五自由度自动焊机结构建模和伺服控制软件的研究
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摘要
随着焊接自动化的不断提高，对管道焊接提出了更高的要求，如何在不增加或少量增加焊接成本的基础上提高管道焊接的质量和效率是急需解决的问题，研制基于PC机的管道专用数控焊接机可望有效地解决这个问题，有利于提高我国焊接自动化水平。
本文在分析国内外管道自动焊机研究状况的基础上，细化了五自由度管道数控专用焊机的设计，确定数控系统由PC机和多轴运动控制器组成，完善了五自由度管道数控专用焊机的空间数学模型。为了适应焊缝的宽度，提高焊缝的质量，并结合焊接过程的实际情况，确定了在理论中心轨迹的基础上添加附加摆动，讨论了圆摆动和正弦摆动两种典型模式，建立了运动轨迹的方程。当焊接两圆管的直径相同时，施焊过程中会产生尖角，导致速度不连续，而难以在焊接过程中实现，由此确定采用圆弧过渡的修正方法。对上述中的运动轨迹方程通过Matlab进行了仿真，论证了运动轨迹方程的正确性及所提出修正方法的可行性。
在确定硬件系统的基础上，编制了适合硬件控制系统的软件。软件设计的主要内容为：(1)编制了友好的人机界面，能方便地完成焊接参数的输入及常用焊接参数的存储；(2)建立PC机与PMAC的通信接口，通过加载动态链接库在程序中调用PMAC的内部函数，控制多轴的协调运动；(3)利用VtoolsD研制VxD实现硬件中断，建立VxD和应用程序的通信接口，通过中断来实现数据的实时读取。
针对附加摆动，设计了附加圆摆动的正弦轨迹曲线和椭圆轨迹曲线实验，论证了在原有模型基础上添加摆动轨迹在实际当中是完全切实可行的，有效地解决了焊接机设计的核心技术问题。同时通过附加圆摆动的折线轨迹曲线的实验和调试，确定了利用圆摆动过渡尖角的方法，避免了当焊接两圆管直径相同或是相近时在焊接过程中产生的冲击。
系统以VC++6.0、BC3.1、VtoolsD3.0和Pcomm Library工具包为软件开发工具，以个人微机和PMAC为硬件开发平台。本文应用的理论已在两轴驱动实验中得到验证，为五自由度管道数控专用焊机的进一步研制打下了坚实的理论和实验基础。
With the development of weld automatization, better performances are repaired in the field of pipeline weld. How to improve the quality and efficiency of pipeline welding has become a urgent problem to be resolved. Development of PC-based numerical control pipeline weld machine will do with such a problem effectively and help to improve the weld automization in our country.
Based on the analysis of civil and abroad research condition of pipeline automatic weld machine, the design of five freedoms numerical control pipeline welding machine is done more thoroughly with the PC and multi-axes move controller composed numerical control system decided and the mathematic model for the machine perfected. To adapt the width of welding lines and improve the welding quality, adding swing to the moving on theoretical center track is put forward with the actual welding process synthetically thought of. Circle swing mode and.sine swing mode are discussed as typical ones and the equations of moving tracks are established. The closed angle produced in the welding process of two round pipelines with the same diameter can result in velocity discontinuity, which makes it sharp for such a welding process to be realized, and so the arc transition correct method is given. The correctness of the moving track equation and the feasibility of the correct method are proved by the simulation of the moving track equation with Matlab.
Software fit for the hardware is developed. Its main contents include: (1) Establish friendly human-computer interface, which make it convenient to input and store the often-used welding parameters. (2) Establish the communication between PC and PMAC, transfer the internal function of PMAC by loading the DLL in the program to harmonize the moving of multi-axes. (3) Develop VxD via VtoolsD to realize hardware interrupt, make the communication between VxD and application program, utilize the interrupt to read data real-timely.
Experiments of sine and ellipse track curves for additional round swing are designed and the feasibility of adding swing track to former model is proved. So the critical technique problem in welding machine design is solved. At the same time a method of utilizing round swing transition horn is put forward to void shock produced in the process of welding two round pipelines of the same or similar diameter by such experiments and debugging.
The software system is developed based on VC++ 6.0, BC3.1, VtoolsDS.O and Pcomm Library, and uses personal microcomputer and PMAC as the hardware development platform. The application theory of this paper, which makes a strong theoretical and experimental cornerstone for the further research on the five freedoms numerical control pipeline welding machine, is proved in two axes servo control system.
