高性能数控系统若干关键技术的研究
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摘要
本论文结合具体科研项目,对高性能数控系统若干关键技术进行了系统和深入的研究,主要涉及:面向高速数控加工的柔性加减速控制方法;连续微段高速自适应前瞻插补方法;多轴运动轮廓误差补偿方法。在此基础上,对多坐标数控高速微细加工系统进行开发,建立了原型系统并结合实例对上述方法的有效性和实用性进行验证。
第一章总结了数控技术的发展历程和趋势,详细分析了高性能数控系统若干关键技术的研究现状,最后给出本文研究意义及内容安排。
第二章对面向高速数控加工的柔性加减速控制方法进行研究。在高速加工过程中,采用传统的直线和指数加减速法不能满足加速度的连续,因此会产生很大的冲击,影响零件加工质量和机床的使用寿命。为满足高速数控加工的要求,对柔性加减速控制方法进行了深入研究,并将其进行了实例验证。试验结果表明,三次多项式柔性加减速法综合性能较好,是一种值得推广的柔性加减速控制方法。
第三章对连续微段高速自适应前瞻插补方法进行研究。目前,复杂型面的高速加工往往先由CAM软件粗插补生成微小直线段,再由数控系统的插补器对微段进行精插补。为保证加工精度,需在微段间进行加减速处理。如果在计算加减速区时使每段的始末速度均为零或某一固定数值,势必造成系统启停频繁、效率低下和加工质量差。为此,提出一种高速自适应前瞻插补方法,该方法的实现包括前瞻插补预处理和实时参数化插补两部分。插补预处理时,按轨迹转接点最高速度确定、减速点位置自适应前瞻确定和整体跨段转接点速度校核三个步骤建立连续微段的高速自适应前瞻控制策略。在此基础上,基于三次多项式柔性加减速和整体跨段参数化插补建立连续微段的实时插补算法。试验结果表明,该方法能实现连续微段间进给速度的高速衔接与高速加工时减速点位置的前瞻确定,从而缩短加工时间并提高加工效率。
第四章研究了多轴运动轮廓误差补偿方法。在轮廓加工中,轮廓精度是重要的精度指标,而耦合轮廓控制能够在不改变各轴位置环的同时,有效地减小系统的轮廓误差。本章首先介绍了直线和圆弧的轮廓误差模型,然后分析了伺服系统的动态特性对轮廓误差的影响。针对复杂型面高精度数控加工的要求,提出了一种多轴运动轮廓误差补偿方法,该方法的实现包括多轴运动轮廓控制器的设计和多轴运动轮廓控制器的集成两个部分,最后结合实例对上述方法的有效性进行验证。仿真结果表明,该方法能有效的减小轮廓误差,提高系统的轮廓控制精度。
第五章对多坐标数控高速微细加工原型系统进行开发。结合具体科研项目,对原型系统进行开发。本章首先对原型系统进行总体设计。在上位控制软件开发中,针对实时多任务调度问题,提出采用基于PC无扩展全软件的开放式体系结构,给出抢占式多任务动态调度策略。在硬件开发方面,自行设计了一种基于串行通信的多轴运动控制卡。最后,对开发的原型系统作了总体介绍并对前面几章的研究内容进行了加工试验。试验结果表明,本系统在柔性加减速控制方法、连续微段高速自适应前瞻插补方法、高精度定位控制算法等方面均获得较好的加工效果。
第六章概括了全文的主要研究成果并指出论文还有待进一步完善的地方。
Combined with the research project, several key techniques of high performance NC system are studied detailedly and systematically, which include flexible acceleration and deceleration control methods for high speed NC machining, adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks, contour error compensation method of the multi-axis motion control. On the basis of analysis for the research on several key techniques of high performance NC system, the multi-axes high speed micro fabrication machining system platform is developed and the above methods are validated on the system platform by experiments.
In chapter one, the development of NC technology and the research status on several key techniques of high performance NC system are summarized detailedly. The main research contents of the dissertation are given.
