3D贴片电感线圈绕制关键技术与装备的研发
|
摘要
本文结合国家火炬计划“SKR-XDQ多轴全自动数控绕线机项目”项目(2008GH040905),与杭州奥士玛数控设备有限公司合作,针对3D贴片电感线圈生产设备控制系统进行研究。其中包括排线轴折返运动速度加减混合算法的研究,3D贴片电感线圈绕制工艺的研究与设计,整机控制流程的制定,实现了设备硬件电路的设计,设备软件的研究与设置,完成了PLC和运动控制程序的设计,实现了设备的整机调试与生产。
首先,研究3D贴片电感线圈生产设备的关键技术。在分析3D贴片电感线圈绕制工艺的基础上,针对绕线过程中的排线轴高速折返运动容易导致设备振动的问题,采用加减速曲线的多项式构造方法,结合加减速过程中加加速不连续的问题分析,提出高速折返运动速度混合算法,保证排线轴高速折返运动时加减速平滑,提高绕线精度。
其次,研究3D贴片电感线圈生产设备的机械组成,阐述设备的关键功能部件。在此基础上,结合产品具体技术要求,研究线圈绕制的工艺方法,确定线圈绕制工艺路线。根据工艺路线,设计系统整机生产控制流程。根据设备控制性能的要求,设计控制系统的硬件总体框架,选择控制系统类型及电子元件具体型号,完成了系统的硬件电路设计与调试。最后,基于3D贴片电感线圈生产设备控制系统的硬件电路设计,结合3D线圈绕制的工艺要求和控制流程,设计控制系统软件,其中包括PLC开发的逻辑控制、运动控制器开发的电机运动控制、VC开发的上位机人机界面等等。完成了系统的软件设计与调试。
经过联机调试运行,3D贴片电感线圈生产设备控制系统满足生产要求,高速折返运动速度混合算法的提出,保证排线轴高速折返运动时加减速平滑,提高绕线精度,硬件电路运行可靠,控制软件运行稳定。
Cooperated with OZMA, the control system of the equipment for production of 3D electric inductions coil is researched and supported by the National Torch Plans(2008GH040905). Velocity blending algorithm for axes moving acceleration and deceleration is firstly researched for winding tooling moving back and forth smoothly. Then the technology for winding of the 3D electric induction coil is developed and confirmed. And the connection circuit between the servo amplifier and motion controller is designed. Based on the technology of winding and hardware design, the control program in PLC and motion controller is programmed. The communication between PC and PLC is established by human-computer interface. At last, the whole system is testing and adjusted. Production for 3D electric induction coil winding is accomplished.
In the first, the key technologies for 3D electric induction coil winding are researched. Based on the key technologies for the winding of 3D electric induction coil and analyzing the harmful vibration due to winding tooling moving back and forth in high speed, a novel velocity blending algorithm is proposed. The algorithm can makes the winding tooling moving smoothly and improves the precision of winding efficiently.
Secondly, the mechanical component of the equipment is introduced. Based on the technology, the flow chart of winding is developed and determined. According to the requirement of the control, the overall structure of control system is constructed. And the controller and servo system are selected. At last, the circuit connections of whole equipment are designed and installed.
Thirdly, Based on the hardware circuit of control system and the technology, the program of PLC and motion controller is developed and debugged.
On-line testing of the equipment shows can makes the winding tooling moving smoothly and improves the precision of winding efficiently. And the hardware circuit is reliable and the program is stable.