本文在分析国内外管道自动焊机研究状况的基础上，细化了五自由度管道数控专用焊机的设计，确定数控系统由PC机和多轴运动控制器组成，完善了五自由度管道数控专用焊机的空间数学模型。为了适应焊缝的宽度，提高焊缝的质量，并结合焊接过程的实际情况，确定了在理论中心轨迹的基础上添加附加摆动，讨论了圆摆动和正弦摆动两种典型模式，建立了运动轨迹的方程。当焊接两圆管的直径相同时，施焊过程中会产生尖角，导致速度不连续，而难以在焊接过程中实现，由此确定采用圆弧过渡的修正方法。对上述中的运动轨迹方程通过Matlab进行了仿真，论证了运动轨迹方程的正确性及所提出修正方法的可行性。
在确定硬件系统的基础上，编制了适合硬件控制系统的软件。软件设计的主要内容为：(1)编制了友好的人机界面，能方便地完成焊接参数的输入及常用焊接参数的存储；(2)建立PC机与PMAC的通信接口，通过加载动态链接库在程序中调用PMAC的内部函数，控制多轴的协调运动；(3)利用VtoolsD研制VxD实现硬件中断，建立VxD和应用程序的通信接口，通过中断来实现数据的实时读取。
针对附加摆动，设计了附加圆摆动的正弦轨迹曲线和椭圆轨迹曲线实验，论证了在原有模型基础上添加摆动轨迹在实际当中是完全切实可行的，有效地解决了焊接机设计的核心技术问题。同时通过附加圆摆动的折线轨迹曲线的实验和调试，确定了利用圆摆动过渡尖角的方法，避免了当焊接两圆管直径相同或是相近时在焊接过程中产生的冲击。
系统以VC++6.0、BC3.1、VtoolsD3.0和Pcomm Library工具包为软件开发工具，以个人微机和PMAC为硬件开发平台。本文应用的理论已在两轴驱动实验中得到验证，为五自由度管道数控专用焊机的进一步研制打下了坚实的理论和实验基础。
With the development of weld automatization, better performances are repaired in the field of pipeline weld. How to improve the quality and efficiency of pipeline welding has become a urgent problem to be resolved. Development of PC-based numerical control pipeline weld machine will do with such a problem effectively and help to improve the weld automization in our country.
Based on the analysis of civil and abroad research condition of pipeline automatic weld machine, the design of five freedoms numerical control pipeline welding machine is done more thoroughly with the PC and multi-axes move controller composed numerical control system decided and the mathematic model for the machine perfected. To adapt the width of welding lines and improve the welding quality, adding swing to the moving on theoretical center track is put forward with the actual welding process synthetically thought of. Circle swing mode and.sine swing mode are discussed as typical ones and the equations of moving tracks are established. The closed angle produced in the welding process of two round pipelines with the same diameter can result in velocity discontinuity, which makes it sharp for such a welding process to be realized, and so the arc transition correct method is given. The correctness of the moving track equation and the feasibility of the correct method are proved by the simulation of the moving track equation with Matlab.
Software fit for the hardware is developed. Its main contents include: (1) Establish friendly human-computer interface, which make it convenient to input and store the often-used welding parameters. (2) Establish the communication between PC and PMAC, transfer the internal function of PMAC by loading the DLL in the program to harmonize the moving of multi-axes. (3) Develop VxD via VtoolsD to realize hardware interrupt, make the communication between VxD and application program, utilize the interrupt to read data real-timely.
Experiments of sine and ellipse track curves for additional round swing are designed and the feasibility of adding swing track to former model is proved. So the critical technique problem in welding machine design is solved. At the same time a method of utilizing round swing transition horn is put forward to void shock produced in the process of welding two round pipelines of the same or similar diameter by such experiments and debugging.
The software system is developed based on VC++ 6.0, BC3.1, VtoolsDS.O and Pcomm Library, and uses personal microcomputer and PMAC as the hardware development platform. The application theory of this paper, which makes a strong theoretical and experimental cornerstone for the further research on the five freedoms numerical control pipeline welding machine, is proved in two axes servo control system.
