可重构数控系统关键技术研究
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摘要
可重构数控系统是实现可重构制造系统的关键技术。可重构技术可以增强数控系统的柔性,合理配置数控系统资源,快速地响应加工需要。本文对实现可重构数控系统的一些理论和应用问题进行了研究。
在分析数控系统功能特点的基础上,提出了可重构数控系统的数控流水线架构。该架构由数控主控流水线线程、驱动程序和数控微代码实时执行单元构成,定义了数控规范指令和数控微代码接口,保证模块的互换性,实现了流水线的可重构。数控流水线线程封装了从指令译码到生成数控微代码的主要控制功能,具备高度的可移植性。微代码是用于数控功能实时执行的精简化操作指令,由一个实时执行单元执行。实验表明,数控流水线架构可以高效实现可重构的数控系统。
速度规划是数控系统的重要模块,对加工效率,运行平稳性等方面都有影响。而前瞻速度规划是提高加工效率的有效方法。本文对一类加减速算法进行数学抽象,提出了对这类加减速算法的可重构的通用前瞻速度规划算法,在理论上证明了通用前瞻速度规划算法对进给速度的优化性质。同时,推导了线性加减速、改进的指数加减速和S型加减速在通用前瞻速度规划下的完整规划算法,验证了该算法的有效性。
微线段的加工是复杂型面加工中常见的程序类型。本文提出了基于伺服系统轮廓误差的直线段转角速度限制算法和连续转弯微线段进给速度修正方法。这两种方法以轮廓误差为依据,能够根据加工路径特征对进给速度进行智能控制。二者与S型加减速算法在通用前瞻规划器架构下可重构成为微线段程序的柔性速度规划模块。
重采样插补可以实现粗插补的非实时批量运行,能够提高数控系统性能并为设计带来便利。本文提出了线性重采样插补方法和基于曲线细分技术的重采样插补方法。分析表明,曲线细分重采样插补能够得到比线性重采样插补更平滑的插补结果。根据重采样算法原理设计了重采样的可重构硬件逻辑,加速算法的执行,并以螺纹车削和电子凸轮为例说明了硬件重采样的应用方法。
在可重构数控系统的实施方法上提出了软、硬件在不同粒度下的重构方案。采用数控流水线架构设计了三种可重构数控系统原型机。实验和应用都证明,数控流水线架构是一种能适应各类平台的开放式可重构数控系统高效实施方案。
The reconfigrable Computer Numerical Controller (CNC) is a key technology in reconfigurable manufacturing systems. The reconfigurable technology could help improving the flexibility and the resource configuration in CNC to rapidly meet the machining process requirement. In this dissertation, servral theory and application problems in the reconfigurable CNC controller are studied.
A reconfigurable Numerical Control (NC) pipeline architechture is proposed based on the analysis of the functions in CNC controllers. The pipeline is consists of a NC pipeline thread, a driver and a NC Microcode Processor (NCMP). In this architecture, the NC Canonical Command (NCCC) interface and the NC Microcode (NCM) interface are defined to ensure the interchangeabilty of different modules and the reconfigurability of the pipeline. The primary controlling functions from code interpretation to NCM generation are encapsulated in the NC pipeline thread with high portability. NC Mircrocodes are simplified operating codes aimed for the real-time execution of CNC functions in NCMP. Experiments demonstrate that the NC pipeline architecture could realize the reconfigurable CNC controller efficiently.
Feedrate plan is an important module in CNC controllers, which affects the efficiency, the smoothness of movements, and many other aspects in the machining process. In this dissertation, a type of Acceleration and Deceleration (ACC/DEC) algorithms is mathematically abstracted, and a Generic Look-Ahead Feedrate Plan (GLAFP) scheme is proposed for this type algorithms. The optimizing properties of GLAFP are theoretically proved. The complete algorithms for linear, modified exponential and S-curve ACC/DEC are derivated under the GLAFP scheme. The proposed scheme is verified by experiments.
The machining of micro-lines is very common in the complex surface maching programs. The speed limit algorithm for the intersection of straight lines and feedrate modification algorithm for the continuously deviating micro-lines based on the contour error of servo systems are developed. These algorithms can intelligently control the feedrate according to the feature of the machining path. The proposed feedrate control methods along with the S-curve ACC/DEC algorithm can be reconfigured in the GLAFP architecture as a feedrate plan module for the smooth machining of micro-lines.
The resampling interpolation enables the coarse interpolation running in a batch and non-real-time pattern. This could not only enhance the performance but also benefits the design of CNC controllers. The linear resampling interpolation and the curve-subdivision-based resampling interpolation are proposed. The analysis shows that the subdivision algorithm can generate more smooth result than the linear algorithm. The reconfigurable logic is designed for accelerate the execution of resampling algorithms. The applications of resampling interpolation in the threading and electronic cam functions are illustrated as examples.
For the implementaionn of reconfigurable CNC controller, several reconfigurable schemes for the hardware and software with different granularities are proposed. Three prototype reconfigurable controllers based on the NC pipeline architechture are developed. The experiments and the applications prove that the NC pipeline architechture is a platform independent, open, reconfigurable and efficient solution for the CNC controller design.
