基于知识的数控轧辊磨床智能控制系统研究
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摘要
轧辊是轧机上承受轧制力并把轧制材料均匀减薄的消耗性工具。板形质量很大程度上取决于轧辊表面质量。在板形轧制过程中,轧辊会产生磨损,轧辊磨损直接影响轧辊辊形及其表面精度,从而影响板材的质量。为了获得理想的板形质量,必须对轧辊进行磨削,以恢复轧辊辊形和表面精度。轧辊磨削是一种具有特殊工艺要求的磨削技术,磨损的轧辊必须通过轧辊磨床来进行磨削。轧辊磨床属于大型精密加工机床,是金属板、带、箔材加工企业的关键设备,对保证和提高产品表面质量起着重要的作用。
近年来,由于冶金、造纸、橡胶、塑料以及印染业等工业经济的迅速发展,轧辊磨削直径已达到3000mm,工件重量达200吨,其几何精度均为μm级。同时重载荷轧辊磨床的出现,对轧辊磨削的技术要求也日趋提高。随着数控(NC)技术的不断发展,轧辊磨床也在由普通轧辊磨床向数控轧辊磨床方向发展。NC技术是现代数控轧辊磨床的核心技术,是轧辊磨床实现自动化、柔性化、集成化的基础。NC技术正在把传统制造业推进到了信息化制造时代,系统结构也从封闭转向开放。开放性是现代控制系统的一个重要特征,利用开放性可以更大程度上利用计算机技术丰富的软硬件资源,融合精确在线传感系统和测量系统。利用智能技术从实践经验中获取知识,为轧辊磨削工艺提供规划策略,实现轧辊的智能磨削。
智能是将是现代数控轧辊磨床的一个主要特征。由于轧辊磨削是一种影响因素非常复杂的加工过程,磨削质量的优劣很大程度上与磨削专家知识和长期积累的磨削实践经验有关。同时由于板材轧制过程非常复杂而严格,为保证钢板质量,需要对轧辊辊形及其磨削精度进行严格的控制,这就需要用到轧辊磨削及轧制工艺知识。知识是揭示事物规律性的信息组合,包含了信息与决策的关系,可直接或间接用于问题的求解。随着知识经济的发展,信息集成处理正在向基于知识处理转变,知识工程(KBE)在磨削应用领域的研究将是一个主要的方向。KBE系统通过一系列知识处理方法来获取领域专家的知识和经验,并运用合适的知识建模方法与语言,将知识计算机化。然后,采用合适的知识处理策略,根据特定的产品模型进行智能推理和演绎,作出决策。利用基于知识的方法不需要精确的数学模型的优点,同时结合基于模型的方法对轧辊磨削进行智能决策与控制。
随着NC技术向经济实用性工艺方向发展,融合制造工艺的专用系统在特殊的制造领域中更能适应特殊产品的高效和高品质制造。通用NC系统与零件加工工艺无关,是适合各种通用零部件制造的控制系统。而对于轧辊智能磨削系统,由于轧辊磨削影响因素多,受轧辊磨削实践知识和领域专家知识的影响,有着特殊的轧辊工艺知识及板轧知识,因此在这个特殊的领域,按照常规思维是行不通的,通用NC系统在轧辊磨削领域中难以发挥更有效的作用。因此控制系统融合轧辊磨削工艺是本文智能磨削控制系统的最重要特征。
智能NC标准是现代智能控制系统必须采用的标准。由于传统ISO6983NC标准存在程序移植性差、CAD/CAM/CNC数据流单向、CAD数据必须经过专门的后处理器、不支持样条数据等局限性,因此国际标准组织制定了新的智能STEP-NC标准。利用STEP-NC在CAX./CNC之间双向信息流等方面的诸多优点,显著提高了信息的可交换性和柔性。由于轧辊辊形特征参数化明显,因此本文利用了STEP-NC思想,对轧辊CAX/CNC进行了有效的实现。
虽然NC技术在通用NC控制系统中已经发展了很多年,但在轧辊磨削领域中,由于磨削过程的非线性、随机性和不确定性等原因,其发展还不尽人意。目前国内外现有的数控轧辊磨削在轧辊辊形生成、轧辊辊形模型描述、轧辊辊形插补策略、砂轮磨损补偿、砂轮修整方法、变速磨削、磨削参数优化决策、轧辊辊形及磨削工艺数据历史追随性、故障智能诊断等方面还存在许多问题。目前在磨削加工中,许多方面仍依赖于操作者的经验和技术熟练程度,对加工过程的实际调整是靠操作者试凑。磨削的现状已成为制约某些先进制造技术发展的关键。
智能磨削控制系统一般采用知识基系统KBS、专家系统ES、模糊逻辑FL、神经网络NN、遗传算法GA、自适应优化AC0以及基于模型的智能系统等方法中的一种或几种。这些方法在磨削中的应用,多数集中在螺纹磨床、机器IC磨床、表面磨床、外圆磨床、内圆磨床、缓进给磨床,在轧辊磨削系统中的应用,目前还没有相关文献详细报道。
针对目前轧辊磨削中存在的问题和现状,结合上海市科委支持的重大产学研攻关项目—面向钢铁汽车行业的高档数控磨床关键技术及装备开发(项目号05dz11c04),本文对轧辊磨削进行了深入的理论和实践研究,对轧辊磨削机理、轧辊磨削影响因素、砂轮磨损机理、砂轮修整机理进行了深入研究,建立了轧辊磨削的动态模型、轧辊和砂轮的接触弧长、轧辊磨削力、磨削功率、砂轮磨损补偿的数学模型,建立了基于知识的融合轧辊工艺的轧辊磨削智能控制系统的结构,提出了基于知识的多目标磨削参数优化决策方法,基于多通道技术的砂轮智能在线磨削修整方法,基于STEP-NC思想的轧辊辊形智能创成及其样条插补策略以及变速磨削自适应控制策略,并把知识工程(KBE)、专家系统、遗传算法、模糊逻辑、神经网络等智能理论与方法引入到轧辊磨削加工控制中,初步实现对轧辊磨削加工中轧辊磨削质量的控制。