引文
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[10]殷人昆。，陶永雷，谢若阳，盛绚华编著．数据结构(C++语言版)．北京：清华大学出版社1999．7
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[14]王军著．五自由度自动焊机伺服控制的研究．长沙铁道学院硕士学位论文，1998．6
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[21]Delta Tau Data System Inc DLLs and C-function Libraries 1998
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[24]易志华．国内电焊机发展概况．电焊机，1997，No4
[25]盂璇．邢玉生，王春．基于PMAC的并行双CPU开放式数控系统的研究与开发．组合机床与自动化加工鼓技术，2000，No10
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[28]Sun D, Mills J.K. A discrete. approach to inner cunent loop control design of PMAC motor control systems.2001, v3(1): 25-27
[29]Wang O.-J,Fong C.T,Chang K.J.based self-tumning P1 controller for precise motion control of PMAC motors. 2001. v48(4):408-415
[30]Grcar B,Caf?ta P, K?in. L Exact tracking by dynamic field-weakemed PMAC servodrive,v16(5):38～42
[31]Grcar B,Cafuta P, Zmidaric DTwo stage nonlinear control design of PMAC servodrive. 1996, v3(1):3-8
[32]黄志辉．专用数控磨床CNC系统的设计与研究．新技术新工艺，2000，No 11
[33]黄志辉，余朋，罗大庸等．多轴CNC交流伺服螺旋传动系统中的误差源分析．长沙铁道学院学报．1999，Mo 3
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[35]王恒升．机电一体化及其应用．机床电器．1998，No5
[36]姜山，程君实．Windows9X硬件中断设备驱动程序的开发．微型电脑应用，2000，Vol 16，No1
[37]许永华，李钢，王纯贤．WIND为OWS环境下硬件中断的实现，机械与电子,1998，No 2
[38]夏雨佳，席裕庚．Windows95数控系统实时中断研究．计算机工程与应用，2000，No 1
[39]关于挂IRQ8的—个完整的VXD例子．bbs水木清华站
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[2][美]David J.Krulinski,Scot Wingo,Gecrge Shephers著．希望图书创作室译．Visual C++技术内幕(第五版)北京：北京希望电子出版社，1999．5
[3][美]Microsoft公司著．希望图书创作室译．Visual C++6.0类库参考手册．北京：北京希望电脑公司,1999．2
[3][美]Herbert Schildt著．杨长虹，徐碚译．C++语言大全．北京：电子工业出版社．1994．8
[4]蔡自兴．机器人学北京：清华大学出版社，2000．9
[6]何克忠．李伟编著．计算机控制系统．北京：清华大学出版社，1998．4
[7]于英名，莫玮，于佳编著．计算机接口技术．北京：电子工业出版社,1999．10
[8]吴新余．周井泉，沈元隆编著．信号与系统北京：电子工业出版社,1999．12
[9]王燕编著．面向对象的理论与C++实践．北京：清华大学出版社，1997．2
[10]殷人昆。，陶永雷，谢若阳，盛绚华编著．数据结构(C++语言版)．北京：清华大学出版社1999．7
[11]全荣主编．五坐标联动数控技术．长沙．湖南科学技术出版社，1995
[12]谢云荪，张志让主编．数学实验．北京：科学出版社，1998．8
[13]程卫国，冯峰，姚东，徐昕等编著．MATLAB5.3应用指南．北京：人民邮电出社，1999．11
[14]王军著．五自由度自动焊机伺服控制的研究．长沙铁道学院硕士学位论文，1998．6
[15]帅梅著．五轴五联动数控系统的内插补算法研究及数控系统的开发与研制．西安交通大学博士学位论文，1998．6
[16]武安河，周利莉编著．Windows设备驱动程序开发实务．北京：电子工业出版社，2001．9
[17]北京元茂兴控制设备技术有限公司．PMAC多轴运动控制器．1998
[18]Delta Tau Data System Inc. PMAC USER'S MANUAL.1998
[19]Delta Tan Data Syscem Inc.PMAC SOFTWARE REFERENCE.1998
[20]Delta Tan Data System Inc,PMAC Option2, Dual Ported RAM User's Gaide,1998
[21]Delta Tau Data System Inc DLLs and C-function Libraries 1998
[22]Delta Tau Data System Inc.Pcomm32 PMAC 32 Bit Driver. 1998
[23]章富元，方江龙，汤季安．对我国数控技术发展的思考机床，中国机械工程，1999，Vol.10,No10
[24]易志华．国内电焊机发展概况．电焊机，1997，No4
[25]盂璇．邢玉生，王春．基于PMAC的并行双CPU开放式数控系统的研究与开发．组合机床与自动化加工鼓技术，2000，No10
[26]石林镇．可编程多轴控制器(PMAC)及其应用．新技术新工艺，1995，No 6
[27]江吉彬，杜桂生．数控焊机CNC系统软件的研究与实现电焊机，1997，No 6
[28]Sun D, Mills J.K. A discrete. approach to inner cunent loop control design of PMAC motor control systems.2001, v3(1): 25-27
[29]Wang O.-J,Fong C.T,Chang K.J.based self-tumning P1 controller for precise motion control of PMAC motors. 2001. v48(4):408-415
[30]Grcar B,Caf?ta P, K?in. L Exact tracking by dynamic field-weakemed PMAC servodrive,v16(5):38～42
[31]Grcar B,Cafuta P, Zmidaric DTwo stage nonlinear control design of PMAC servodrive. 1996, v3(1):3-8
[32]黄志辉．专用数控磨床CNC系统的设计与研究．新技术新工艺，2000，No 11
[33]黄志辉，余朋，罗大庸等．多轴CNC交流伺服螺旋传动系统中的误差源分析．长沙铁道学院学报．1999，Mo 3
[34]黄志辉，罗大庸．数控焊接机床伺服控制算法的研究．长沙铁道学院学报，1998，No 2
[35]王恒升．机电一体化及其应用．机床电器．1998，No5
[36]姜山，程君实．Windows9X硬件中断设备驱动程序的开发．微型电脑应用，2000，Vol 16，No1
[37]许永华，李钢，王纯贤．WIND为OWS环境下硬件中断的实现，机械与电子,1998，No 2
[38]夏雨佳，席裕庚．Windows95数控系统实时中断研究．计算机工程与应用，2000，No 1
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