通用回转体检测仪的软硬件设计
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摘要
回转体工件的生产在制造行业中占有很大的比重,由于内燃机的广泛使用,气缸套、活塞等回转体工件在国民经济中更是占有极重要的地位,而随着现代工业的快速发展,传统的回转体检测仪器不能很好地满足高精度在线检测的要求,从而对高精度高效率的回转体检测仪器研制提出了要求,本课题的研究即是在这种形势下开展的。
本文设计的通用回转体测量仪在检测原理上属于坐标测量,是一种将接触和非接触两种探测技术结合的坐标测量系统,能够很好地满足工业生产提出的高精度快速高效检测的要求,且具有较好的通用性和开放性,并在一定程度上实现了仪器的智能化。
论文主要研究内容和工作如下:
根据回转体的特点,对传统的标准三坐标测量机进行改造,更适合于回转体的检测,并节省了仪器的制造成本;将接触和非接触测量结合,继承两者的优势,使仪器能同时具备高精度和快速高效的优点;建立了以“PMAC+IPC”的双CPU硬件结构为基础的运动控制系统,再与开放性良好的测量软件相结合,使仪器具有较好的开放和扩展性;使用各硬件模块搭建了完整的运动控制系统,对该系统的参数进行合理的设置与调试,并通过PMAC实现了手轮功能、触发式测头的保护以及典型的操作面板等功能;编写了智能化的测量软件,说明了测量软件的设计思想和实现方法,并给出了一键快速测量的详细实现框架和步骤;根据国家或行业的相关安全标准,对仪器进行了预先危险性分析,并采取了多种安全保护措施保障仪器中的安全可靠运行;对检测仪进行了测量系统分析(MSA),分别对仪器的偏倚、稳定性、线性以及重复性和再现性等重要统计特性进行了研究,并根据MSA的判定原理和流程对仪器进行了实际评定。
The total production of axisymmetric workpiece has accounted for a large percentage of manufacturing industry. Along with wide application of internal-combustion engine, axisymmetric workpiece such as cylinder liner, plunger has played more and more important role in national economy. With the rapid development of modern industry, the traditional axisymmetric workpiece detector can no longer fulfills the requirement of on-line detection, axisymmetric workpiece detector of high precision and high efficiency has become the trend of development.
This paper presents a general detecting instrument of axisymmetric body using a coordinate measuring system based on the combination of the contact measurement and non-contact measurement. It can fulfill the requirements of industrial production as high precision and on-line detection, and it also has advantages like good generality and openness. Besides these, it is an intelligent instrument to some extent.
The main research works are as follows.
According to the characteristics of the axisymmetric body, the traditional and standard CMM is reformed to make this instrument be more suitable for the detection of the axisymmetric body, and to lower manufacturing cost. This instrument inherits advantages of the contact measurement and non-contact measurement, so it has both high precision and high efficiency. It also has good openness and expansibility, because its motion control system is based on a dual CPU architecture composed by PMAC and IPC, and also because its measurement software has good openness. This paper presents a complete motion control system with various hardware modules and makes reasonable parameters for it. This system uses PMAC to complete functions such as handwheel, protection of the touch trigger probe and operation panel. Intelligent measurement software is edited for this instrument, and the designing thought, realizing method of the whole software and the detailed implementation steps for one-key fast measurement are included in this paper. According to relevant country or industry safety standards, the preliminary hazard analysis is made, and some safety measures are taken to ensure the safety and reliability of the operation. The basic principle of MSA is introduced, and bias, stability, linearity, repeatability, reproducibility and other important statistical characteristics are researched as its main contents. Finally this paper makes a actual evaluation for this instrument according to the assessment methodologies and procedure of MSA.
