虚拟五轴铺放机及其数控系统研究
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摘要
纤维铺放成型技术是通过加热装置把纤维带加热到适当的温度后,再由铺放头上的压靴机构压贴到芯模上。纤维铺放技术由早期的手工铺放,现在已经发展成为了一种新型的自动化复合材料加工成型技术。相比于纤维缠绕技术,其对复杂曲面表现出更加强的适应性。由于复合材料制品相比于传统的金属结构零件,具有更高的强度质量比,抗疲劳性和减振性,因此纤维铺放技术是一种得到高强度轻质量制件的绝佳的方法。但由于铺放成型工艺的成本高,所以主要用于军品和航空航天等领域,但是随着技术的发展,成本也有了大幅的下降。现在在发达国家,纤维铺放技术已经得到了相当广泛的应用,但在我国,该项技术的研究还处于起步阶段。
本文是旨在对虚拟五轴铺放机及其数控系统进行研究。主要做了以下几个方面的工作：
首先为铺放机建立简化的三维模型。为了后期能够驱动模型运动,因此为模型定义了一个坐标系统。其机械部分由导轨、龙门架、小车、铺放臂和铺放头组成。由于本系统的目的是反映铺放机的铺放运动,因此对于一些细小的部件在建模的时候被略去了。
其次,本系统在虚拟模型算法方面主要分为两部分,一,对虚拟模型运动算法的研究,包括五轴联动算法、加减速模型算法。实现了模型五轴联动数据的计算,模型加减速运动。二,对虚拟铺放机数控系统的研究。为系统添加了一个数控代码编译模块,实现了数控代码的读取,翻译和模型驱动。通过系统提供的一个人机界面,把外界的文本格式的数控代码加载进系统,运行程序,程序能够通过数控代码编译模块把代码中的数据提取出来,并加以计算,得出驱动模型的点坐标信息。
最后,进行了铺放过程的虚拟研究。使系统能够反映铺放过程效果,也就是显示铺放运动过程,并绘制铺放纤维丝的轨迹。首先利用前面得到的信息不断地刷新屏幕,从而实现模型的运动。同时,从数控代码中提取出来的数据,经过一定的算法处理,计算出纤维丝的轨迹点坐标信息,并以此来绘制纤维轨迹。并且利用VC++为模型建立了人机界面,实现了人机交互。
本课题利用OpenGL建立虚拟五轴铺放机三维模型,借助VC++设计人机界面,并实现了铺放机各运动控制轴的虚拟联动运动算法。采用VC++建立了虚拟数控模块,实现了数控代码的导入、编译、提取和处理等数控程序运行过程的虚拟,获得了纤维铺放数控代码的生产过程运动数据,并实现了运动和铺放轨迹的显示。本课题的研究开发构建了一套柔性纤维铺放过程虚拟系统,为纤维铺放技术研究提供了一个基本的虚拟铺放试验平台。
Fiber placement technology place the tape, which was heated into a cerain temperature by heating device, into mold with certain pressure by using the roller on placement head. Derived from manual placement several decades before, Currently fiber placement technology has developed into a new type automatic composite material manufacturing technology. Compared to fiber winding technology, it shows more adaptability to more complex curved surface. Due to higher strength to mass ratio, fatigue endurance and shock absorption, it serves as a extremely decent way to produce high strength but low mass products. However, as it would cost more, this techonology was only confined to military, aviation and aerospace field. With the development of technology, its expense was decreasing a lot. By now, fiber placement technology was widely used in developed countries, while it was on the preliminary stage in home.
This thesis did some research on virtual five-axies placement machine and its numerical controlling system. And the principal works contain the following parts.
Firstly, it establishes a three-dimension model for placement machine. It was consist of rails, portal frame, trolley, placement hand and placement head. In order to realize impelling the model to move via NC code, the system also devise a coorination system for model. On account of manifesting the mechanical motion process of the model, the system stripped some small components of the real placement machine.
