相贯线切割机数控仿真系统的研究
摘要
随着我国经济的飞速发展和工业化进程的进一步加快,管材的应用已经逐步扩展到建筑、机械、汽车、造船、石油等众多行业。管材在使用前需要通过数控切割机进行精确切割以保证切割后的焊接质量和性能,因此,要求割炬在切割时严格按照其相贯线来进行,并根据需要预留出一定角度的坡口。
本论文搭建了以“NC嵌入PC”式结构为系统框架、以运动控制卡为核心的数控硬件系统。该系统由工控机、PMAC卡、I/O接口、A/D转换器和伺服电机等部件组成,具有强大的伺服能力、高度的灵活性和良好的可靠性。按照模块化思想对CNC软件进行了功能设计,其中仿真功能作为其核心功能是现代先进数控技术发展的标志之一。对割炬的运动学规律展开了深入的研究,并利用线性代数学和空间解析几何学等知识建立了相交两管之间的相贯线数学模型和具有任意角度的相交两管之间的相贯线数学模型。此外,还对切割过程中与坡口相关的各个参数进行了详细的数学分析,其中坡口角度是严格按照美国石油协会规定进行计算的。
在充分研究仿真算法的基础上,利用VC++和OpenGL设计并开发了切割机仿真软件,实现了CNC软件的仿真功能。该软件通过人机界面提供的各项参数自动计算出切割过程中所需要的各种数据,并利用这些数据完成了切割轨迹的动态仿真,为进一步开发切割机控制软件创造了重要前提。
With the rapid development of our economy and the further speeding up of industrialization, tubes have been applied to many fields like architecture, mechanics, automotives, ship-building and petroleum and so on. The tube needs to be cut precisely by NC cutting machine before usage so as to make sure its welding quality and performance after being cut. Thus, the torch is required to move strictly along the intersection curves and as is needed some certain angle should be precut.
In this thesis a NC hardware system with the core of motion-control card under the structure of NC-embedded PC was assembled. Composed of components like IPC, PMAC, I/O interface, A/D converter and servo-motor, this system has powerful servo-control ability, extraordinary flexibility and good reliability. Functions of CNC software were designed in the thought of COM and as its core function, simulation function has become the sign of modern advanced NC technology. The motion rules of torch was studied thoroughly and a general mathematical model for intersections between tubes and a mathematical model for intersections between tubes with any angle were established according to analytic geometry and linear algebra. Besides, parameters relative to groove which was strictly calculated according to rules in American Petroleum Institute were carefully analyzed.
Based on a thorough research on the simulation algorithm, a simulation software of pipe cutting machine was designed and developed through the use of VC++ coupled with OpenGL and the simulation function of CNC software was implemented. This software could automatically calculate the datas needed in the process of cutting through its human-computer interface and complete the dynamic simulation of cutting trace by using the datas and create an important premise for the further development of CNC software.
本论文搭建了以“NC嵌入PC”式结构为系统框架、以运动控制卡为核心的数控硬件系统。该系统由工控机、PMAC卡、I/O接口、A/D转换器和伺服电机等部件组成,具有强大的伺服能力、高度的灵活性和良好的可靠性。按照模块化思想对CNC软件进行了功能设计,其中仿真功能作为其核心功能是现代先进数控技术发展的标志之一。对割炬的运动学规律展开了深入的研究,并利用线性代数学和空间解析几何学等知识建立了相交两管之间的相贯线数学模型和具有任意角度的相交两管之间的相贯线数学模型。此外,还对切割过程中与坡口相关的各个参数进行了详细的数学分析,其中坡口角度是严格按照美国石油协会规定进行计算的。
在充分研究仿真算法的基础上,利用VC++和OpenGL设计并开发了切割机仿真软件,实现了CNC软件的仿真功能。该软件通过人机界面提供的各项参数自动计算出切割过程中所需要的各种数据,并利用这些数据完成了切割轨迹的动态仿真,为进一步开发切割机控制软件创造了重要前提。
With the rapid development of our economy and the further speeding up of industrialization, tubes have been applied to many fields like architecture, mechanics, automotives, ship-building and petroleum and so on. The tube needs to be cut precisely by NC cutting machine before usage so as to make sure its welding quality and performance after being cut. Thus, the torch is required to move strictly along the intersection curves and as is needed some certain angle should be precut.
In this thesis a NC hardware system with the core of motion-control card under the structure of NC-embedded PC was assembled. Composed of components like IPC, PMAC, I/O interface, A/D converter and servo-motor, this system has powerful servo-control ability, extraordinary flexibility and good reliability. Functions of CNC software were designed in the thought of COM and as its core function, simulation function has become the sign of modern advanced NC technology. The motion rules of torch was studied thoroughly and a general mathematical model for intersections between tubes and a mathematical model for intersections between tubes with any angle were established according to analytic geometry and linear algebra. Besides, parameters relative to groove which was strictly calculated according to rules in American Petroleum Institute were carefully analyzed.