课题的研究为提高现代板材质量,提高轧辊磨削质量和精度,提升轧辊磨削智能磨削过程奠定了理论基础和知识支撑,对现有的国内外轧辊磨削提供了新的思维,将会产生重要的指导意义,创造可观的经济效益和社会效益。
Rolling is a process where the metal is compressed between two rotating rolls for reducing its cross-section area. The rolls are expensive and consumptive tools. They are used to endure rolling force and make rolling material thin in roll grinding. There are some requirements for roll such as sufficient intensity, higher surface hardness, accurate structure and size, and roll shape and its grinding accuracy which can meet the product quality and proper rolling process.Roll grinding is a kind of special grinding technique which requires some special process technology. During the rolling process of profile and shape of plate, roll begins to wear. Worn roll must be ground in roll grinder. Roll grinder is a large type precision machine tool, and it is a key device in manufacturing metal plate, strip, foil material enterprise. Hence it is very important to ensure and improve product quality.
In recent years, with the rapid development of metallurgy, paper making, rubber, plastic, printing and dyeing industries economy, roll diameter is up to 3000mm, roll weight is also close to 300 tons and its geometric accuracy isμm degree. Meantime, with the coming of heavy load roll grinder, the requirement of roll grinding technique is more and more high. With the lasting development of NC, traditional roll grinder is introducing in the direction of NC roll grinder. NC technology is not only kernel technology of modern NC roll grinder, but also the base of automation, flexibility and integration of it. Under the action of NC technology, traditional manufacturing industries are being converted to information manufacturing stage, system architecture is also converting from closeness to openness. Openness is an important characteristic of modern control system. This will make plentiful software and hardware resource of computer technology to be employed in a greater degree, simultaneously make precision on-line sensor and measurement system to be integrated. Intelligence technology can help the system to acquire knowledge from practical experiences, provide process planning strategy for roll grinding, and ultimately realize the intelligent roll grinding.