Furthermore, the research on virtual model arithmetic can be divided in to categories. First, the research on virtual model movement, which cosist of five axies linkage movement arithmetic, model accelerate-decelerate movement arithmetic. What's more, the research on virtual placement numerical controlling sysem arithmetic, we add a NC code trasforming module, so that the system can accomplish reading, trasforming and propelling the model to move. Throgh the the interface of the system, we can input some NC code in txt format into the system,then run the program. The program can extract important data from the NC code and calculate the point coodination for late using. Afterwards, the system would continue flushing the screen by using the data prepared before to renew the positon of the model, so that to realize the movement of the model.
Eventually, this system was supposed to show the quality of placement, that is to draw fiber placement track. Extracting some useful information from the NC, though certain algorithem, the system can calcualte the point information for drawing the fiber track.
This thesis take advantage of OpenGL to establish a virtual five-axies placement machine. With the help of VC++, it designed a human-computer interface and realize the algorithm of linkage of virtual movement. And it built a virtual numerical module to accomplish NC code input, translation, extraction and process, and gain the data for placement process motion and illustrate placement process and placement track. This thesis focus on the development of designing a set of flexible virtual placement system and provide a foundmental virtual placement test platform.
本文是旨在对虚拟五轴铺放机及其数控系统进行研究。主要做了以下几个方面的工作：
首先为铺放机建立简化的三维模型。为了后期能够驱动模型运动,因此为模型定义了一个坐标系统。其机械部分由导轨、龙门架、小车、铺放臂和铺放头组成。由于本系统的目的是反映铺放机的铺放运动,因此对于一些细小的部件在建模的时候被略去了。
其次,本系统在虚拟模型算法方面主要分为两部分,一,对虚拟模型运动算法的研究,包括五轴联动算法、加减速模型算法。实现了模型五轴联动数据的计算,模型加减速运动。二,对虚拟铺放机数控系统的研究。为系统添加了一个数控代码编译模块,实现了数控代码的读取,翻译和模型驱动。通过系统提供的一个人机界面,把外界的文本格式的数控代码加载进系统,运行程序,程序能够通过数控代码编译模块把代码中的数据提取出来,并加以计算,得出驱动模型的点坐标信息。
最后,进行了铺放过程的虚拟研究。使系统能够反映铺放过程效果,也就是显示铺放运动过程,并绘制铺放纤维丝的轨迹。首先利用前面得到的信息不断地刷新屏幕,从而实现模型的运动。同时,从数控代码中提取出来的数据,经过一定的算法处理,计算出纤维丝的轨迹点坐标信息,并以此来绘制纤维轨迹。并且利用VC++为模型建立了人机界面,实现了人机交互。
本课题利用OpenGL建立虚拟五轴铺放机三维模型,借助VC++设计人机界面,并实现了铺放机各运动控制轴的虚拟联动运动算法。采用VC++建立了虚拟数控模块,实现了数控代码的导入、编译、提取和处理等数控程序运行过程的虚拟,获得了纤维铺放数控代码的生产过程运动数据,并实现了运动和铺放轨迹的显示。本课题的研究开发构建了一套柔性纤维铺放过程虚拟系统,为纤维铺放技术研究提供了一个基本的虚拟铺放试验平台。
Fiber placement technology place the tape, which was heated into a cerain temperature by heating device, into mold with certain pressure by using the roller on placement head. Derived from manual placement several decades before, Currently fiber placement technology has developed into a new type automatic composite material manufacturing technology. Compared to fiber winding technology, it shows more adaptability to more complex curved surface. Due to higher strength to mass ratio, fatigue endurance and shock absorption, it serves as a extremely decent way to produce high strength but low mass products. However, as it would cost more, this techonology was only confined to military, aviation and aerospace field. With the development of technology, its expense was decreasing a lot. By now, fiber placement technology was widely used in developed countries, while it was on the preliminary stage in home.
