两轴高速直驱伺服进给系统控制策略与实验平台
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摘要
高速加工使得传统机床行业出现了一次变革，原有的机床结构、主轴系统、伺服进给系统、数控系统以及加工工艺等都随之发生巨大变化，在这些变化中以伺服进给系统最为突出。直线电机直接驱动方式以其高速、高效、高精的特点被普遍认为是高速伺服进给系统的最佳选择。但是直线电机本身存在的端部效应和磁路开断现象使得其推力存在波动，同时，直线电机直接驱动系统由于缺少中间传动环节的缓冲作用，使得外界扰动信号的作用效果直接而明显，导致直线电机伺服系统控制困难。因此，研究直线电机伺服进给系统的控制策略具有重要的理论意义及工程实用价值。本文以两轴高速直驱伺服进给系统为研究对象，设计并搭建了永磁直线同步电机伺服进给实验平台，并以此为基础开展相应的控制理论与方法研究，并进行了实验验证。全文主要工作及成果如下：
在系统分析永磁同步电机结构与工作原理的基础上，运用坐标变换法建立了同步电机数学模型，并基于此构建了两轴伺服进给系统传递函数模型。
滑模变结构控制器设计与鲁棒性控制方法。在系统归纳连续系统和离散系统滑模控制器的工作原理及组成结构基础上，综合运用极点配置技术，系统研究了滑模控制器的切换面和趋近律，采用不连续控制策略，基于两轴伺服进给系统的数学模型设计了滑模变结构位置控制器；针对伺服控制系统存在的系统结构不确定性及外部扰动等问题，提出控制信号修正方法，通过增加补偿信号来应对结构不确定及输入信号的未知扰动。通过卡尔曼滤波有效抑制系统抖振；基于Matlab/Simulink进行了系统仿真实验，仿真实验结果验证了本文开发的滑模变结构控制器在直线电机伺服系统控制方面的有效性和鲁棒性。
伺服进给系统自抗扰控制器设计与控制器参数整定。在系统分析自抗扰控制器的原理及结构组成基础上，将“基于误差消除误差”的策略用现代控制思想加以改进，针对两轴伺服进给系统，设计面向直线电机未知扰动的自抗扰控制器，采用试凑法对控制器参数进行了整定，通过仿真手段测试并验证了控制器的控制能力。
基于永磁直线同步电机的伺服进给实验平台。运用高性能双边型永磁直线同步电机、高精度光栅尺、PMAC运动控制器、PLC控制系统、可控液压加载系统/可控电磁加载系统等为主要设备的两轴定位与加载实验平台。在上位控制层面，基于LabVIEW/G语言开发了实验平台总控模块；在运动控制层面，基于PMAC/PEWIN开发了2轴运动控制程序；在加载控制层面，开发了针对直线与圆周加载系统软件模块；上述实验平台除通常意义的伺服进给系统实验外，可完成控制策略的切换以及多种形式的变载荷加载实验。
单轴电机特性、控制策略与综合加载实验。基于上述实验平台，开展了单轴直线电机特性实验和两轴进给系统综合实验，包括：单轴空载特性实验、单轴可变载荷实验、双轴变载实验等，通过实验结果的分析对直线电机单机特性和两轴进给特性进行讨论，并对全文提出的控制策略及具体方法进行了实验验证。
The concept of high-speed machining (HSM) has brought a revolution to thetraditional machine tool industry. Conventional machine tool structure, spindletechnology, servo system and processing techniques have been greatly evolved.Among the evolutions, that of the servo system is most prominent. Direct-drive linearmotor is considered as an optimal choice for high speed servo system due to its highspeed, high efficiency and high accuracy. Nevertheless linear motors also come withthe problem of force ripples produced by the end effect. Moreover direct-drive linearmotor system is more sensitive to external disturbances due to the lack of intermediatetransmission reducers. As a result, the control of a linear motor system is generallymore difficult. Hence, research on the control strategy for linear motor servo systemsis important from both theoretical aspect and practical aspect. This thesis investigatedthe control of a two-axis high-speed direct-drive servo feed system. A force loadingexperimental platform is developed and some control strategies are proposed anddemonstrated. The main content of the thesis includes:
The structure and the work principle of a permanent magnet linearsynchronous motor (PMLSM) are firstly analyzed. Then, a mathematicmodel for the PMLSM and the two-axis servo feed system is produced usingthe method of coordinate system transformation.