本文设计的通用回转体测量仪在检测原理上属于坐标测量,是一种将接触和非接触两种探测技术结合的坐标测量系统,能够很好地满足工业生产提出的高精度快速高效检测的要求,且具有较好的通用性和开放性,并在一定程度上实现了仪器的智能化。
论文主要研究内容和工作如下:
根据回转体的特点,对传统的标准三坐标测量机进行改造,更适合于回转体的检测,并节省了仪器的制造成本;将接触和非接触测量结合,继承两者的优势,使仪器能同时具备高精度和快速高效的优点;建立了以“PMAC+IPC”的双CPU硬件结构为基础的运动控制系统,再与开放性良好的测量软件相结合,使仪器具有较好的开放和扩展性;使用各硬件模块搭建了完整的运动控制系统,对该系统的参数进行合理的设置与调试,并通过PMAC实现了手轮功能、触发式测头的保护以及典型的操作面板等功能;编写了智能化的测量软件,说明了测量软件的设计思想和实现方法,并给出了一键快速测量的详细实现框架和步骤;根据国家或行业的相关安全标准,对仪器进行了预先危险性分析,并采取了多种安全保护措施保障仪器中的安全可靠运行;对检测仪进行了测量系统分析(MSA),分别对仪器的偏倚、稳定性、线性以及重复性和再现性等重要统计特性进行了研究,并根据MSA的判定原理和流程对仪器进行了实际评定。
The total production of axisymmetric workpiece has accounted for a large percentage of manufacturing industry. Along with wide application of internal-combustion engine, axisymmetric workpiece such as cylinder liner, plunger has played more and more important role in national economy. With the rapid development of modern industry, the traditional axisymmetric workpiece detector can no longer fulfills the requirement of on-line detection, axisymmetric workpiece detector of high precision and high efficiency has become the trend of development.
This paper presents a general detecting instrument of axisymmetric body using a coordinate measuring system based on the combination of the contact measurement and non-contact measurement. It can fulfill the requirements of industrial production as high precision and on-line detection, and it also has advantages like good generality and openness. Besides these, it is an intelligent instrument to some extent.
The main research works are as follows.
According to the characteristics of the axisymmetric body, the traditional and standard CMM is reformed to make this instrument be more suitable for the detection of the axisymmetric body, and to lower manufacturing cost. This instrument inherits advantages of the contact measurement and non-contact measurement, so it has both high precision and high efficiency. It also has good openness and expansibility, because its motion control system is based on a dual CPU architecture composed by PMAC and IPC, and also because its measurement software has good openness. This paper presents a complete motion control system with various hardware modules and makes reasonable parameters for it. This system uses PMAC to complete functions such as handwheel, protection of the touch trigger probe and operation panel. Intelligent measurement software is edited for this instrument, and the designing thought, realizing method of the whole software and the detailed implementation steps for one-key fast measurement are included in this paper. According to relevant country or industry safety standards, the preliminary hazard analysis is made, and some safety measures are taken to ensure the safety and reliability of the operation. The basic principle of MSA is introduced, and bias, stability, linearity, repeatability, reproducibility and other important statistical characteristics are researched as its main contents. Finally this paper makes a actual evaluation for this instrument according to the assessment methodologies and procedure of MSA.
