基于开放型数控系统的螺纹修复技术研究
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摘要
数控机床是提高产品质量和生产率必不可少的物质手段。机床数控改造是恢复机床生命力的有效方法,其成本低、周期短,并能增强原机床技术性能指标,这已经成为适合我国国情,促进制造业技术进步的重要手段。目前,石油行业迫切需要数控加工技术对螺纹牙型进行修复,因而,研究螺纹修复技术具有十分重要的意义。
本文在研究数控技术国内外发展概况的基础上,提出了建立开放式数控系统的必要性。通过分析标准机床上螺纹工件的定位问题,确定了在已有螺纹工件轴向和周向均不确定的情况下任意装夹,通过对某一螺纹沟槽的对刀,结合位置确定方法把螺纹修复工件的位置、螺纹修复轨迹完全定位于工件坐标系中。采用PC+运动控制单元结构形式的数控系统,将CAK6150简易数控车床改造成为集开放式数控系统和闭环控制于一身的数控车床。该数控系统的建立包括软件和硬件的结构设计。应用数控系统的运动控制单元的高速位置捕获功能及与主轴完全同步的光电编码器的反馈信号,补偿车床的起刀点信号和原螺纹轨迹起点之间的偏差,在车床上完成了螺纹修复技术的应用研究,实现了“螺纹重复切削”功能,解决了加工螺纹的乱扣问题。进一步完成了自动编程和加工动态仿真软件的设计,软件包括主控模块、修复参数输入模块、数控代码生成模块、修复螺纹仿真模块。在软件中只需输入关键的参数,即可生成螺纹的数控加工程序并进行加工动态仿真,以检验数控程序的正确性。
改造后的机床系统可靠性高、性能稳定、操作界面友好、降低了操作者的劳动强度,提高了生产率,达到了预期的目标。
CNC machine is an essential material means to improve the quality of product and the productivity. Reconstruction of machine by using CNC system, which has the characters of low cost and short period, is an efficient means to restitute the machine, meanwhile, it can reinforce the old technology index. This means promotes the progress of the manufactory industry, which is adapted to the circumstance of our country. Currently, according to the urgent need of the NC machining technology, which repairs the thread groove of the screwed workpieces in oil industry, it is very important to study the technology of repairing screw thread.Based on studying numerical control technology about development general situation of abroad and home in this thesis, the necessity of building Open NC system is put forward. Through analyzing the problem of position-setting for the thread workpiece on the standard NC lathe in the theory, the workpiece is determined to be fixed without precise position-setting in both axial direction and circumferential direction, the screwer is adjusted by one thread groove. The finding position algorithm for the screw workpiece and the thread trace is applied, then the position of the workpiece and the screw track are located exactly in the workpiece coordinate system. With the NC system which integrates the personal computer and the movement controller, the simple NC system of CAK6150 lathe is improved to NC system of integrating the Open NC system and closed-loop control method. To build Open NC system includes configuration design of software and hardware. High speed position capture function of the movement controller and the feedback signal of the photoelectric encoder which is synchronizing with main axle absolutely are applied, the offset between the actual starting point and the thread groove starting point is compensated. The theory of repairing screw thread technology is applied on the improved lathe. The continuously function of resumption thread cutting is achieved and the trace disorder problem is solved. Furthermore, the auto-program and dynamic emulation software is designed. The software includes main control software
module, repairing parameters input module, numerical control code build module and repairing screw emulation module. In this software, as long as the key parameters are inputted, the NC program will be created out immediately, and the dynamic emulation will be accomplished to check up the validity of the NC program.It shows that the reconstructed system has high reliability, steady capability and friendly interface. The productive efficiency is improved, and the anticipant target is achieved.