Intelligence will be a main characteristic of modern NC roll grinder. Because roll grinding is very complex machining process with too many influence factors, the final quality and performance of grinding is deeply correlated with specialist knowledge, previous grinding practical experiences. Because there is strict quality requirement in complex rolling process of plate, roll profile and its grinding accuracy must be strictly controlled, this requires knowledge of roll grinding and rolling process. Knowledge is used to reveal information combination on regularity of thing. It contains relation between information and decision, and is used to directly or indirectly solve problem. With the development of knowledge economy, information integration is converted to knowledge based processing method. Research on knowledge based engineering (KBE) in the field of grinding will be a main trend. KBE system obtains knowledge and practical experiences of field specialist by means of a series of processing methods on knowledge, selects reasonable modeling method and language of knowledge, computer knowledge, and selects adequate knowledge strategy to make intellectual reasoning, deduction and decision according to given production model. The control system can make intellectual decision and control for roll grinding by combination of knowledge based method and mathematics model based method.
Because NC technology is developing towards to practicality technology, special system integrated with manufacturing technology is more applicable to high efficient and quality machining of special product. General NC system can not include machining technology of part. It is a control system which suits various general parts. Due to many influence factors such as specialist knowledge, roll technology knowledge and. plate rolling knowledge etc, traditional ideals using general NC system is not effective in this special manufacturing field. Hence roll grinding technology integrated into control system is most important characteristic of intelligent NC roll grinding system in this dissertation.
Modern intelligent control system should adopt intelligent NC standard. Due to traditional ISO6983 NC standard has many disadvantages such as bad flexibility, one-way data flow from CAD/CAM/CNC, postprocess, no spline data etc, new intelligent STEP-NC standard is built by ISO. STEP-NC has many advantages such as bi-directional data flow between CAX and CNC etc, and it can improve interchangeablity and flexibility of information. Because of obvious parameterized characteristic of roll shape, STEP-NC ideal is adapted to efficiently realize CAX/CNC of roll in this dissertation.
Though NC technology has developed in general NC control system for many years, it indicated slow development in roll grinding field. Because of nonlinearity, randomicity, uncertainty in grinding process, there are many insufficiency facts in roll grinder. At the present time, many problems about existing NC roll grinder at home and abroad need to be solved, such as creation of roll shape, expression of roll shape model, interpolation strategy of roll shape, compensation for grinding wheel wear, wheel dressing method, grinding of alternating speed, optimization of grinding parameters, historical data traceability of roll shape and grinding process data, intelligent fault diagnosis. At present, adjusting the grinding process strongly relies on the operator's experience and skill. The grinding is one of the key technologies that constraints some elements of advanced technology development.
Intelligent system used in the field of abrasive processes usually draw on one or more of the following approaches such as KBS, ES, FL, NN, GA, ACO and model based method etc. The most common operation researched is external and internal cylindrical grinder, robotic IC grinder, screw grinder, surface grinder and creep grinder. At present, related literatures on roll grinding system are seldom reported.
The paper is supported by the production, teaching, and scientific research project of Science and Technology Commission of Shanghai Municipality (05dz11c04). In this paper, aiming at the problems existing in the roll grinding, the theoretical and experimental study were conducted for roll grinding, principle of roll grinding, influence elements of roll grinding, principle of grinding wheel wear, principle of wheel dressing. Some mathematical model were built such as the dynamic model of roll grinding, contact length between grinding wheel and roll, grinding force, grinding power, compensation for grinding wheel wear. Architecture on NC roll grinding intelligent control system integrated with roll grinding process based on knowledge was built. Some key techniques and strategies were also studied, such as multi-objective optimization and decision of grinding parameters based on knowledge, on-line intelligent grinding wheel dressing method based on dual channels, intelligent roll shape based on STE-NC ideal and its spline interpolation strategy, adaptive optimization control for grinding of alternating speed etc In this paper, in order to obtain better quality of roll grinding, intelligent theory and methods such as KBE, ES, GA, FL, NN etc were introduced into roll grinding control system.