首先,研究3D贴片电感线圈生产设备的关键技术。在分析3D贴片电感线圈绕制工艺的基础上,针对绕线过程中的排线轴高速折返运动容易导致设备振动的问题,采用加减速曲线的多项式构造方法,结合加减速过程中加加速不连续的问题分析,提出高速折返运动速度混合算法,保证排线轴高速折返运动时加减速平滑,提高绕线精度。
其次,研究3D贴片电感线圈生产设备的机械组成,阐述设备的关键功能部件。在此基础上,结合产品具体技术要求,研究线圈绕制的工艺方法,确定线圈绕制工艺路线。根据工艺路线,设计系统整机生产控制流程。根据设备控制性能的要求,设计控制系统的硬件总体框架,选择控制系统类型及电子元件具体型号,完成了系统的硬件电路设计与调试。最后,基于3D贴片电感线圈生产设备控制系统的硬件电路设计,结合3D线圈绕制的工艺要求和控制流程,设计控制系统软件,其中包括PLC开发的逻辑控制、运动控制器开发的电机运动控制、VC开发的上位机人机界面等等。完成了系统的软件设计与调试。
经过联机调试运行,3D贴片电感线圈生产设备控制系统满足生产要求,高速折返运动速度混合算法的提出,保证排线轴高速折返运动时加减速平滑,提高绕线精度,硬件电路运行可靠,控制软件运行稳定。
Cooperated with OZMA, the control system of the equipment for production of 3D electric inductions coil is researched and supported by the National Torch Plans(2008GH040905). Velocity blending algorithm for axes moving acceleration and deceleration is firstly researched for winding tooling moving back and forth smoothly. Then the technology for winding of the 3D electric induction coil is developed and confirmed. And the connection circuit between the servo amplifier and motion controller is designed. Based on the technology of winding and hardware design, the control program in PLC and motion controller is programmed. The communication between PC and PLC is established by human-computer interface. At last, the whole system is testing and adjusted. Production for 3D electric induction coil winding is accomplished.
In the first, the key technologies for 3D electric induction coil winding are researched. Based on the key technologies for the winding of 3D electric induction coil and analyzing the harmful vibration due to winding tooling moving back and forth in high speed, a novel velocity blending algorithm is proposed. The algorithm can makes the winding tooling moving smoothly and improves the precision of winding efficiently.
Secondly, the mechanical component of the equipment is introduced. Based on the technology, the flow chart of winding is developed and determined. According to the requirement of the control, the overall structure of control system is constructed. And the controller and servo system are selected. At last, the circuit connections of whole equipment are designed and installed.
Thirdly, Based on the hardware circuit of control system and the technology, the program of PLC and motion controller is developed and debugged.
On-line testing of the equipment shows can makes the winding tooling moving smoothly and improves the precision of winding efficiently. And the hardware circuit is reliable and the program is stable.
引文
[1]刘正琼,韦康,吴玺,孙述鹏.智能PKE系统设计[J].仪器仪表学报,2007,28(4):339-346.
[2]韦康,刘正琼,吴玺.PKE系统在汽车电子中的应用[J].国外电子测量技术,2007,26(8):53-55.
[3]王超,郑宾,吴柯锐.汽车被动无钥门禁系统(PKE)研究[J].电脑知识与技术:学术交流,2009,5(7):5304-5305.
[4]刘利祥,Mattias.Voss,刘晓梁.基于虚拟仪器技术的汽车遥控钥匙(RKE)功能测试平台实现[J].现代电子技术,2005,28(13):111-112.
[5]品佳集团.PKE完全解决方案[J].电子产品世界,2009,(8):59.
[6] Brown Geoff. PKE for sensitive mobile application:An implementaion of TLS 1.0[J].IEE Colloquium.2003.3(10059):139-141.
[7]兰天,汪宏杰,汪镭,吴启迪.基于RFID的PKE系统[J].微型电脑应用,2010,26(1):34-36.
[8]徐斌.国外绕线机动态[J].电子工艺简讯,1989,(2):21-22.
[9]康善存.国内外小型绕线机概况与发展趋势[J].电子工艺简讯,1992,(11):14-18.
[10]易晋湘.日产绕线机系统及其故障分析[J].微特电机,1993,(3):41-42.
[11]纪洪波.自动绕线机控制系统的研究[J].烟台大学学报,1995,(1):50-53.
[12]霍孟友,马征,艾兴.新型自动绕线机设计[J].机械与电子,1999,(6):54-55.
[13]王伟民,李庆亮,赵付超,王建花.多轴绕线机的研究[J].电子电工专用设备,2010,(184):50-53.
[14]于克龙.绕线机排线机构的运动分析与控制[J].机械制造与自动化,2005,34(3):102-103.
[15]钱吴全.一种负反馈式绕线机恒张力机构原理浅探[J].中小型电机,1995,22(4):29-30.
[16]陈文华,张征林,马子魁,李立新,郑卫东.数控绕线机高速主轴单元的动力学分析[J].机电工程,2007,24(11):32-35.
[17]王晓磊,许皆平,崔建.一种基于矢量变频技术的超导线专用恒张力绕线机[J].低温与超导,2010,(4):25-29.
[18]胡建华,廖文和,周儒荣.CNC系统中几种升降速控制曲线的研究与比较[J].南京航空航天大学学报,1999,31(6):706-710.
