三轴电火花成型加工机床数控系统的研究
|
摘要
电火花加工技术属于特种加工领域的范畴,是解决一般金切机床难加工材料或形状复杂材料的加工途径之一。面对近几十年来生产的发展和科技的进步,对材料和零件的加工工艺提出了更高的要求,进一步要求电火花加工技术向高效率、高精度、智能化方向发展。在这种研究背景下,本论文对电火花成型加工机床的数控系统进行了研究设计。
论文首先对电火花加工技术进行了概述,介绍了其发展现状并对其原理进行了分析,初步探讨了电火花的加工机理。随后进一步提出了电火花成型加工技术的概念,阐述了成型加工控制系统的特点及控制方式,对影响成型加工效果的因素进行了分析,为系统控制方案的制定提供了依据。
根据电火花加工工艺特点,本文提出了基于PC控制技术的软CNC控制系统,PC控制软件负责运行主要NC控制任务和人机交互系统,结合PC外围的微控制器PIC程序控制实现了对放电加工过程的优化控制。由于电加工实时性和非实时性控制任务的并行运行特点,制定了控制软件基于前后台进程的实时中断结构,前台程序主要是负责实时性控制任务,由系统调度运行一段固定或可变的时间(称为时间片)。后台程序是在时间片运行间隙进行的非实时性程序,在后台程序循环中不断被前台实时性控制任务打断。
根据放电加工电信号变化规律,制定放电间隙控制策略,NC控制软件采用了根据经验公式建立的伺服控制策略,利用改进的平均电压法既考虑到算法的精简性又确保控制的有效性,使伺服控制具有较高的适用性和稳定性。在伺服控制的同时,运动控制系统采用优化的DDA运动插补算法,保证伺服过程中精确的运动轨迹控制。
利用PC外围微控制器配合NC控制软件完成对加工过程检测,最终实现了机床系统的整体自动化控制,实时性控制和非实时性控制得到较好的整合,使机床性能和自动化水平大幅提高。
Electric discharge machining(EDM) belongs to special machining technique field, aimed tosolve the problem of machining the material which hard to machining due to its complex figureor special hardness by ordinary machine tool. The fast development of manufacture andtechnology in recent years showed more strict demand on the machining craftwork of materialand workpiece. As a result, the EDM technique have to develop itself to be more efficiency,more precise and more intelligence. According to this, this paper take research on the numericcontrol system of electric discharge machine tool.
First, the paper summarized the EDM technique, introduced the development situation andanalyzed the EDM basic theory and machining mechanism. Then the paper brought forward theconcept of EDM moulding technique, explained its character and control method, analyzed thefactor affect the machining result, according to these materials the paper made the control systemblueprint.
According to the characteristic of machining craftwork, this paper bring forward the softCNC control system based on PC control technology. The software on PC charges for main NCcontrol task and human-machine intercommunication system, and the outer micro controller takecharge of optimum control of discharging process. Because the real time and non real timeprocess take place at the same time during machining, the paper established the control softwarebased on realtime interrupt, with foreground application and background application.
According to the electric signal transform rule during discharging, the paper alsoestablished the control strategy for discharging gap. The numeric control software adopt a kindof strategy cased on experience, realized the briefness and validity of control arithmetic at thesame time. During discharging, the software also use DDA(Digital Differential Analyzer)interpolation arithmetic for motion control.
The NC control software cooperate with microcontroller program, utilized the hardwarecommunication circuit, realized the general control of machine tool.