A variable structure sliding mode control (SMC) method and robust controlmethods are presented and are applied to the two-axis servo feed system inclosed-loop. The theory of the sliding mode control is firstly briefly reviewedand is then studied for both the continuous-time system and the discrete-timesystem. The SMC utilizing reaching law method is presented in details. Thedesign method of reaching law is discussed in particular. An integrateddesign procedure based on the pole-placement method for determining thereaching law and the switching surface is proposed. And the procedure isapplied to the mathematical model of the two-axis servo feed system. Someextra control items for correcting control signals are introduced to enhancethe robustness of the tracking controller against the model uncertainty and external disturbance. The effectiveness and robustness properties of aproposed control system with SMC are discussed using Matlab/Simulinksimulations.
A controller based on Active Disturbance Rejection Control (ADRC) for thetwo-axis servo feed system is presented. ADRC inherits the error-drivenapproach (or in principle “use error to eliminate the error”) from traditionalPID method but enhances the later with modern control theory. In theresearch, the ADRC structure is analyzed and designed first, and then tunedfor the two axis servo drive system in order to reject the unknowndisturbance. Finally, simulations validate the controllability of the newcontroller.
An experimental platform is developed for the direct drive servo feed systemin order to verify and investigate the effect of different control strategies andthe load response of the servo system. The platform is constructed using highperformance double-side type PMLSM, high precision linear encoder,PMAC controller and PLC system, controllable hydraulic loading systemand magnetic loading system. A computer application for SCADA isdeveloped using LabVIEW/G lanuage, while PMAC/PEWIN are employedto control the two axis system. A most prominent feature of this platform isthat the control strategy can be switched online and a variety of load signalto the feed system can be applied.
Comprehensive experiments are carried out for both the single-axis linearmotor system and the two-axis feed system. No-load experiments andvarying load experiments are applied for both cases. The characteristics ofthe linear motor and the two-axis feed system are discussed through theanalysis of experimental results. The experiments verify the proposed controlstrategies and implementations.
在系统分析永磁同步电机结构与工作原理的基础上，运用坐标变换法建立了同步电机数学模型，并基于此构建了两轴伺服进给系统传递函数模型。
滑模变结构控制器设计与鲁棒性控制方法。在系统归纳连续系统和离散系统滑模控制器的工作原理及组成结构基础上，综合运用极点配置技术，系统研究了滑模控制器的切换面和趋近律，采用不连续控制策略，基于两轴伺服进给系统的数学模型设计了滑模变结构位置控制器；针对伺服控制系统存在的系统结构不确定性及外部扰动等问题，提出控制信号修正方法，通过增加补偿信号来应对结构不确定及输入信号的未知扰动。通过卡尔曼滤波有效抑制系统抖振；基于Matlab/Simulink进行了系统仿真实验，仿真实验结果验证了本文开发的滑模变结构控制器在直线电机伺服系统控制方面的有效性和鲁棒性。
伺服进给系统自抗扰控制器设计与控制器参数整定。在系统分析自抗扰控制器的原理及结构组成基础上，将“基于误差消除误差”的策略用现代控制思想加以改进，针对两轴伺服进给系统，设计面向直线电机未知扰动的自抗扰控制器，采用试凑法对控制器参数进行了整定，通过仿真手段测试并验证了控制器的控制能力。
基于永磁直线同步电机的伺服进给实验平台。运用高性能双边型永磁直线同步电机、高精度光栅尺、PMAC运动控制器、PLC控制系统、可控液压加载系统/可控电磁加载系统等为主要设备的两轴定位与加载实验平台。在上位控制层面，基于LabVIEW/G语言开发了实验平台总控模块；在运动控制层面，基于PMAC/PEWIN开发了2轴运动控制程序；在加载控制层面，开发了针对直线与圆周加载系统软件模块；上述实验平台除通常意义的伺服进给系统实验外，可完成控制策略的切换以及多种形式的变载荷加载实验。
单轴电机特性、控制策略与综合加载实验。基于上述实验平台，开展了单轴直线电机特性实验和两轴进给系统综合实验，包括：单轴空载特性实验、单轴可变载荷实验、双轴变载实验等，通过实验结果的分析对直线电机单机特性和两轴进给特性进行讨论，并对全文提出的控制策略及具体方法进行了实验验证。