在分析数控系统功能特点的基础上,提出了可重构数控系统的数控流水线架构。该架构由数控主控流水线线程、驱动程序和数控微代码实时执行单元构成,定义了数控规范指令和数控微代码接口,保证模块的互换性,实现了流水线的可重构。数控流水线线程封装了从指令译码到生成数控微代码的主要控制功能,具备高度的可移植性。微代码是用于数控功能实时执行的精简化操作指令,由一个实时执行单元执行。实验表明,数控流水线架构可以高效实现可重构的数控系统。
速度规划是数控系统的重要模块,对加工效率,运行平稳性等方面都有影响。而前瞻速度规划是提高加工效率的有效方法。本文对一类加减速算法进行数学抽象,提出了对这类加减速算法的可重构的通用前瞻速度规划算法,在理论上证明了通用前瞻速度规划算法对进给速度的优化性质。同时,推导了线性加减速、改进的指数加减速和S型加减速在通用前瞻速度规划下的完整规划算法,验证了该算法的有效性。
微线段的加工是复杂型面加工中常见的程序类型。本文提出了基于伺服系统轮廓误差的直线段转角速度限制算法和连续转弯微线段进给速度修正方法。这两种方法以轮廓误差为依据,能够根据加工路径特征对进给速度进行智能控制。二者与S型加减速算法在通用前瞻规划器架构下可重构成为微线段程序的柔性速度规划模块。
重采样插补可以实现粗插补的非实时批量运行,能够提高数控系统性能并为设计带来便利。本文提出了线性重采样插补方法和基于曲线细分技术的重采样插补方法。分析表明,曲线细分重采样插补能够得到比线性重采样插补更平滑的插补结果。根据重采样算法原理设计了重采样的可重构硬件逻辑,加速算法的执行,并以螺纹车削和电子凸轮为例说明了硬件重采样的应用方法。
在可重构数控系统的实施方法上提出了软、硬件在不同粒度下的重构方案。采用数控流水线架构设计了三种可重构数控系统原型机。实验和应用都证明,数控流水线架构是一种能适应各类平台的开放式可重构数控系统高效实施方案。
The reconfigrable Computer Numerical Controller (CNC) is a key technology in reconfigurable manufacturing systems. The reconfigurable technology could help improving the flexibility and the resource configuration in CNC to rapidly meet the machining process requirement. In this dissertation, servral theory and application problems in the reconfigurable CNC controller are studied.
A reconfigurable Numerical Control (NC) pipeline architechture is proposed based on the analysis of the functions in CNC controllers. The pipeline is consists of a NC pipeline thread, a driver and a NC Microcode Processor (NCMP). In this architecture, the NC Canonical Command (NCCC) interface and the NC Microcode (NCM) interface are defined to ensure the interchangeabilty of different modules and the reconfigurability of the pipeline. The primary controlling functions from code interpretation to NCM generation are encapsulated in the NC pipeline thread with high portability. NC Mircrocodes are simplified operating codes aimed for the real-time execution of CNC functions in NCMP. Experiments demonstrate that the NC pipeline architecture could realize the reconfigurable CNC controller efficiently.
Feedrate plan is an important module in CNC controllers, which affects the efficiency, the smoothness of movements, and many other aspects in the machining process. In this dissertation, a type of Acceleration and Deceleration (ACC/DEC) algorithms is mathematically abstracted, and a Generic Look-Ahead Feedrate Plan (GLAFP) scheme is proposed for this type algorithms. The optimizing properties of GLAFP are theoretically proved. The complete algorithms for linear, modified exponential and S-curve ACC/DEC are derivated under the GLAFP scheme. The proposed scheme is verified by experiments.
The machining of micro-lines is very common in the complex surface maching programs. The speed limit algorithm for the intersection of straight lines and feedrate modification algorithm for the continuously deviating micro-lines based on the contour error of servo systems are developed. These algorithms can intelligently control the feedrate according to the feature of the machining path. The proposed feedrate control methods along with the S-curve ACC/DEC algorithm can be reconfigured in the GLAFP architecture as a feedrate plan module for the smooth machining of micro-lines.
The resampling interpolation enables the coarse interpolation running in a batch and non-real-time pattern. This could not only enhance the performance but also benefits the design of CNC controllers. The linear resampling interpolation and the curve-subdivision-based resampling interpolation are proposed. The analysis shows that the subdivision algorithm can generate more smooth result than the linear algorithm. The reconfigurable logic is designed for accelerate the execution of resampling algorithms. The applications of resampling interpolation in the threading and electronic cam functions are illustrated as examples.
For the implementaionn of reconfigurable CNC controller, several reconfigurable schemes for the hardware and software with different granularities are proposed. Three prototype reconfigurable controllers based on the NC pipeline architechture are developed. The experiments and the applications prove that the NC pipeline architechture is a platform independent, open, reconfigurable and efficient solution for the CNC controller design.
引文
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