论文首先对电火花加工技术进行了概述,介绍了其发展现状并对其原理进行了分析,初步探讨了电火花的加工机理。随后进一步提出了电火花成型加工技术的概念,阐述了成型加工控制系统的特点及控制方式,对影响成型加工效果的因素进行了分析,为系统控制方案的制定提供了依据。
根据电火花加工工艺特点,本文提出了基于PC控制技术的软CNC控制系统,PC控制软件负责运行主要NC控制任务和人机交互系统,结合PC外围的微控制器PIC程序控制实现了对放电加工过程的优化控制。由于电加工实时性和非实时性控制任务的并行运行特点,制定了控制软件基于前后台进程的实时中断结构,前台程序主要是负责实时性控制任务,由系统调度运行一段固定或可变的时间(称为时间片)。后台程序是在时间片运行间隙进行的非实时性程序,在后台程序循环中不断被前台实时性控制任务打断。
根据放电加工电信号变化规律,制定放电间隙控制策略,NC控制软件采用了根据经验公式建立的伺服控制策略,利用改进的平均电压法既考虑到算法的精简性又确保控制的有效性,使伺服控制具有较高的适用性和稳定性。在伺服控制的同时,运动控制系统采用优化的DDA运动插补算法,保证伺服过程中精确的运动轨迹控制。
利用PC外围微控制器配合NC控制软件完成对加工过程检测,最终实现了机床系统的整体自动化控制,实时性控制和非实时性控制得到较好的整合,使机床性能和自动化水平大幅提高。
Electric discharge machining(EDM) belongs to special machining technique field, aimed tosolve the problem of machining the material which hard to machining due to its complex figureor special hardness by ordinary machine tool. The fast development of manufacture andtechnology in recent years showed more strict demand on the machining craftwork of materialand workpiece. As a result, the EDM technique have to develop itself to be more efficiency,more precise and more intelligence. According to this, this paper take research on the numericcontrol system of electric discharge machine tool.
First, the paper summarized the EDM technique, introduced the development situation andanalyzed the EDM basic theory and machining mechanism. Then the paper brought forward theconcept of EDM moulding technique, explained its character and control method, analyzed thefactor affect the machining result, according to these materials the paper made the control systemblueprint.
According to the characteristic of machining craftwork, this paper bring forward the softCNC control system based on PC control technology. The software on PC charges for main NCcontrol task and human-machine intercommunication system, and the outer micro controller takecharge of optimum control of discharging process. Because the real time and non real timeprocess take place at the same time during machining, the paper established the control softwarebased on realtime interrupt, with foreground application and background application.
According to the electric signal transform rule during discharging, the paper alsoestablished the control strategy for discharging gap. The numeric control software adopt a kindof strategy cased on experience, realized the briefness and validity of control arithmetic at thesame time. During discharging, the software also use DDA(Digital Differential Analyzer)interpolation arithmetic for motion control.
The NC control software cooperate with microcontroller program, utilized the hardwarecommunication circuit, realized the general control of machine tool.
引文
[1] 秦勇,王霖,张建华等.电火花成形加工技术的现状与发展趋势.工具技术,2002,36(1): 21-26.
[2] 曹凤国等.电火花成形加工技术发展的新趋势.第 11 届全国特种加工学术会议专辑 2005 年中国机械工程学会年会论文集.
[3] (美)埃利斯(Ellis,G.)著;刘君华,汤晓军译. 控制系统设计指南: 第三版. 电子工业出版社,2006.9
[4] 曹凤国主编.电火花加工技术.化学工业出版社,2005.
[5] 赵万生,刘晋春.实用电加工技术.机械工业出版社,2002.
[6] 赵万生.先进电火花加工技术.国防工业出版社,2003.
[7] 李清新主编.伺服系统与机床电器控制.机械工业出版社,2003.
[8] 刘和平等. PIC18Fxxx 单片机程序设计及应用. 北京航空航天大学出版社,2005.2.
[9] 秦勇等.数控技术在电火花成型加工中的应用现状和发展趋势.机械工程师,2001.3.
[10] 伍俊等.电火花加工过程中的先进控制技术研究.电子工艺技术,1999,11.
[11] 张桂香.旋转电加工数控系统及伺服控制的研究.中国农业大学硕士学位论文.2001,12.
[12] Anonymous. History and development[M].The Techniques and Practice of Spark Erosion Machining.Sparcatron Limited, Gloucester, UK,1965:6.
[13] L. Houman. Total EDM in E.C. Jameson(Ed), Electrical Discharge Machining: Tooling,Methods andApplication[J].Society of Manufacturing Engineers,Dearbern,Michigan,2001:12.
[14] W.M. Wang. K.P. Rajurkar. Digital Gap Monitor and Adaptive Integral Control for Auto-Jumping inEDM.Journal of Engineering for Industry,1995,117: 253-258.
[15] Lvano Beltrami.Micro and Nano Electric-Discharge Machining.14th International Symposium onElectromachining,Edinburgh,2004,257～259.