引文
[1]张国雄、裘祖荣,测试技术的社会作用及发展方向,全国生产工程第九届年会暨第四届青年科技工作者学术会议论文集,2004
[2]王宝超,便携式关节型三坐标测量仪的研制:[硕士学位论文],北京:机械科学研究总院,2007.6
[3]张国雄,三坐标测量机,天津:天津大学出版社,1999
[4]张云电,薄壁缸套生产技术,北京:国防工业出版社,2000:1~5
[5]宁亮,基于PMAC的通用测量仪控制系统的研究与开发:[硕士学位论文],天津:天津大学,2007
[6]郑文学,仪器精度设计,北京:兵器工业出版社,1992
[7]廖效果、朱启逑,数字控制机床,武汉:华中理工大学出版社,1999:202~233
[8]梁荣铭,三坐标测量机的设计、使用、维修与检定,北京,中国计量出版社,2000
[9]PMAC2 USER MANUAL,Delta Tau Data Systems lnc,2004
[10]PMAC Catalog,Delta Tau Data Systems lnc,2004
[11]PMAC用户手册版本V1.1,北京元茂兴控制技术设备有限责任公司,2001
[12]苏伟,基于PMAC的开放式数控教学平台的研究:[硕士学位论文],天津;天津大学,2005
[13]多轴运动控制器,北京元茂兴控制技术设备有限责任公司,2005
[14]PMAC2A-PC/104 PRODUCT GUIDE,Delta Tau Data Systems lnc,2004
[15]白恩远、王俊元、孙爱国,现代数控机床伺服及检测技术,北京:国防工业出版社,2002
[16]舒志兵,交流伺服运动控制系统,北京:清华大学出版社,2006
[17]史爱峰,电厚度测量设备控制系统设计:[硕士学位论文],大连:大连理工大学,2005
[18]SigmaⅡSeries Servo System Users’Manual,YASKAWA Electric Corporation,2001
[19]Σ-Ⅱ系列SGM□H/SGDM用户手册,安川电机株式会社,2004
[20]张宇、朱巧荣,数控技术实践,北京:机械工业出版社,2001:125~121
[21]TP20 system installation and user’s guide,Renishaw,2002
[22]燕永田,工业控制计算机系统的设计与应用,北京:中国铁道出版社,1999:5~10
[23]PMAC2用户手册,北京元茂兴控制技术设备有限责任公司,2005
[24]PMAC2A-PC/104 HARDWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[25]PMAC/PMAC2 SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[26]PMAC软件手册版本V1.1,北京元茂兴控制技术设备有限责任公司,2001
[27]陈红春,基于PMAC的开放式数控系统的研究:[硕士学位论文],杭州;浙江大学,2006
[28]赵文祥,开放式机器人控制器的设计与研究:[硕士学位论文],镇江;江苏大学,2003
[29]史爱峰、张生芳、盛贤君等,基于PMAC数控系统手轮脉冲跟随功能的实现,制造技术与机床,2004(10):42~45
[30]Pewin32 PRO SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[31]PMAC Tuning PRO(Release Version 1.x)SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2003
[32]PMAC多轴运动控制卡(初级培训),北京元茂兴控制技术设备有限责任公司,2006
[33]侯俊杰,深入浅出MFC(第2版),武汉:华中科技大学出版社,2001
[34]全国机械安全标准化技术委员会,GB/T 15706.1-2007,机械安全基本概念与设计通则第1部分:基本术语和方法,北京:中国标准出版社,2007-03-02
[35]中华人民共和国国家技术监督局,GB/T 16755-1997,机械安全:安全标准的起草与表述规则,北京:中国标准出版社,1997-03-06
[36]全国机械安全标准化技术委员会,GB/T 15706.2-2007,机械安全基本概念与设计通则第2部分:技术原则,北京:中国标准出版社,2007-03-02
[37]中华人民共和国国家技术监督局,GB/T 16855.1-2005,机械安全控制系统有关安全部件第1部分:设计通则,北京:中国标准出版社,2005-08-30
[38]中华人民共和国国家技术监督局,GB/T 16856-1997,机械安全风险评价的原则,北京:中国标准出版社,1997-06-06
[39]中华人民共和国国家技术监督局,GB 5226.1-2002,机械安全机械电气设备第1部分:通用技术条件,北京:中国标准出版社,2002-10-08
[40]朱国宏,预先危险性分析法在工程中的应用,山西煤炭,2007,27(2):40~43
[41]谢少锋,测量系统及其分析方法综述与分析,电子质量,2006(12):18~19
[42]Ford、GM、Chrysler,Measurements systems analysis reference manual,AIAG,Detroit,Michiga,2002.3
[43]王秉刚,Keh Tung,测量系统分析参考手册第三版,天津:中国汽车技术研究中心,2003.5