This thesis did some research on virtual five-axies placement machine and its numerical controlling system. And the principal works contain the following parts.
Firstly, it establishes a three-dimension model for placement machine. It was consist of rails, portal frame, trolley, placement hand and placement head. In order to realize impelling the model to move via NC code, the system also devise a coorination system for model. On account of manifesting the mechanical motion process of the model, the system stripped some small components of the real placement machine.
Furthermore, the research on virtual model arithmetic can be divided in to categories. First, the research on virtual model movement, which cosist of five axies linkage movement arithmetic, model accelerate-decelerate movement arithmetic. What's more, the research on virtual placement numerical controlling sysem arithmetic, we add a NC code trasforming module, so that the system can accomplish reading, trasforming and propelling the model to move. Throgh the the interface of the system, we can input some NC code in txt format into the system,then run the program. The program can extract important data from the NC code and calculate the point coodination for late using. Afterwards, the system would continue flushing the screen by using the data prepared before to renew the positon of the model, so that to realize the movement of the model.
Eventually, this system was supposed to show the quality of placement, that is to draw fiber placement track. Extracting some useful information from the NC, though certain algorithem, the system can calcualte the point information for drawing the fiber track.
This thesis take advantage of OpenGL to establish a virtual five-axies placement machine. With the help of VC++, it designed a human-computer interface and realize the algorithm of linkage of virtual movement. And it built a virtual numerical module to accomplish NC code input, translation, extraction and process, and gain the data for placement process motion and illustrate placement process and placement track. This thesis focus on the development of designing a set of flexible virtual placement system and provide a foundmental virtual placement test platform.
引文
[1]碳纤维的需求、前景和研发新动向.http://www.carbonfiber.cc/TradeNews/ViewTradeInfo.aspx?InfoId=342
[2]李勇,肖军.复合材料纤维铺放技术及其应用.纤维复合材料,2002,(9)：39-41
[3]苏玉堂,鲁博.纤维缠绕复合材料结构制造技术.中国玻璃钢工业协会,2003
[4]自动化的重要进展.http://www.aviationnow.com.cn/webviews/dongtai/content.aspx?newsid=2007042 2091434765&classid=7
[5]韩振宇,孟庆鑫,路华,等.新型纤维铺放头的方案设计与实验研究.玻璃钢/复合材料,2007,(3)：25-27
[6]徐再,吴耀楚,田会方.FRP铺放成型技术的研究,玻璃钢／复合材料,2002,(5)：44-46
[7]丁韬.自动纤维铺放机.航空制造技术,2007,(9)：60-64
[8]陈亚莉.复合材料在飞机上的新应用.航空维修与工程,2005,(3)：31-32
[9]胡仁喜,张红松,刘昌丽SolidWorks 2007中文版机械设计工程实践.科学出版社：2007
[10]谢昱北SolidWorks 2007中文版机械设计与典型范例.电子工业出版社：2007
[11]岳荣刚,宋凌珺SolidWorks 2006零件与装配设计教程.冶金工业出版社：2006
[12]王志辉,曹德华.纤维铺放系统的机构分析.中国水运,2006.(2)：82-83