本文在研究数控技术国内外发展概况的基础上,提出了建立开放式数控系统的必要性。通过分析标准机床上螺纹工件的定位问题,确定了在已有螺纹工件轴向和周向均不确定的情况下任意装夹,通过对某一螺纹沟槽的对刀,结合位置确定方法把螺纹修复工件的位置、螺纹修复轨迹完全定位于工件坐标系中。采用PC+运动控制单元结构形式的数控系统,将CAK6150简易数控车床改造成为集开放式数控系统和闭环控制于一身的数控车床。该数控系统的建立包括软件和硬件的结构设计。应用数控系统的运动控制单元的高速位置捕获功能及与主轴完全同步的光电编码器的反馈信号,补偿车床的起刀点信号和原螺纹轨迹起点之间的偏差,在车床上完成了螺纹修复技术的应用研究,实现了“螺纹重复切削”功能,解决了加工螺纹的乱扣问题。进一步完成了自动编程和加工动态仿真软件的设计,软件包括主控模块、修复参数输入模块、数控代码生成模块、修复螺纹仿真模块。在软件中只需输入关键的参数,即可生成螺纹的数控加工程序并进行加工动态仿真,以检验数控程序的正确性。
改造后的机床系统可靠性高、性能稳定、操作界面友好、降低了操作者的劳动强度,提高了生产率,达到了预期的目标。
CNC machine is an essential material means to improve the quality of product and the productivity. Reconstruction of machine by using CNC system, which has the characters of low cost and short period, is an efficient means to restitute the machine, meanwhile, it can reinforce the old technology index. This means promotes the progress of the manufactory industry, which is adapted to the circumstance of our country. Currently, according to the urgent need of the NC machining technology, which repairs the thread groove of the screwed workpieces in oil industry, it is very important to study the technology of repairing screw thread.Based on studying numerical control technology about development general situation of abroad and home in this thesis, the necessity of building Open NC system is put forward. Through analyzing the problem of position-setting for the thread workpiece on the standard NC lathe in the theory, the workpiece is determined to be fixed without precise position-setting in both axial direction and circumferential direction, the screwer is adjusted by one thread groove. The finding position algorithm for the screw workpiece and the thread trace is applied, then the position of the workpiece and the screw track are located exactly in the workpiece coordinate system. With the NC system which integrates the personal computer and the movement controller, the simple NC system of CAK6150 lathe is improved to NC system of integrating the Open NC system and closed-loop control method. To build Open NC system includes configuration design of software and hardware. High speed position capture function of the movement controller and the feedback signal of the photoelectric encoder which is synchronizing with main axle absolutely are applied, the offset between the actual starting point and the thread groove starting point is compensated. The theory of repairing screw thread technology is applied on the improved lathe. The continuously function of resumption thread cutting is achieved and the trace disorder problem is solved. Furthermore, the auto-program and dynamic emulation software is designed. The software includes main control software