[16] Cao Fenggou ,Yang Dayong.The Study of High Efficiency and Intelligent Optimization System inEDM Sinking Process.14th International Symposium On Electromachining,Edinburgh, 2004,
[17] D.Grevey,L.Maiffredy,A.B.Vannes. Laser Shock on a TRIP ALLOY:Mechanical and MetallurgicalConsequences. Journal of Materials Secience,1992, 27
[18] K.P.Rajurkar, W.M.Wang, Real-Time Stochastic Model and Control of EDM. Annals of theCIRP.1990
[19] 井上洁.放电加工的基本原理.国防工业出版社,1983.
[20] 李明辉.电火花加工理论基础.北京国防工业出版社,1989.
[21] 谷安,刘正埙.数控伺服精度的研究.电加上与模具,2001,1.
[22] 刘忠炼.慢走丝电火花线切割机间隙控制系统的研究.南昌大学硕士学位论文.2005,6.
[16] N.Mohri,H.Takeiawa,N.Saito.On-line Machine Measurement in EDM Process by a CalibrationSystem with Polyhedra.Annals of the CIRP,1994, 43(1):202-206.
[17] 卢存伟.电火花加工工艺学.北京国防工业出版社,1988.
[18] Hayakawa,Kunieda.Numerical analysis of arc plasma temperature in EDM process based onmagnetohydrodynamics.Transactions of the Japan Society of Mechanical Engineers,1996.Part B,62(600 ):3171-3177.
[19] H.Xia,H.Hashimoto,M.Kunieda,N.Nishiwaki.Measurement of Energy Distribution in ContinuousEDM Process . Seimitsu Kogaku Kaishi/Journal of the Japan Society for PrecisionEngineering.1996,62(8):1141-1145.
[20] D.D.Dibitonto,etc.Theoretical Models of The Electrical Discharge Machining Process.I .A SimpleCathode Erosion Model.Journal of Applied Physics, 1989.
[21] Eubank etc.Theoretical Models of The Electrical Discharge Machining Process.III. The VariableMass Cylindrical Plasma Model.Journal of Applied Physics,1993.
[22] 上蔚屺,赵万生,白基成.电火花放电状态的检测及微机自适应控制脉冲电源.电加工,1998
[23] Seiji Niwa,Masanori Furuya.A Study on Optimum Machining Conditions in EDM Process forMaking Molds and Dies.ISEM-11,1995:325-332.
[24] 王蔚眠.电火花加工放电状态多参数检测及自适应控制脉冲电源和系统的研究.哈尔滨工业大学博十学位论文,1985.
[25] 赵万生.电火花加工稳定性及自适应控制的研究.哈尔滨工业大学博士学位论文,1989.
[26] 肖玲妮,袁增贵.Protel 99SE 印刷电路板设计教程.清华大学出版社,2003.8.
[27] 杨素行等.微型计算机系统原理及应用(第 2 版).清华大学出版社,2003.10.
[28] 仇玉章.32 位微型计算机原理与接口技术.清华大学出版社,2000.
[29] 游有鹏,开放式数控系统关键技术研究,南京航空航天大学博士学位论文,2001,12.
[30] 梁福军.石治平.21 世纪的制造技术.机械工程学报[J], 2002, 38 (1): 1-8.
[31] 廖效果,刘又午,数控技术,湖北科学技术出版社,2000.
[32] 吴祖育,秦鹏飞,数控技术(第三版),上海科学技术出版社,2000.
[33] 林奕鸿,机床数控技术及其应用,机械工业出版社,1994.
[34] 申丽国等,国外数控技术的研究动向和发展趋势,机械工业自动化,1996(2).
[35] 文广,马宏伟,数控技术的现状及发展趋势,机械工程师,2003 (1).
[36] 赖国庭,吴玉厚,富大伟,开放式数控系统的发展及性能研究,机械与电子,2003.
[37] 陆启建,刘明灯,数控技术的新发展,制造技术与机床,2002 (5 ).
[38] Y Yamazak.High Performance Motion Control for Feed Drive Systems of NC Machine Tools, PhD.Tokyo University of Agriculture and Technology. Tokyo, 2000.
[39] Rober Stephen J, Shin Yung C. Modeling and control of CNC machines using a PC-based openarchitecture controller[J]. Mechanics,1995,5(4):401-420.
[40] Ann Arbor Software CNC for High Speed Machining 一 Manufacturing Data Systems. 2003.12.