[44]董双财,测量系统分析:理沦、方法和应用,北京:中国计量出版社,2006.6
[45]陈晋美,国内外企业常用抽样检验与测量技术,北京:中国计量出版社,2006.5
[46]宗缚鹏,测量系统分析(MSA)及其应用,中国计量,2005.3:72~74
[47]代大山、谢少锋,测量系统分析第三版之线性分析,第五届海峡两岸计量与质量学术研讨会论文集,2004
[48]史道济、张玉环,应用数理统计,天津:天津大学出版社,2008.4
[2]王宝超,便携式关节型三坐标测量仪的研制:[硕士学位论文],北京:机械科学研究总院,2007.6
[3]张国雄,三坐标测量机,天津:天津大学出版社,1999
[4]张云电,薄壁缸套生产技术,北京:国防工业出版社,2000:1~5
[5]宁亮,基于PMAC的通用测量仪控制系统的研究与开发:[硕士学位论文],天津:天津大学,2007
[6]郑文学,仪器精度设计,北京:兵器工业出版社,1992
[7]廖效果、朱启逑,数字控制机床,武汉:华中理工大学出版社,1999:202~233
[8]梁荣铭,三坐标测量机的设计、使用、维修与检定,北京,中国计量出版社,2000
[9]PMAC2 USER MANUAL,Delta Tau Data Systems lnc,2004
[10]PMAC Catalog,Delta Tau Data Systems lnc,2004
[11]PMAC用户手册版本V1.1,北京元茂兴控制技术设备有限责任公司,2001
[12]苏伟,基于PMAC的开放式数控教学平台的研究:[硕士学位论文],天津;天津大学,2005
[13]多轴运动控制器,北京元茂兴控制技术设备有限责任公司,2005
[14]PMAC2A-PC/104 PRODUCT GUIDE,Delta Tau Data Systems lnc,2004
[15]白恩远、王俊元、孙爱国,现代数控机床伺服及检测技术,北京:国防工业出版社,2002
[16]舒志兵,交流伺服运动控制系统,北京:清华大学出版社,2006
[17]史爱峰,电厚度测量设备控制系统设计:[硕士学位论文],大连:大连理工大学,2005
[18]SigmaⅡSeries Servo System Users’Manual,YASKAWA Electric Corporation,2001
[19]Σ-Ⅱ系列SGM□H/SGDM用户手册,安川电机株式会社,2004
[20]张宇、朱巧荣,数控技术实践,北京:机械工业出版社,2001:125~121
[21]TP20 system installation and user’s guide,Renishaw,2002
[22]燕永田,工业控制计算机系统的设计与应用,北京:中国铁道出版社,1999:5~10
[23]PMAC2用户手册,北京元茂兴控制技术设备有限责任公司,2005
[24]PMAC2A-PC/104 HARDWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[25]PMAC/PMAC2 SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[26]PMAC软件手册版本V1.1,北京元茂兴控制技术设备有限责任公司,2001
[27]陈红春,基于PMAC的开放式数控系统的研究:[硕士学位论文],杭州;浙江大学,2006
[28]赵文祥,开放式机器人控制器的设计与研究:[硕士学位论文],镇江;江苏大学,2003
[29]史爱峰、张生芳、盛贤君等,基于PMAC数控系统手轮脉冲跟随功能的实现,制造技术与机床,2004(10):42~45
[30]Pewin32 PRO SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2004
[31]PMAC Tuning PRO(Release Version 1.x)SOFTWARE REFERENCE MANUAL,Delta Tau Data Systems lnc,2003
[32]PMAC多轴运动控制卡(初级培训),北京元茂兴控制技术设备有限责任公司,2006
[33]侯俊杰,深入浅出MFC(第2版),武汉:华中科技大学出版社,2001
[34]全国机械安全标准化技术委员会,GB/T 15706.1-2007,机械安全基本概念与设计通则第1部分:基本术语和方法,北京:中国标准出版社,2007-03-02
[35]中华人民共和国国家技术监督局,GB/T 16755-1997,机械安全:安全标准的起草与表述规则,北京:中国标准出版社,1997-03-06
[36]全国机械安全标准化技术委员会,GB/T 15706.2-2007,机械安全基本概念与设计通则第2部分:技术原则,北京:中国标准出版社,2007-03-02
[37]中华人民共和国国家技术监督局,GB/T 16855.1-2005,机械安全控制系统有关安全部件第1部分:设计通则,北京:中国标准出版社,2005-08-30
[38]中华人民共和国国家技术监督局,GB/T 16856-1997,机械安全风险评价的原则,北京:中国标准出版社,1997-06-06
[39]中华人民共和国国家技术监督局,GB 5226.1-2002,机械安全机械电气设备第1部分:通用技术条件,北京:中国标准出版社,2002-10-08
[40]朱国宏,预先危险性分析法在工程中的应用,山西煤炭,2007,27(2):40~43
[41]谢少锋,测量系统及其分析方法综述与分析,电子质量,2006(12):18~19
[42]Ford、GM、Chrysler,Measurements systems analysis reference manual,AIAG,Detroit,Michiga,2002.3
[43]王秉刚,Keh Tung,测量系统分析参考手册第三版,天津:中国汽车技术研究中心,2003.5
[44]董双财,测量系统分析:理沦、方法和应用,北京:中国计量出版社,2006.6
[45]陈晋美,国内外企业常用抽样检验与测量技术,北京:中国计量出版社,2006.5
[46]宗缚鹏,测量系统分析(MSA)及其应用,中国计量,2005.3:72~74
[47]代大山、谢少锋,测量系统分析第三版之线性分析,第五届海峡两岸计量与质量学术研讨会论文集,2004
[48]史道济、张玉环,应用数理统计,天津:天津大学出版社,2008.4