In chapter two, the flexible acc/dec control methods for high speed NC machining are studied. The commonly used methods in most domestic economical NC system are linear and exponential acceleration and deceleration control methods. But the vibration is easily caused by discontinuity of acceleration, which affects machining quality and equipment life. To satisfy the need of high speed NC machining, flexble acc/dec control methods, including 7-segment s-curve, cubic polynomial and quintic polynomial flexible acc/dec control method, are studied. The proposed methods are verified by examplification. The experimental result proves that the cubic polynomial flexible acc/dec control method has the characteristic of easily implementing, stable moving and low impact.
In chapters three, an adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks is proposed. Since a complex contour machining program generated by CAD/CAM systems usually composes a lot of consecutive micro line blocks, actual feedrate is heavily reduced and the consequential machining efficiency becomes very low when the conventional interpolation velocity control method is used in NC machining. An adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks, including interpolation preprocess and real time parametric interpolation, is proposed. During interpolation preprocess, the high speed adaptive look-ahead control strategy is established by using path transfer point maximum velocity confirming, adaptive predetermination of deceleration point position and stride segment transfer point speed checking. During real time interpolation, stride multi-path parametric interpolation algorithm is set up based on the cubic polynomial flexible acc/dec control method. The experiment results demonstrated the proposed method realize high speed machining of consecutive micro line blocks and determination of deceleration point position in advance. The method achieved high speed machining and the productivity is improved significantly.
In chapter four, a contour error compensation method of the multi-axis motion control is researched. In the contour machining, contour accuracy is an important accuracy criterion. The controller objective of cross-coupling control is to eliminate the contour error, rather than the reduction of the individual axial errors. The contour- error model for 2D straight line and circular arc contours is introduced, and the impact on contour error affected by dynamic characteristics of the servo system is analyzed. To satisfy the need of high precision NC machining, a contour error compensation method is proposed and the effectivity of the above method is verified by examplification. The simulation results demonstrate that the proposed method achieves high precision machining and the contour accuracy is improved greatly.
In chapter five, the multi-axes high speed micro fabrication machining system platform is developed. The prototype system is designed firstly, then an open architecture NC system based on NC embedded into PC is proposed, the preemptive multitask scheduling strategy is presented, and the multi-axis motion control card based on serial communication is self-designed. Finally, a total introduction of the multi-axes high speed micro fabrication machining system platform is given and relative research results are validated on the system platform by experiments. The experiment results prove the better performance on flexible acc/dec control method, adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks and high accuracy positioning control algorithm.
In chapter six, the main conclusions of this dissertation are summarized and the further research work is put forward.
第一章总结了数控技术的发展历程和趋势,详细分析了高性能数控系统若干关键技术的研究现状,最后给出本文研究意义及内容安排。
第二章对面向高速数控加工的柔性加减速控制方法进行研究。在高速加工过程中,采用传统的直线和指数加减速法不能满足加速度的连续,因此会产生很大的冲击,影响零件加工质量和机床的使用寿命。为满足高速数控加工的要求,对柔性加减速控制方法进行了深入研究,并将其进行了实例验证。试验结果表明,三次多项式柔性加减速法综合性能较好,是一种值得推广的柔性加减速控制方法。
第三章对连续微段高速自适应前瞻插补方法进行研究。目前,复杂型面的高速加工往往先由CAM软件粗插补生成微小直线段,再由数控系统的插补器对微段进行精插补。为保证加工精度,需在微段间进行加减速处理。如果在计算加减速区时使每段的始末速度均为零或某一固定数值,势必造成系统启停频繁、效率低下和加工质量差。为此,提出一种高速自适应前瞻插补方法,该方法的实现包括前瞻插补预处理和实时参数化插补两部分。插补预处理时,按轨迹转接点最高速度确定、减速点位置自适应前瞻确定和整体跨段转接点速度校核三个步骤建立连续微段的高速自适应前瞻控制策略。在此基础上,基于三次多项式柔性加减速和整体跨段参数化插补建立连续微段的实时插补算法。试验结果表明,该方法能实现连续微段间进给速度的高速衔接与高速加工时减速点位置的前瞻确定,从而缩短加工时间并提高加工效率。
第四章研究了多轴运动轮廓误差补偿方法。在轮廓加工中,轮廓精度是重要的精度指标,而耦合轮廓控制能够在不改变各轴位置环的同时,有效地减小系统的轮廓误差。本章首先介绍了直线和圆弧的轮廓误差模型,然后分析了伺服系统的动态特性对轮廓误差的影响。针对复杂型面高精度数控加工的要求,提出了一种多轴运动轮廓误差补偿方法,该方法的实现包括多轴运动轮廓控制器的设计和多轴运动轮廓控制器的集成两个部分,最后结合实例对上述方法的有效性进行验证。仿真结果表明,该方法能有效的减小轮廓误差,提高系统的轮廓控制精度。
第五章对多坐标数控高速微细加工原型系统进行开发。结合具体科研项目,对原型系统进行开发。本章首先对原型系统进行总体设计。在上位控制软件开发中,针对实时多任务调度问题,提出采用基于PC无扩展全软件的开放式体系结构,给出抢占式多任务动态调度策略。在硬件开发方面,自行设计了一种基于串行通信的多轴运动控制卡。最后,对开发的原型系统作了总体介绍并对前面几章的研究内容进行了加工试验。试验结果表明,本系统在柔性加减速控制方法、连续微段高速自适应前瞻插补方法、高精度定位控制算法等方面均获得较好的加工效果。