The concept of high-speed machining (HSM) has brought a revolution to thetraditional machine tool industry. Conventional machine tool structure, spindletechnology, servo system and processing techniques have been greatly evolved.Among the evolutions, that of the servo system is most prominent. Direct-drive linearmotor is considered as an optimal choice for high speed servo system due to its highspeed, high efficiency and high accuracy. Nevertheless linear motors also come withthe problem of force ripples produced by the end effect. Moreover direct-drive linearmotor system is more sensitive to external disturbances due to the lack of intermediatetransmission reducers. As a result, the control of a linear motor system is generallymore difficult. Hence, research on the control strategy for linear motor servo systemsis important from both theoretical aspect and practical aspect. This thesis investigatedthe control of a two-axis high-speed direct-drive servo feed system. A force loadingexperimental platform is developed and some control strategies are proposed anddemonstrated. The main content of the thesis includes:
The structure and the work principle of a permanent magnet linearsynchronous motor (PMLSM) are firstly analyzed. Then, a mathematicmodel for the PMLSM and the two-axis servo feed system is produced usingthe method of coordinate system transformation.
A variable structure sliding mode control (SMC) method and robust controlmethods are presented and are applied to the two-axis servo feed system inclosed-loop. The theory of the sliding mode control is firstly briefly reviewedand is then studied for both the continuous-time system and the discrete-timesystem. The SMC utilizing reaching law method is presented in details. Thedesign method of reaching law is discussed in particular. An integrateddesign procedure based on the pole-placement method for determining thereaching law and the switching surface is proposed. And the procedure isapplied to the mathematical model of the two-axis servo feed system. Someextra control items for correcting control signals are introduced to enhancethe robustness of the tracking controller against the model uncertainty and external disturbance. The effectiveness and robustness properties of aproposed control system with SMC are discussed using Matlab/Simulinksimulations.
A controller based on Active Disturbance Rejection Control (ADRC) for thetwo-axis servo feed system is presented. ADRC inherits the error-drivenapproach (or in principle “use error to eliminate the error”) from traditionalPID method but enhances the later with modern control theory. In theresearch, the ADRC structure is analyzed and designed first, and then tunedfor the two axis servo drive system in order to reject the unknowndisturbance. Finally, simulations validate the controllability of the newcontroller.
An experimental platform is developed for the direct drive servo feed systemin order to verify and investigate the effect of different control strategies andthe load response of the servo system. The platform is constructed using highperformance double-side type PMLSM, high precision linear encoder,PMAC controller and PLC system, controllable hydraulic loading systemand magnetic loading system. A computer application for SCADA isdeveloped using LabVIEW/G lanuage, while PMAC/PEWIN are employedto control the two axis system. A most prominent feature of this platform isthat the control strategy can be switched online and a variety of load signalto the feed system can be applied.
Comprehensive experiments are carried out for both the single-axis linearmotor system and the two-axis feed system. No-load experiments andvarying load experiments are applied for both cases. The characteristics ofthe linear motor and the two-axis feed system are discussed through theanalysis of experimental results. The experiments verify the proposed controlstrategies and implementations.
引文
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