are applying synthetically, such as support vector machine, granular computing,immune algorithm, particle swarm optimization algorithm, and genetic algorithm. The modelstructures of the CNC servo control system are identified with2-dimensional searching algorithmand support vector machine. In order to improve model identification accuracy, a method ofinformation granular support vector machine is proposed to identify the model parameter of theservo control system, and the immune particle swarm optimization algorithm with crossover andmutation operator is presented to improve identification effect. The experimental results show thatthe proposed method can effectively improve the accuracy of the system model.
(3) In order to improve motional smoothness and precision of the independent axis, the compound mode control strategy of improved generalized predictive control and nonlinear adaptive fuzzy controlare proposed by using generalized predictive control and fuzzy control theory methodcomprehensively. To advance the control performance of the servo control system, a performanceoptimization index of generalized predictive control is improved. To improve the control performanceof the system, an algorithm that adaptively adjusts parameters of improved generalized predictivecontrol is put forward. To meet the requirement of real-time system, a simplified calculation model ispresented to solve control input. To improve anti-interference ability of the system, an adaptive fuzzycontrol algorithm of variable structure parameters is proposed, which adaptively adjusts fuzzyquantitative domain and fuzzy control rules. The experiments show that the proposed compoundcontrol strategy effectively improves the dynamic response ability, steady performance and robustnessof the independent-axis position servo control system, and enhances the independent-axis motionsmoothness and precision of CNC system.
(4) Research about multi-axis position servo control technology. Contour error model, velocityerror model and acceleration error model are established. To improve motional smoothness andcontouring precision of the multi-axis CNC system, the compound mode control strategy, which baseson parameter model predictive control and nonlinear adaptive fuzzy PID control, is proposed. Toguarantee minimum contouring error, tracking error, velocity error, and acceleration error duringnumerical control machining, a performance optimization index is proposed. To solve the real-timeproblem of control system, a simplified calculation model is presented to solve control signal by usingthe idea of sliding filter. To strengthen the robustness of the multi-axis CNC system, a nonlinearadaptive fuzzy PID control method is presented. The experiments show that the proposed methodeffectively improves the control performance and robustness of the multi-axis position servo controlsystem, and enhances motion smoothness and contouring precision of CNC system.
(5) The corresponding CNC system is independently designed and exploited with milling andcarved machine platform. The engineering verifications are implemented for cubic parametric splinecurve transition algorithm of continuous micro line contour machining, the model identification andmodeling of the servo control system, control methods of independent-axis position servo controlsystem, and control strategies of multi-axis position servo control system. Through data acquisitionand physical processing, the feasibility and effectiveness of the proposed methods are certified.
（1）为减小数控系统连续短线轮廓加工过程中速度较大的波动，研究一种三次参数样条曲线局部平滑过渡方法，设计内接过渡法和外接过渡法两种过渡类型，在转接点附近插入两段或三段三次参数样条曲线进行局部处理，实现转接速度高平稳过渡；为解决嵌入式数控系统柔性加减速速度规划的实时性问题，提出一种简化快速的S形速度规划算法，实现连续短线段高平稳运动。通过仿真和加工实验，验证所提出的方法有效地提高连续短线段轮廓加工的运动平稳性和加工效率。
（2）为提高系统模型的建模精度，综合运用支持向量机、粒度计算、系统辨识、免疫算法、微粒群算法等多种交叉学科的先进理论和方法，对数控伺服控制系统模型辨识与建模进行研究。采用二维搜索算法和支持向量机相结合的思想对数控伺服控制系统的模型结构进行辨识；为提高模型辨识精度，研究一种基于信息粒度支持向量机的辨识方法，对数控伺服控制系统的模型参数进行辨识；提出基于交叉变异功能的免疫微粒群优化算法对信息粒度支持向量机的参数进行优化，改善辨识效果。实验结果表明，所提出的方法可有效地提高系统的辨识精度。
（3）为提高独立轴运动平稳性和运动精度，综合运用广义预测控制和模糊控制等理论方法，研究一种改进型广义预测控制和非线性自适应模糊控制相结合的复合模式控制策略。为减小独立轴运动速度波动、加速度波动和跟踪误差，改进广义预测控制的性能优化指标；提出一种自适应调整改进型广义预测控制参数的方法，提高系统的控制性能；为满足控制系统的实时性要求，提出一种简化计算模型求解控制输入量；为提高系统的抗干扰能力，提出一种自适应变结构参数的模糊控制算法。实验表明，所提出的创新性方法可有效提高数控系统独立轴运动平稳性和运动精度。
（4）为提高多轴联动数控系统的运动平稳性和轮廓加工精度，研究一种多轴参数模型预测控制和非线性自适应模糊PID控制的复合模式控制方法，采用多轴参数模型预测控制方法对系统的线性模型进行控制，采用非线性自适应模糊PID控制对系统的非线性模型进行误差补偿控制。为提高模型计算效率，构建一种轮廓误差模型、速度误差模型和加速度误差模型；为提高多轴伺服控制系统的控制性能，提出一种性能优化指标，使系统的跟踪误差、轮廓误差、速度误差和加速度误差最小；为满足控制系统的实时性，设计一种简化的计算模型求解多轴参数模型预测控制增量；为提高多轴联动数控系统鲁棒性，提出一种非线性自适应模糊PID控制方法。实验结果表明，所提出的创新性成果可有效地提高多轴联动数控系统的运动平稳性和轮廓精度。
（5）以数控雕铣机为机械平台，自主设计和研发相应的数控系统，并对本文所提出的连续短线段三次参数样条曲线过渡算法、简化快速的S形速度规划算法、数控伺服控制系统模型辨识与建模方法、独立轴位置伺服控制和多轴联动位置伺服控制方法等进行工程验证。实验结果表明，所提出的创新性方法具有良好的可行性和有效性。
With the development of virtual technology, cloud computing, the internet of things, cloudmanufacturing, high speed cutting, and precision machining technology, the advanced manufacturingtechnology puts higher request on CNC system. For meeting the requirement of the advancedmanufacturing technology, various interdisciplinary theories and methods are applied synthetically.By centering on motional smoothness and contouring error control of CNC system, the paperresearches about continuous micro line contour machining technology, model identification andmodeling technology of the servo control system, independent-axis position servo control technology,and multi-axis position servo control technology. The main research work and results of this paper areas follows:
(1) For the issue of continuous micro line contour machining, the traditional method takes eachprogram segment of micro line as a unit to deal with the problems, which leads to lower turningvelocity of the connective points, causes losing motional smoothness, influences processing efficiency,and machining quality. To improve turning velocity, the transition method of cubic parametric splinecurve is presented. Two type of approach about inscribed transition and external transition aredesigned according to the characteristics of the transitional line, and realizes high smooth transition ofturning velocity according to gradual change characteristics of the parameters spline curve tangent.The calculation of traditional S-curve velocity planning algorithm is so complex, that cannot meetreal-time requirement of the embedded CNC system. To solve this problem, a simplified fast S-curveplanning algorithm is proposed, which realizes high smooth machining. The simulative andexperimental results verify the feasibility and validity of the proposed approach.
(2) In order to improve the system modeling accuracy, various theories and methods ofinterdisciplinary are applying synthetically, such as support vector machine, granular computing,immune algorithm, particle swarm optimization algorithm, and genetic algorithm. The modelstructures of the CNC servo control system are identified with2-dimensional searching algorithmand support vector machine. In order to improve model identification accuracy, a method ofinformation granular support vector machine is proposed to identify the model parameter of theservo control system, and the immune particle swarm optimization algorithm with crossover andmutation operator is presented to improve identification effect. The experimental results show thatthe proposed method can effectively improve the accuracy of the system model.
(3) In order to improve motional smoothness and precision of the independent axis, the compound mode control strategy of improved generalized predictive control and nonlinear adaptive fuzzy controlare proposed by using generalized predictive control and fuzzy control theory methodcomprehensively. To advance the control performance of the servo control system, a performanceoptimization index of generalized predictive control is improved. To improve the control performanceof the system, an algorithm that adaptively adjusts parameters of improved generalized predictivecontrol is put forward. To meet the requirement of real-time system, a simplified calculation model ispresented to solve control input. To improve anti-interference ability of the system, an adaptive fuzzycontrol algorithm of variable structure parameters is proposed, which adaptively adjusts fuzzyquantitative domain and fuzzy control rules. The experiments show that the proposed compoundcontrol strategy effectively improves the dynamic response ability, steady performance and robustnessof the independent-axis position servo control system, and enhances the independent-axis motionsmoothness and precision of CNC system.
(4) Research about multi-axis position servo control technology. Contour error model, velocityerror model and acceleration error model are established. To improve motional smoothness andcontouring precision of the multi-axis CNC system, the compound mode control strategy, which baseson parameter model predictive control and nonlinear adaptive fuzzy PID control, is proposed. Toguarantee minimum contouring error, tracking error, velocity error, and acceleration error duringnumerical control machining, a performance optimization index is proposed. To solve the real-timeproblem of control system, a simplified calculation model is presented to solve control signal by usingthe idea of sliding filter. To strengthen the robustness of the multi-axis CNC system, a nonlinearadaptive fuzzy PID control method is presented. The experiments show that the proposed methodeffectively improves the control performance and robustness of the multi-axis position servo controlsystem, and enhances motion smoothness and contouring precision of CNC system.
(5) The corresponding CNC system is independently designed and exploited with milling andcarved machine platform. The engineering verifications are implemented for cubic parametric splinecurve transition algorithm of continuous micro line contour machining, the model identification andmodeling of the servo control system, control methods of independent-axis position servo controlsystem, and control strategies of multi-axis position servo control system. Through data acquisitionand physical processing, the feasibility and effectiveness of the proposed methods are certified.
引文
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