[19]潘敏,邬义杰,冷洪滨.数控系统加减速控制方法的研究[J].制造自动化,2005,27(9):29-30.
[20]廖德刚,蔡悦华,车晓毅.插补器与数控机床的合理使用[J].常德师范学院学报,1999,11(4):71-73.
[21] Dong Il Kim,Sungkwun Kim.Performance evaluation of software acceleration/deceleration algorithms in machining and contouring[J]. IEEE Transactions on Industrial Electronics,1992,3:1263-1269.
[22]廖德刚,蔡悦华,车晓毅.插补器与数控机床的合理使用[J].常德师范学院学报,1999,11(4):71-73.
[23]郭新贵,李从心.一种新型柔性加减速算法[J].上海交通大学学报,2003,37(2):205-212.
[24]林一松,汤兆红,区锐相,林金萍,龚德明.一种S型曲线加减速计算方法[J].制造技术与机床,2005,(11):205-212.
[25]张华宇,王孚懋,徐方全.S形曲线加减速算法的研究[J].现代制造技术与装备,2006,(2):21-22.
[26] Kaan Erkorkmaz,Yusuf Altintas.High speed CNC system design.Part I:jerk limited trajectory generation and quintic spline interpolation[J].International Journal of Machine Tools & Manufacture,2000, 41(2001):1323-1345.
[27] JEON J W,HA Y Y. A generalized approach for the acceleration deceleration of industrial robots and CNC machine tools[J].IEEE Transactions on Industrial Electronics,2000,47(1):133-139.
[28] K Ren,H.G.Chen,W.H.Chen,J Pan.Research on Vector Blending Algorithm of Velocity for Acceleration and Decdleration of High Speed Machining[J].Materials Science Forum Vols, 2009,626-627(2009):243-248.
[29] JEON J W. Efficient acceleration and deceleration technique for short distance movement in industrial robots and CNC machine tools[J].IEEE Transactions on Industrial Electronics,2000,36(8):766-767.
[30]冷洪滨,潘敏,邬义杰.三次多项式型段内加减速控制新方法[J].浙江大学学报,2008,42(8):1440-1444.
[31]李庆杨,王能超,易大义.数值分析[M].武汉:华中科技大学出版社,2006.
[32]杨建刚.旋转机械振动分析与工程应用[M].北京:中国电力出版社,2007.
[33] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER User’s Manual.
[34]秦琴.基于PLC控制的丝网印刷机电气控制系统的研制[D].广州:中山大学学报,2009.
[35] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER Programming Manual.
[36] MITSUBISHI ELECTRIC CO.SERVO AMPLIFIER INSTRUCTION MANUAL.
[37] MITSUBISHI ELECTRIC CO.CC-LINK User’s Manual.
[38] MITSUBISHI ELECTRIC CO.GX Developer操作手册.
[39] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER(REAL MODE) Programming Manual.
[40] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER(Motion SFC) Programming Manual.
[41]侯俊杰.深入浅出MFC[M].武汉:华中科技大学出版社,2008.
[42]曾凡锋,苗雨.MFC编程技巧与范例详解[M].北京:清华大学出版社,2008.
[2]韦康,刘正琼,吴玺.PKE系统在汽车电子中的应用[J].国外电子测量技术,2007,26(8):53-55.
[3]王超,郑宾,吴柯锐.汽车被动无钥门禁系统(PKE)研究[J].电脑知识与技术:学术交流,2009,5(7):5304-5305.
[4]刘利祥,Mattias.Voss,刘晓梁.基于虚拟仪器技术的汽车遥控钥匙(RKE)功能测试平台实现[J].现代电子技术,2005,28(13):111-112.
[5]品佳集团.PKE完全解决方案[J].电子产品世界,2009,(8):59.
[6] Brown Geoff. PKE for sensitive mobile application:An implementaion of TLS 1.0[J].IEE Colloquium.2003.3(10059):139-141.
[7]兰天,汪宏杰,汪镭,吴启迪.基于RFID的PKE系统[J].微型电脑应用,2010,26(1):34-36.
[8]徐斌.国外绕线机动态[J].电子工艺简讯,1989,(2):21-22.
[9]康善存.国内外小型绕线机概况与发展趋势[J].电子工艺简讯,1992,(11):14-18.