第六章概括了全文的主要研究成果并指出论文还有待进一步完善的地方。
Combined with the research project, several key techniques of high performance NC system are studied detailedly and systematically, which include flexible acceleration and deceleration control methods for high speed NC machining, adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks, contour error compensation method of the multi-axis motion control. On the basis of analysis for the research on several key techniques of high performance NC system, the multi-axes high speed micro fabrication machining system platform is developed and the above methods are validated on the system platform by experiments.
In chapter one, the development of NC technology and the research status on several key techniques of high performance NC system are summarized detailedly. The main research contents of the dissertation are given.
In chapter two, the flexible acc/dec control methods for high speed NC machining are studied. The commonly used methods in most domestic economical NC system are linear and exponential acceleration and deceleration control methods. But the vibration is easily caused by discontinuity of acceleration, which affects machining quality and equipment life. To satisfy the need of high speed NC machining, flexble acc/dec control methods, including 7-segment s-curve, cubic polynomial and quintic polynomial flexible acc/dec control method, are studied. The proposed methods are verified by examplification. The experimental result proves that the cubic polynomial flexible acc/dec control method has the characteristic of easily implementing, stable moving and low impact.
In chapters three, an adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks is proposed. Since a complex contour machining program generated by CAD/CAM systems usually composes a lot of consecutive micro line blocks, actual feedrate is heavily reduced and the consequential machining efficiency becomes very low when the conventional interpolation velocity control method is used in NC machining. An adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks, including interpolation preprocess and real time parametric interpolation, is proposed. During interpolation preprocess, the high speed adaptive look-ahead control strategy is established by using path transfer point maximum velocity confirming, adaptive predetermination of deceleration point position and stride segment transfer point speed checking. During real time interpolation, stride multi-path parametric interpolation algorithm is set up based on the cubic polynomial flexible acc/dec control method. The experiment results demonstrated the proposed method realize high speed machining of consecutive micro line blocks and determination of deceleration point position in advance. The method achieved high speed machining and the productivity is improved significantly.
In chapter four, a contour error compensation method of the multi-axis motion control is researched. In the contour machining, contour accuracy is an important accuracy criterion. The controller objective of cross-coupling control is to eliminate the contour error, rather than the reduction of the individual axial errors. The contour- error model for 2D straight line and circular arc contours is introduced, and the impact on contour error affected by dynamic characteristics of the servo system is analyzed. To satisfy the need of high precision NC machining, a contour error compensation method is proposed and the effectivity of the above method is verified by examplification. The simulation results demonstrate that the proposed method achieves high precision machining and the contour accuracy is improved greatly.
In chapter five, the multi-axes high speed micro fabrication machining system platform is developed. The prototype system is designed firstly, then an open architecture NC system based on NC embedded into PC is proposed, the preemptive multitask scheduling strategy is presented, and the multi-axis motion control card based on serial communication is self-designed. Finally, a total introduction of the multi-axes high speed micro fabrication machining system platform is given and relative research results are validated on the system platform by experiments. The experiment results prove the better performance on flexible acc/dec control method, adaptive look-ahead interpolation method for high speed machining of consecutive micro line blocks and high accuracy positioning control algorithm.
In chapter six, the main conclusions of this dissertation are summarized and the further research work is put forward.
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