module, repairing parameters input module, numerical control code build module and repairing screw emulation module. In this software, as long as the key parameters are inputted, the NC program will be created out immediately, and the dynamic emulation will be accomplished to check up the validity of the NC program.It shows that the reconstructed system has high reliability, steady capability and friendly interface. The productive efficiency is improved, and the anticipant target is achieved.
引文
[1] 吴祖育,秦鹏飞主编.数控机床(第二版).上海:上海科技出版社,1990
[2] 刘又午.数字控制机床.北京:机械工业出版社,1997
[3] 彭炎午.计算机数控系统.西安:西北工业大学出版社,1988
[4] Joseph Pusztai and Michael Sava. Computer Numarical Control. Virginia: Reston Publishing Company, Inc. 1983
[5] Warren S. Seames. Computer Numerical Control: Concepts and Programming. New York: Delmar publishers Inc. 1986
[6] 张宝林.数控技术.北京:机械工业出版社,1997
[7] 蒋新平.数控技术的发展及面临的任务.机电工程,1992(2):32～36
[8] 张曙.机床数控技术的发展现状与趋势.组合机床与自动化加工技术,1993(1):25～28
[9] 朱国力,段正澄.现代数控系统的特点和发展方向.机械与电子,2001(1):52
[10] 周延佑.数控系统的发展与机床数控化改造.机械制造,1999(5):16～20
[11] 廖德岗.开放式数控系统的研究及其发展现状.机械,1999(3):13
[12] Frederick M Proctor. Open-architecture Controllers.IEEE Spectrum, June 1997: 60～64
[13] 朴英锡,石玉祥.综观开放式数控系统.磨床与磨削,1998(4):14～16
[14] 周延佑.我国机床数控系统的现状与机床数控化改造.设备管理与维修,1999(8):20～21
[15] 张建明.机电一体化原理与应用.北京:国防工业出版社,1992
[16] 卓国光,韩丽珍.机电一体化产品系统工程设计研究.计算机应用,1999(5):33～36
[17] 洪鹰,宋美江,王刚等.用DMC构造开放式数控系统.制作业自动化,2003(6):31～33
[18] Y. Altintas. Open Architecture Modular Tool Kit for Motion and Maching Process Control. Annals of the CIRP Vol. 47, No. 1, 1997: 295～300
[19] 杨有成,杨贺来.基于DMC1800的开放式数控系统研究.组合机床与自动化加工技术,2004(7):83～89
[20] Kazuo Yamazaki. Autonomously Proficient CNC Controller for High-performance Machine Tools Based on an Open Architecture Aoncept, Annals of the CIRP, Vol. 46, No. 1, 1997: 275～278
[21] 田应仲,沈建忠,何永义.基于DMC数字运动控制器的研究及应用.机械与电子,2004(3):23～25
[22] 张占收,李力,袁立强.普通车床增加数控车螺纹功能.河北工业科技,1999(1):27～29
[23] 王计文,景顺,志强.浅析普通车床的数控改造.机床与液压,1999(3):82～83
[24] 李杰,刘宏杰,唐宗军.基于管螺纹车床的数控化改造设计.机械,2003增刊:253～255
[25] 王可,唐宗军,赵文珍.管螺纹数控加工中的几个技术问题.石油机械,1998.11
[26] 周永鹏,沈安文,万淑芸.螺纹加工伺服的高精度切入控制.机械与电子,2002(2):61～62
[27] 彭晓艳,王虎符,王文格.CNC车床螺纹加工的插补方法.机械与电子,1997(2):15～16
[28] 项占琴.螺纹加工的控制方法.机电丁程,1996(4):24～25
[29] 张耀辉,王启民,王秀梅等.石油钻杆接头螺纹的数控修复加工方法.中国机械工程,1999(6):633～635
[30] 傅晓林.基于DMC控制卡的两轴运动控制系统.重庆交通学院学报,2001(4):135～140
[31] Greg Paula. New Processors Transform Motion Control. Mechanical Engineering, April 1997: 79～80
[32] 吴逸贤,吴目诚.精彩C+Builder 6程序设计.北京:科学出版社,2003
[33] Brian W. Kernighan and Dennis M. Ritchie. The C Programming Language, 1998
[34] 费广正,芦丽丹,陈立新等编.可视化OpenGL程序设计.北京:清华大学出版社,2001
[35] 陈劲松.螺纹的重复切削.制作技术与机床,2000(12):46
[36] 黄雪梅,韩腾蛟.车螺纹等车削加工仿真动画的研制.现代教育技术,2001(2):73～76
[37] MiKell P. Groover and Emorys W.zimmers, JR. CAD/CAM Computer-Aided Design and Manufacturing. 1988
[38] 杜忠友,姜玉波,李红等.模拟车削成型的三维螺纹计算机建模方法.山东建筑工程学院学报,2004(2):67～69
[39] Rogers D F. Procedural Elements for Computer Graphic[M]. Second Edition. New York: Mc Graw-Hill Companies, 1998
[40] Heare D, Baker M P. Computer Graphics(C Version)[M]. Second Edition. New Jersey: Prentice Hall International Inc, 1998