This study is of great theoretical and practical value to improve quality and accuracy of roll grinding. Research result also provided new ideal for roll grinding in home and abroad, this will be helpful for producing the remarkably socioeconomic benefit.
近年来,由于冶金、造纸、橡胶、塑料以及印染业等工业经济的迅速发展,轧辊磨削直径已达到3000mm,工件重量达200吨,其几何精度均为μm级。同时重载荷轧辊磨床的出现,对轧辊磨削的技术要求也日趋提高。随着数控(NC)技术的不断发展,轧辊磨床也在由普通轧辊磨床向数控轧辊磨床方向发展。NC技术是现代数控轧辊磨床的核心技术,是轧辊磨床实现自动化、柔性化、集成化的基础。NC技术正在把传统制造业推进到了信息化制造时代,系统结构也从封闭转向开放。开放性是现代控制系统的一个重要特征,利用开放性可以更大程度上利用计算机技术丰富的软硬件资源,融合精确在线传感系统和测量系统。利用智能技术从实践经验中获取知识,为轧辊磨削工艺提供规划策略,实现轧辊的智能磨削。
智能是将是现代数控轧辊磨床的一个主要特征。由于轧辊磨削是一种影响因素非常复杂的加工过程,磨削质量的优劣很大程度上与磨削专家知识和长期积累的磨削实践经验有关。同时由于板材轧制过程非常复杂而严格,为保证钢板质量,需要对轧辊辊形及其磨削精度进行严格的控制,这就需要用到轧辊磨削及轧制工艺知识。知识是揭示事物规律性的信息组合,包含了信息与决策的关系,可直接或间接用于问题的求解。随着知识经济的发展,信息集成处理正在向基于知识处理转变,知识工程(KBE)在磨削应用领域的研究将是一个主要的方向。KBE系统通过一系列知识处理方法来获取领域专家的知识和经验,并运用合适的知识建模方法与语言,将知识计算机化。然后,采用合适的知识处理策略,根据特定的产品模型进行智能推理和演绎,作出决策。利用基于知识的方法不需要精确的数学模型的优点,同时结合基于模型的方法对轧辊磨削进行智能决策与控制。
随着NC技术向经济实用性工艺方向发展,融合制造工艺的专用系统在特殊的制造领域中更能适应特殊产品的高效和高品质制造。通用NC系统与零件加工工艺无关,是适合各种通用零部件制造的控制系统。而对于轧辊智能磨削系统,由于轧辊磨削影响因素多,受轧辊磨削实践知识和领域专家知识的影响,有着特殊的轧辊工艺知识及板轧知识,因此在这个特殊的领域,按照常规思维是行不通的,通用NC系统在轧辊磨削领域中难以发挥更有效的作用。因此控制系统融合轧辊磨削工艺是本文智能磨削控制系统的最重要特征。
智能NC标准是现代智能控制系统必须采用的标准。由于传统ISO6983NC标准存在程序移植性差、CAD/CAM/CNC数据流单向、CAD数据必须经过专门的后处理器、不支持样条数据等局限性,因此国际标准组织制定了新的智能STEP-NC标准。利用STEP-NC在CAX./CNC之间双向信息流等方面的诸多优点,显著提高了信息的可交换性和柔性。由于轧辊辊形特征参数化明显,因此本文利用了STEP-NC思想,对轧辊CAX/CNC进行了有效的实现。
虽然NC技术在通用NC控制系统中已经发展了很多年,但在轧辊磨削领域中,由于磨削过程的非线性、随机性和不确定性等原因,其发展还不尽人意。目前国内外现有的数控轧辊磨削在轧辊辊形生成、轧辊辊形模型描述、轧辊辊形插补策略、砂轮磨损补偿、砂轮修整方法、变速磨削、磨削参数优化决策、轧辊辊形及磨削工艺数据历史追随性、故障智能诊断等方面还存在许多问题。目前在磨削加工中,许多方面仍依赖于操作者的经验和技术熟练程度,对加工过程的实际调整是靠操作者试凑。磨削的现状已成为制约某些先进制造技术发展的关键。
智能磨削控制系统一般采用知识基系统KBS、专家系统ES、模糊逻辑FL、神经网络NN、遗传算法GA、自适应优化AC0以及基于模型的智能系统等方法中的一种或几种。这些方法在磨削中的应用,多数集中在螺纹磨床、机器IC磨床、表面磨床、外圆磨床、内圆磨床、缓进给磨床,在轧辊磨削系统中的应用,目前还没有相关文献详细报道。
针对目前轧辊磨削中存在的问题和现状,结合上海市科委支持的重大产学研攻关项目—面向钢铁汽车行业的高档数控磨床关键技术及装备开发(项目号05dz11c04),本文对轧辊磨削进行了深入的理论和实践研究,对轧辊磨削机理、轧辊磨削影响因素、砂轮磨损机理、砂轮修整机理进行了深入研究,建立了轧辊磨削的动态模型、轧辊和砂轮的接触弧长、轧辊磨削力、磨削功率、砂轮磨损补偿的数学模型,建立了基于知识的融合轧辊工艺的轧辊磨削智能控制系统的结构,提出了基于知识的多目标磨削参数优化决策方法,基于多通道技术的砂轮智能在线磨削修整方法,基于STEP-NC思想的轧辊辊形智能创成及其样条插补策略以及变速磨削自适应控制策略,并把知识工程(KBE)、专家系统、遗传算法、模糊逻辑、神经网络等智能理论与方法引入到轧辊磨削加工控制中,初步实现对轧辊磨削加工中轧辊磨削质量的控制。