[41] Hideo Matsuka. Japanese PC-based Open Control System for Manufacturing Equipment[J]. lnt. J.Japan Soc. Prec. Eng,1996, 30(3)
[42] 窦振中.PIC 系列单片机原理和程序设计.北京航空航天大学出版社,1998.
[43] 窦振中,汪立森.PIC 系列单片机应用设计与实例.北京航空航天大学出版社,1998.
[44] 武锋.PIC 系列单片机的开发应用技术.北京航空航天大学出版社,1998.
[45] 钟约先,林亨、机械系统与计算机控制.北京清华大学出版社,2001.
[46] 王春海,樊锐,赵先仲.数字化加工技术.北京化学工业出版社,2003.
[47] 辛世界.电火花成型机自动进给调节系统的研究.电加工与模具,2000 年第4期
[48] 徐盛林.日本电火花加工技术的发展现状.电加工与模具,2001 年第 3 期
[49] 刘书华.数控机床与编程.北京:机械工业出版社,2001.
[50] 蔡兰,王霄.数控加工工艺学.北京化学工业出版社,2005.
[51] 王贵成.数控机床故障诊断技术.北京化学工业出版社,2005.
[52] 叶蓓华主编.数字控制技术.北京:清华大学出版社,2002.
[2] 曹凤国等.电火花成形加工技术发展的新趋势.第 11 届全国特种加工学术会议专辑 2005 年中国机械工程学会年会论文集.
[3] (美)埃利斯(Ellis,G.)著;刘君华,汤晓军译. 控制系统设计指南: 第三版. 电子工业出版社,2006.9
[4] 曹凤国主编.电火花加工技术.化学工业出版社,2005.
[5] 赵万生,刘晋春.实用电加工技术.机械工业出版社,2002.
[6] 赵万生.先进电火花加工技术.国防工业出版社,2003.
[7] 李清新主编.伺服系统与机床电器控制.机械工业出版社,2003.
[8] 刘和平等. PIC18Fxxx 单片机程序设计及应用. 北京航空航天大学出版社,2005.2.
[9] 秦勇等.数控技术在电火花成型加工中的应用现状和发展趋势.机械工程师,2001.3.
[10] 伍俊等.电火花加工过程中的先进控制技术研究.电子工艺技术,1999,11.
[11] 张桂香.旋转电加工数控系统及伺服控制的研究.中国农业大学硕士学位论文.2001,12.
[12] Anonymous. History and development[M].The Techniques and Practice of Spark Erosion Machining.Sparcatron Limited, Gloucester, UK,1965:6.
[13] L. Houman. Total EDM in E.C. Jameson(Ed), Electrical Discharge Machining: Tooling,Methods andApplication[J].Society of Manufacturing Engineers,Dearbern,Michigan,2001:12.
[14] W.M. Wang. K.P. Rajurkar. Digital Gap Monitor and Adaptive Integral Control for Auto-Jumping inEDM.Journal of Engineering for Industry,1995,117: 253-258.
[15] Lvano Beltrami.Micro and Nano Electric-Discharge Machining.14th International Symposium onElectromachining,Edinburgh,2004,257～259.
[16] Cao Fenggou ,Yang Dayong.The Study of High Efficiency and Intelligent Optimization System inEDM Sinking Process.14th International Symposium On Electromachining,Edinburgh, 2004,
[17] D.Grevey,L.Maiffredy,A.B.Vannes. Laser Shock on a TRIP ALLOY:Mechanical and MetallurgicalConsequences. Journal of Materials Secience,1992, 27
[18] K.P.Rajurkar, W.M.Wang, Real-Time Stochastic Model and Control of EDM. Annals of theCIRP.1990
[19] 井上洁.放电加工的基本原理.国防工业出版社,1983.
[20] 李明辉.电火花加工理论基础.北京国防工业出版社,1989.
[21] 谷安,刘正埙.数控伺服精度的研究.电加上与模具,2001,1.
[22] 刘忠炼.慢走丝电火花线切割机间隙控制系统的研究.南昌大学硕士学位论文.2005,6.
[16] N.Mohri,H.Takeiawa,N.Saito.On-line Machine Measurement in EDM Process by a CalibrationSystem with Polyhedra.Annals of the CIRP,1994, 43(1):202-206.
[17] 卢存伟.电火花加工工艺学.北京国防工业出版社,1988.
[18] Hayakawa,Kunieda.Numerical analysis of arc plasma temperature in EDM process based onmagnetohydrodynamics.Transactions of the Japan Society of Mechanical Engineers,1996.Part B,62(600 ):3171-3177.