[13]田会方,黄亚辉.纤维铺放机的机构设计及仿真.机械工程师,2005.(8)：92-94
[14]于传浩,吴耀楚,王志辉.FRP铺放技术的机构分析.武汉化工学院学报,2003.(2)：54-56
[15]Hogg, Merrill W. Method for laying composite tape. United States Patent, 20060073309,2006-04-06
[16]Martin, James P. Multiple tape laying apparatus and method. United States Patent,20050061422,2005-03-24
[17]Zaballos, Kenneth P. Device for laying tape materials for aerospace applications. United States Patent,20060118244,2006-06-08
[18]Grimshaw, Michael N. Method for laying cut composite tape on a mold having scrap removal. United States Patent,5114519,1992-05-19
[19]Dawn K. Russell. INCORPORATING ENVIRONMENTAL ISSUES IN A FILAMENT WINDING COMPOSITE MANUFACTURING SYSTEM SIMULATION. Winter Simulation Conference:1998
[20]Bell, P. R., et al. Review of Point-to-point Network Routing Algorithms. IEEE Commun. Magazien,1996 (1)
[21]Sharp, Terrance M. Robotic tape applicator and method. United States Patent, 7093641,2006-08-22
[22]超声波切割应用技术.http://www. discousa. com/cn_s/solution/library/usw. html
[23]Messner, Bernd A. K. Tape laying head with curved tape laying capability and improved adaptive steering. United States Patent,5431749,1995-07-11
[24]Blaimschein, Gottfried. Method and apparatus for laying strips of tape material. United States Patent,5402962,1995-04-04
[25]Grimshaw, Michael N.; Peterson, David A. Tape laying apparatus and method, United States Patent,5352306,1994-10-04
[26]Grimshaw, Michael N.; Peterson, David A. Tape laying and compaction apparatus. United States Patent,5314563.1994-05-24
[27]Peterson, David A. Tape laying apparatus. United States Patent,5269869, 1993-12-14
[28]Krogager, Max; Weidmann, Bjorn; Petersson, Mikael. AUTOMATIC TAPE LAYING APPARATUS AND METHOD. United States Patent,20060289111,2006-12-28
[29]Andersen, Stig Jarle; Stangeland,.0 slashed, ivind. Method and apparatus for laying elongated articles. United States Patent,6641330,2003-11-04
[30]Redd, Bryan; Enders, Mark L.; Young, Michael H. Combination filament winding and tape laying apparatus and method for making and using the same. United States Patent,5145543,1992-09-08
[31]江洪,陈燎,王智等SolidWorks有限元分析实例解析.机械工业出版社：2007
[32]SolidWorks公司著COSMOS基础教程.机械工业出版社：2007
[33]SolidWorks动画演示与运动分析实例解析.机械工业出版社：2006
[34]陈芝.OpenGL三维图形系统开发与实用技术.重庆大学出版社：2003
[35]李颖Open GL函数与范例解析手册.国防工业出版社：2002
[36]和平鸽工作室OpenGL高级编程与可视化系统开发.中国水利水电出版社：2006
[37]郭兆荣,李菁,王彦Visual C++ OpenGL应用程序开发.人民邮电出版社：2006
[38]邓郑祥OpenGL编程指南.人民邮电出版社：2005
[39]Richard S. Wright, Jr., Benjamin Lipchak. OpenGL超级宝典.人民邮电出版社： 2005
[40]David J.Krugl inski.Visual C++技术内幕(第四版).清华大学出版社：2002
[41]Eugene 01afsen等.MFC Visual C++6编程技术内幕.机械工业出版社：2000
[42]Lippman,Stanley B.C++primer.Posts ＆ Telecom Press:2006
[2]李勇,肖军.复合材料纤维铺放技术及其应用.纤维复合材料,2002,(9)：39-41
[3]苏玉堂,鲁博.纤维缠绕复合材料结构制造技术.中国玻璃钢工业协会,2003
[4]自动化的重要进展.http://www.aviationnow.com.cn/webviews/dongtai/content.aspx?newsid=2007042 2091434765&classid=7
[5]韩振宇,孟庆鑫,路华,等.新型纤维铺放头的方案设计与实验研究.玻璃钢/复合材料,2007,(3)：25-27
[6]徐再,吴耀楚,田会方.FRP铺放成型技术的研究,玻璃钢／复合材料,2002,(5)：44-46