课题的研究为提高现代板材质量,提高轧辊磨削质量和精度,提升轧辊磨削智能磨削过程奠定了理论基础和知识支撑,对现有的国内外轧辊磨削提供了新的思维,将会产生重要的指导意义,创造可观的经济效益和社会效益。
Rolling is a process where the metal is compressed between two rotating rolls for reducing its cross-section area. The rolls are expensive and consumptive tools. They are used to endure rolling force and make rolling material thin in roll grinding. There are some requirements for roll such as sufficient intensity, higher surface hardness, accurate structure and size, and roll shape and its grinding accuracy which can meet the product quality and proper rolling process.Roll grinding is a kind of special grinding technique which requires some special process technology. During the rolling process of profile and shape of plate, roll begins to wear. Worn roll must be ground in roll grinder. Roll grinder is a large type precision machine tool, and it is a key device in manufacturing metal plate, strip, foil material enterprise. Hence it is very important to ensure and improve product quality.
In recent years, with the rapid development of metallurgy, paper making, rubber, plastic, printing and dyeing industries economy, roll diameter is up to 3000mm, roll weight is also close to 300 tons and its geometric accuracy isμm degree. Meantime, with the coming of heavy load roll grinder, the requirement of roll grinding technique is more and more high. With the lasting development of NC, traditional roll grinder is introducing in the direction of NC roll grinder. NC technology is not only kernel technology of modern NC roll grinder, but also the base of automation, flexibility and integration of it. Under the action of NC technology, traditional manufacturing industries are being converted to information manufacturing stage, system architecture is also converting from closeness to openness. Openness is an important characteristic of modern control system. This will make plentiful software and hardware resource of computer technology to be employed in a greater degree, simultaneously make precision on-line sensor and measurement system to be integrated. Intelligence technology can help the system to acquire knowledge from practical experiences, provide process planning strategy for roll grinding, and ultimately realize the intelligent roll grinding.