[19] H.Xia,H.Hashimoto,M.Kunieda,N.Nishiwaki.Measurement of Energy Distribution in ContinuousEDM Process . Seimitsu Kogaku Kaishi/Journal of the Japan Society for PrecisionEngineering.1996,62(8):1141-1145.
[20] D.D.Dibitonto,etc.Theoretical Models of The Electrical Discharge Machining Process.I .A SimpleCathode Erosion Model.Journal of Applied Physics, 1989.
[21] Eubank etc.Theoretical Models of The Electrical Discharge Machining Process.III. The VariableMass Cylindrical Plasma Model.Journal of Applied Physics,1993.
[22] 上蔚屺,赵万生,白基成.电火花放电状态的检测及微机自适应控制脉冲电源.电加工,1998
[23] Seiji Niwa,Masanori Furuya.A Study on Optimum Machining Conditions in EDM Process forMaking Molds and Dies.ISEM-11,1995:325-332.
[24] 王蔚眠.电火花加工放电状态多参数检测及自适应控制脉冲电源和系统的研究.哈尔滨工业大学博十学位论文,1985.
[25] 赵万生.电火花加工稳定性及自适应控制的研究.哈尔滨工业大学博士学位论文,1989.
[26] 肖玲妮,袁增贵.Protel 99SE 印刷电路板设计教程.清华大学出版社,2003.8.
[27] 杨素行等.微型计算机系统原理及应用(第 2 版).清华大学出版社,2003.10.
[28] 仇玉章.32 位微型计算机原理与接口技术.清华大学出版社,2000.
[29] 游有鹏,开放式数控系统关键技术研究,南京航空航天大学博士学位论文,2001,12.
[30] 梁福军.石治平.21 世纪的制造技术.机械工程学报[J], 2002, 38 (1): 1-8.
[31] 廖效果,刘又午,数控技术,湖北科学技术出版社,2000.
[32] 吴祖育,秦鹏飞,数控技术(第三版),上海科学技术出版社,2000.
[33] 林奕鸿,机床数控技术及其应用,机械工业出版社,1994.
[34] 申丽国等,国外数控技术的研究动向和发展趋势,机械工业自动化,1996(2).
[35] 文广,马宏伟,数控技术的现状及发展趋势,机械工程师,2003 (1).
[36] 赖国庭,吴玉厚,富大伟,开放式数控系统的发展及性能研究,机械与电子,2003.
[37] 陆启建,刘明灯,数控技术的新发展,制造技术与机床,2002 (5 ).
[38] Y Yamazak.High Performance Motion Control for Feed Drive Systems of NC Machine Tools, PhD.Tokyo University of Agriculture and Technology. Tokyo, 2000.
[39] Rober Stephen J, Shin Yung C. Modeling and control of CNC machines using a PC-based openarchitecture controller[J]. Mechanics,1995,5(4):401-420.
[40] Ann Arbor Software CNC for High Speed Machining 一 Manufacturing Data Systems. 2003.12.
[41] Hideo Matsuka. Japanese PC-based Open Control System for Manufacturing Equipment[J]. lnt. J.Japan Soc. Prec. Eng,1996, 30(3)
[42] 窦振中.PIC 系列单片机原理和程序设计.北京航空航天大学出版社,1998.
[43] 窦振中,汪立森.PIC 系列单片机应用设计与实例.北京航空航天大学出版社,1998.
[44] 武锋.PIC 系列单片机的开发应用技术.北京航空航天大学出版社,1998.
[45] 钟约先,林亨、机械系统与计算机控制.北京清华大学出版社,2001.
[46] 王春海,樊锐,赵先仲.数字化加工技术.北京化学工业出版社,2003.
[47] 辛世界.电火花成型机自动进给调节系统的研究.电加工与模具,2000 年第4期
[48] 徐盛林.日本电火花加工技术的发展现状.电加工与模具,2001 年第 3 期
[49] 刘书华.数控机床与编程.北京:机械工业出版社,2001.
[50] 蔡兰,王霄.数控加工工艺学.北京化学工业出版社,2005.
[51] 王贵成.数控机床故障诊断技术.北京化学工业出版社,2005.
[52] 叶蓓华主编.数字控制技术.北京:清华大学出版社,2002.