[7]丁韬.自动纤维铺放机.航空制造技术,2007,(9)：60-64
[8]陈亚莉.复合材料在飞机上的新应用.航空维修与工程,2005,(3)：31-32
[9]胡仁喜,张红松,刘昌丽SolidWorks 2007中文版机械设计工程实践.科学出版社：2007
[10]谢昱北SolidWorks 2007中文版机械设计与典型范例.电子工业出版社：2007
[11]岳荣刚,宋凌珺SolidWorks 2006零件与装配设计教程.冶金工业出版社：2006
[12]王志辉,曹德华.纤维铺放系统的机构分析.中国水运,2006.(2)：82-83
[13]田会方,黄亚辉.纤维铺放机的机构设计及仿真.机械工程师,2005.(8)：92-94
[14]于传浩,吴耀楚,王志辉.FRP铺放技术的机构分析.武汉化工学院学报,2003.(2)：54-56
[15]Hogg, Merrill W. Method for laying composite tape. United States Patent, 20060073309,2006-04-06
[16]Martin, James P. Multiple tape laying apparatus and method. United States Patent,20050061422,2005-03-24
[17]Zaballos, Kenneth P. Device for laying tape materials for aerospace applications. United States Patent,20060118244,2006-06-08
[18]Grimshaw, Michael N. Method for laying cut composite tape on a mold having scrap removal. United States Patent,5114519,1992-05-19
[19]Dawn K. Russell. INCORPORATING ENVIRONMENTAL ISSUES IN A FILAMENT WINDING COMPOSITE MANUFACTURING SYSTEM SIMULATION. Winter Simulation Conference:1998
[20]Bell, P. R., et al. Review of Point-to-point Network Routing Algorithms. IEEE Commun. Magazien,1996 (1)
[21]Sharp, Terrance M. Robotic tape applicator and method. United States Patent, 7093641,2006-08-22
[22]超声波切割应用技术.http://www. discousa. com/cn_s/solution/library/usw. html
[23]Messner, Bernd A. K. Tape laying head with curved tape laying capability and improved adaptive steering. United States Patent,5431749,1995-07-11
[24]Blaimschein, Gottfried. Method and apparatus for laying strips of tape material. United States Patent,5402962,1995-04-04
[25]Grimshaw, Michael N.; Peterson, David A. Tape laying apparatus and method, United States Patent,5352306,1994-10-04
[26]Grimshaw, Michael N.; Peterson, David A. Tape laying and compaction apparatus. United States Patent,5314563.1994-05-24
[27]Peterson, David A. Tape laying apparatus. United States Patent,5269869, 1993-12-14
[28]Krogager, Max; Weidmann, Bjorn; Petersson, Mikael. AUTOMATIC TAPE LAYING APPARATUS AND METHOD. United States Patent,20060289111,2006-12-28
[29]Andersen, Stig Jarle; Stangeland,.0 slashed, ivind. Method and apparatus for laying elongated articles. United States Patent,6641330,2003-11-04
[30]Redd, Bryan; Enders, Mark L.; Young, Michael H. Combination filament winding and tape laying apparatus and method for making and using the same. United States Patent,5145543,1992-09-08
[31]江洪,陈燎,王智等SolidWorks有限元分析实例解析.机械工业出版社：2007
[32]SolidWorks公司著COSMOS基础教程.机械工业出版社：2007
[33]SolidWorks动画演示与运动分析实例解析.机械工业出版社：2006
[34]陈芝.OpenGL三维图形系统开发与实用技术.重庆大学出版社：2003
[35]李颖Open GL函数与范例解析手册.国防工业出版社：2002
[36]和平鸽工作室OpenGL高级编程与可视化系统开发.中国水利水电出版社：2006
[37]郭兆荣,李菁,王彦Visual C++ OpenGL应用程序开发.人民邮电出版社：2006
[38]邓郑祥OpenGL编程指南.人民邮电出版社：2005
[39]Richard S. Wright, Jr., Benjamin Lipchak. OpenGL超级宝典.人民邮电出版社： 2005
[40]David J.Krugl inski.Visual C++技术内幕(第四版).清华大学出版社：2002
[41]Eugene 01afsen等.MFC Visual C++6编程技术内幕.机械工业出版社：2000
[42]Lippman,Stanley B.C++primer.Posts ＆ Telecom Press:2006