[41] 孙家广,杨长贵.计算机图形学(新版).北京:清华大学出版社,1994
[42] 姜波,梁岚珍.DMC—PID复合控制研究.新疆工学院学报,1998(3):11～14
[43] 徐建中,张彦斌,贾立新等.DMC-PID串级控制及其应用研究.西安交通大学学报,1996(11):869～94
[44] 卢晓平.数控机床加工与编程.成都:电子科技大学出版社,1999
[2] 刘又午.数字控制机床.北京:机械工业出版社,1997
[3] 彭炎午.计算机数控系统.西安:西北工业大学出版社,1988
[4] Joseph Pusztai and Michael Sava. Computer Numarical Control. Virginia: Reston Publishing Company, Inc. 1983
[5] Warren S. Seames. Computer Numerical Control: Concepts and Programming. New York: Delmar publishers Inc. 1986
[6] 张宝林.数控技术.北京:机械工业出版社,1997
[7] 蒋新平.数控技术的发展及面临的任务.机电工程,1992(2):32～36
[8] 张曙.机床数控技术的发展现状与趋势.组合机床与自动化加工技术,1993(1):25～28
[9] 朱国力,段正澄.现代数控系统的特点和发展方向.机械与电子,2001(1):52
[10] 周延佑.数控系统的发展与机床数控化改造.机械制造,1999(5):16～20
[11] 廖德岗.开放式数控系统的研究及其发展现状.机械,1999(3):13
[12] Frederick M Proctor. Open-architecture Controllers.IEEE Spectrum, June 1997: 60～64
[13] 朴英锡,石玉祥.综观开放式数控系统.磨床与磨削,1998(4):14～16
[14] 周延佑.我国机床数控系统的现状与机床数控化改造.设备管理与维修,1999(8):20～21
[15] 张建明.机电一体化原理与应用.北京:国防工业出版社,1992
[16] 卓国光,韩丽珍.机电一体化产品系统工程设计研究.计算机应用,1999(5):33～36
[17] 洪鹰,宋美江,王刚等.用DMC构造开放式数控系统.制作业自动化,2003(6):31～33
[18] Y. Altintas. Open Architecture Modular Tool Kit for Motion and Maching Process Control. Annals of the CIRP Vol. 47, No. 1, 1997: 295～300
[19] 杨有成,杨贺来.基于DMC1800的开放式数控系统研究.组合机床与自动化加工技术,2004(7):83～89
[20] Kazuo Yamazaki. Autonomously Proficient CNC Controller for High-performance Machine Tools Based on an Open Architecture Aoncept, Annals of the CIRP, Vol. 46, No. 1, 1997: 275～278
[21] 田应仲,沈建忠,何永义.基于DMC数字运动控制器的研究及应用.机械与电子,2004(3):23～25
[22] 张占收,李力,袁立强.普通车床增加数控车螺纹功能.河北工业科技,1999(1):27～29
[23] 王计文,景顺,志强.浅析普通车床的数控改造.机床与液压,1999(3):82～83
[24] 李杰,刘宏杰,唐宗军.基于管螺纹车床的数控化改造设计.机械,2003增刊:253～255
[25] 王可,唐宗军,赵文珍.管螺纹数控加工中的几个技术问题.石油机械,1998.11
[26] 周永鹏,沈安文,万淑芸.螺纹加工伺服的高精度切入控制.机械与电子,2002(2):61～62
[27] 彭晓艳,王虎符,王文格.CNC车床螺纹加工的插补方法.机械与电子,1997(2):15～16
[28] 项占琴.螺纹加工的控制方法.机电丁程,1996(4):24～25
[29] 张耀辉,王启民,王秀梅等.石油钻杆接头螺纹的数控修复加工方法.中国机械工程,1999(6):633～635
[30] 傅晓林.基于DMC控制卡的两轴运动控制系统.重庆交通学院学报,2001(4):135～140
[31] Greg Paula. New Processors Transform Motion Control. Mechanical Engineering, April 1997: 79～80
[32] 吴逸贤,吴目诚.精彩C+Builder 6程序设计.北京:科学出版社,2003
[33] Brian W. Kernighan and Dennis M. Ritchie. The C Programming Language, 1998
[34] 费广正,芦丽丹,陈立新等编.可视化OpenGL程序设计.北京:清华大学出版社,2001
[35] 陈劲松.螺纹的重复切削.制作技术与机床,2000(12):46
[36] 黄雪梅,韩腾蛟.车螺纹等车削加工仿真动画的研制.现代教育技术,2001(2):73～76
[37] MiKell P. Groover and Emorys W.zimmers, JR. CAD/CAM Computer-Aided Design and Manufacturing. 1988
[38] 杜忠友,姜玉波,李红等.模拟车削成型的三维螺纹计算机建模方法.山东建筑工程学院学报,2004(2):67～69
[39] Rogers D F. Procedural Elements for Computer Graphic[M]. Second Edition. New York: Mc Graw-Hill Companies, 1998
[40] Heare D, Baker M P. Computer Graphics(C Version)[M]. Second Edition. New Jersey: Prentice Hall International Inc, 1998
[41] 孙家广,杨长贵.计算机图形学(新版).北京:清华大学出版社,1994
[42] 姜波,梁岚珍.DMC—PID复合控制研究.新疆工学院学报,1998(3):11～14
[43] 徐建中,张彦斌,贾立新等.DMC-PID串级控制及其应用研究.西安交通大学学报,1996(11):869～94
[44] 卢晓平.数控机床加工与编程.成都:电子科技大学出版社,1999