[10]易晋湘.日产绕线机系统及其故障分析[J].微特电机,1993,(3):41-42.
[11]纪洪波.自动绕线机控制系统的研究[J].烟台大学学报,1995,(1):50-53.
[12]霍孟友,马征,艾兴.新型自动绕线机设计[J].机械与电子,1999,(6):54-55.
[13]王伟民,李庆亮,赵付超,王建花.多轴绕线机的研究[J].电子电工专用设备,2010,(184):50-53.
[14]于克龙.绕线机排线机构的运动分析与控制[J].机械制造与自动化,2005,34(3):102-103.
[15]钱吴全.一种负反馈式绕线机恒张力机构原理浅探[J].中小型电机,1995,22(4):29-30.
[16]陈文华,张征林,马子魁,李立新,郑卫东.数控绕线机高速主轴单元的动力学分析[J].机电工程,2007,24(11):32-35.
[17]王晓磊,许皆平,崔建.一种基于矢量变频技术的超导线专用恒张力绕线机[J].低温与超导,2010,(4):25-29.
[18]胡建华,廖文和,周儒荣.CNC系统中几种升降速控制曲线的研究与比较[J].南京航空航天大学学报,1999,31(6):706-710.
[19]潘敏,邬义杰,冷洪滨.数控系统加减速控制方法的研究[J].制造自动化,2005,27(9):29-30.
[20]廖德刚,蔡悦华,车晓毅.插补器与数控机床的合理使用[J].常德师范学院学报,1999,11(4):71-73.
[21] Dong Il Kim,Sungkwun Kim.Performance evaluation of software acceleration/deceleration algorithms in machining and contouring[J]. IEEE Transactions on Industrial Electronics,1992,3:1263-1269.
[22]廖德刚,蔡悦华,车晓毅.插补器与数控机床的合理使用[J].常德师范学院学报,1999,11(4):71-73.
[23]郭新贵,李从心.一种新型柔性加减速算法[J].上海交通大学学报,2003,37(2):205-212.
[24]林一松,汤兆红,区锐相,林金萍,龚德明.一种S型曲线加减速计算方法[J].制造技术与机床,2005,(11):205-212.
[25]张华宇,王孚懋,徐方全.S形曲线加减速算法的研究[J].现代制造技术与装备,2006,(2):21-22.
[26] Kaan Erkorkmaz,Yusuf Altintas.High speed CNC system design.Part I:jerk limited trajectory generation and quintic spline interpolation[J].International Journal of Machine Tools & Manufacture,2000, 41(2001):1323-1345.
[27] JEON J W,HA Y Y. A generalized approach for the acceleration deceleration of industrial robots and CNC machine tools[J].IEEE Transactions on Industrial Electronics,2000,47(1):133-139.
[28] K Ren,H.G.Chen,W.H.Chen,J Pan.Research on Vector Blending Algorithm of Velocity for Acceleration and Decdleration of High Speed Machining[J].Materials Science Forum Vols, 2009,626-627(2009):243-248.
[29] JEON J W. Efficient acceleration and deceleration technique for short distance movement in industrial robots and CNC machine tools[J].IEEE Transactions on Industrial Electronics,2000,36(8):766-767.
[30]冷洪滨,潘敏,邬义杰.三次多项式型段内加减速控制新方法[J].浙江大学学报,2008,42(8):1440-1444.
[31]李庆杨,王能超,易大义.数值分析[M].武汉:华中科技大学出版社,2006.
[32]杨建刚.旋转机械振动分析与工程应用[M].北京:中国电力出版社,2007.
[33] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER User’s Manual.
[34]秦琴.基于PLC控制的丝网印刷机电气控制系统的研制[D].广州:中山大学学报,2009.
[35] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER Programming Manual.
[36] MITSUBISHI ELECTRIC CO.SERVO AMPLIFIER INSTRUCTION MANUAL.
[37] MITSUBISHI ELECTRIC CO.CC-LINK User’s Manual.
[38] MITSUBISHI ELECTRIC CO.GX Developer操作手册.
[39] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER(REAL MODE) Programming Manual.
[40] MITSUBISHI ELECTRIC CO.MOTION CONTROLLER(Motion SFC) Programming Manual.
[41]侯俊杰.深入浅出MFC[M].武汉:华中科技大学出版社,2008.
[42]曾凡锋,苗雨.MFC编程技巧与范例详解[M].北京:清华大学出版社,2008.