Intelligence will be a main characteristic of modern NC roll grinder. Because roll grinding is very complex machining process with too many influence factors, the final quality and performance of grinding is deeply correlated with specialist knowledge, previous grinding practical experiences. Because there is strict quality requirement in complex rolling process of plate, roll profile and its grinding accuracy must be strictly controlled, this requires knowledge of roll grinding and rolling process. Knowledge is used to reveal information combination on regularity of thing. It contains relation between information and decision, and is used to directly or indirectly solve problem. With the development of knowledge economy, information integration is converted to knowledge based processing method. Research on knowledge based engineering (KBE) in the field of grinding will be a main trend. KBE system obtains knowledge and practical experiences of field specialist by means of a series of processing methods on knowledge, selects reasonable modeling method and language of knowledge, computer knowledge, and selects adequate knowledge strategy to make intellectual reasoning, deduction and decision according to given production model. The control system can make intellectual decision and control for roll grinding by combination of knowledge based method and mathematics model based method.
Because NC technology is developing towards to practicality technology, special system integrated with manufacturing technology is more applicable to high efficient and quality machining of special product. General NC system can not include machining technology of part. It is a control system which suits various general parts. Due to many influence factors such as specialist knowledge, roll technology knowledge and. plate rolling knowledge etc, traditional ideals using general NC system is not effective in this special manufacturing field. Hence roll grinding technology integrated into control system is most important characteristic of intelligent NC roll grinding system in this dissertation.
Modern intelligent control system should adopt intelligent NC standard. Due to traditional ISO6983 NC standard has many disadvantages such as bad flexibility, one-way data flow from CAD/CAM/CNC, postprocess, no spline data etc, new intelligent STEP-NC standard is built by ISO. STEP-NC has many advantages such as bi-directional data flow between CAX and CNC etc, and it can improve interchangeablity and flexibility of information. Because of obvious parameterized characteristic of roll shape, STEP-NC ideal is adapted to efficiently realize CAX/CNC of roll in this dissertation.
Though NC technology has developed in general NC control system for many years, it indicated slow development in roll grinding field. Because of nonlinearity, randomicity, uncertainty in grinding process, there are many insufficiency facts in roll grinder. At the present time, many problems about existing NC roll grinder at home and abroad need to be solved, such as creation of roll shape, expression of roll shape model, interpolation strategy of roll shape, compensation for grinding wheel wear, wheel dressing method, grinding of alternating speed, optimization of grinding parameters, historical data traceability of roll shape and grinding process data, intelligent fault diagnosis. At present, adjusting the grinding process strongly relies on the operator's experience and skill. The grinding is one of the key technologies that constraints some elements of advanced technology development.
Intelligent system used in the field of abrasive processes usually draw on one or more of the following approaches such as KBS, ES, FL, NN, GA, ACO and model based method etc. The most common operation researched is external and internal cylindrical grinder, robotic IC grinder, screw grinder, surface grinder and creep grinder. At present, related literatures on roll grinding system are seldom reported.
The paper is supported by the production, teaching, and scientific research project of Science and Technology Commission of Shanghai Municipality (05dz11c04). In this paper, aiming at the problems existing in the roll grinding, the theoretical and experimental study were conducted for roll grinding, principle of roll grinding, influence elements of roll grinding, principle of grinding wheel wear, principle of wheel dressing. Some mathematical model were built such as the dynamic model of roll grinding, contact length between grinding wheel and roll, grinding force, grinding power, compensation for grinding wheel wear. Architecture on NC roll grinding intelligent control system integrated with roll grinding process based on knowledge was built. Some key techniques and strategies were also studied, such as multi-objective optimization and decision of grinding parameters based on knowledge, on-line intelligent grinding wheel dressing method based on dual channels, intelligent roll shape based on STE-NC ideal and its spline interpolation strategy, adaptive optimization control for grinding of alternating speed etc In this paper, in order to obtain better quality of roll grinding, intelligent theory and methods such as KBE, ES, GA, FL, NN etc were introduced into roll grinding control system.
This study is of great theoretical and practical value to improve quality and accuracy of roll grinding. Research result also provided new ideal for roll grinding in home and abroad, this will be helpful for producing the remarkably socioeconomic benefit.
引文
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