Based on a thorough research on the simulation algorithm, a simulation software of pipe cutting machine was designed and developed through the use of VC++ coupled with OpenGL and the simulation function of CNC software was implemented. This software could automatically calculate the datas needed in the process of cutting through its human-computer interface and complete the dynamic simulation of cutting trace by using the datas and create an important premise for the further development of CNC software.
引文
[1]James Blackburn.Advancements in pipe cutting operations[J].THE ABRICATOR,1994,4:14-15.
[2]冯兴财,郭艳玲.多类型管切割数控轨迹建模与仿真[J]新技术新工艺,2006,2:50.
[3]陆启祥.中国切割机具行业现状及未来市场的需求[J].焊接,2006,9:10.
[4]李莉.管件相贯线数控切割数学模型及其自动编程系统的研发[J].组合机床与自动化加工技术,2001,12:34-35.
[5]季钟,刘韧.管管相交数学模型及其在数控加工中的应用[J].工程图学学报,2002,2:139.
[6]董桂西,赵文霞.多边形钢管相贯线的计算机放样研究[J].广东电力,2006,19(5):25.
[7]向平.具有误差补偿的五轴联动数控管切割机控制系统开发[D].武汉大学硕士学位论文,2005:2.
[8]韩传华.数控圆管切割机自动编程系统的开发[D].武汉大学硕士学位论文,2004:2.
[9]吴萍.方、圆管两用五轴数控切割机控制系统开发[D].武汉大学硕士学位论,2005:2.
[10]李爱平,张建国.NC嵌入PC型开放式数控系统的研究[J].组合机床与自动化加工技术,2001,12:31-32.
[11]郭艳玲.数控发展的趋势——开放式体系结构数控系统[J].东北林业大学学报,2000,28(5):148-149.
[12]Altintas Y.Munasinghe WK.A Hierarchichal Open Architechture CNC System for Machine Tools.Annals of the CIRP.1994,43(1):349-354.
[13]王成元,郭雨梅.开放式数控系统的发展现状及其趋势[J].沈阳工业大学学报,2007,29(1):61-62.
[14]彭子龙.基于IPC的数控火焰切割机数控系统开发[D].哈尔滨理工大学硕士学位论文,2006:5-6.
[15]王睿鹏.基于PC的开放式数控系统[J].宁夏机械,2006,2:18-19.
[16]杨晓京.开放式微机数控系统实现技术研究[J].昆明理工大学学报.2002,27(1):50-51.
[17]Zhu Tong-xing.The development tendency of home and overseas NC technology[J].Numerical Control Technique and Application,2001(3):10-11.
[18]房淑红.PMAC卡在数控火焰切割机上的应用研究[J].中国科技信息,2005,3:14.
[19]谭民,景奉水.开放式先进机器人控制器开发[J].http://www.cas.ac.cn/html/dir/2001/10/19/2023.htm.
[20]康文惠.基于工业PC机的数控火焰切割机控制系统的开发[J].科技情报开发与经济,2003,13(10):177.
[21]赵海军.开放式数控火焰切割机系统设计与开发[J].自动化技术与应,2007,26(7)97:98.
[22]邱润生.基于PC运动控制卡的开放式数控系统的研究[J].宁夏工程技术,2006,5(4):351-352.
[23]李显,王明红.基于开放式运动控制器PMAC的数控系统的研究[J].控制工程,2007,14(7):151-152.
[24]肖会军,黄健.基于PMAC的数控管切割机的开发[J].石油机械,2004,32(2):32-33.
[25]刘梅清,张锁山.基于PMAC的数控管切割机的开发[J].数控技术与装备,2004,4:101-102.
[26]章生.基于PMAC的数控火焰切割机数控系统的开发[J].航空制造技术,2004,4:74-75.
[27]陈金成.基于工业PC机的数控火焰切割机数控系统开发[J].机床与液压,1999,5:18.
[28]余建军.燃气管道在线智能切割的研究[D].华中科技大学硕士学位论文,2005:33-35.
[29]Delta Tau Data System Inc Installation Manual[Z].January 29,2003.
[30]章生.基于PMAC的数控火焰切割机数控系统开发[J].机电工程,2002,19(2):38-39.
[31]PMAC Pcomm32PRO Software Reference Manua.Delta Tau Data System Inc,2003.
[32]黄振山,王国栋.管端相贯焊接坡口数控切割研究[J].制造业自动化,2005,17(9):34-36.
[33]王国栋,肖聚亮.管端相贯线坡口切割割炬位姿控制[J].天津大学学报,2005,38(8):685.
[34]4 and 5-Axis Microprocessor Pipe Machine Instruction Manual[Z].USA:Vernon Tool Company,2003.
[35]王国栋.管环相贯焊接坡口数控切割研究[J].中国机械工,2005,16(6):561-563.
[36]肖聚亮.火焰数控切管机割炬轨迹研究及仿真[J].机械工程学报 2005,41(4):234.
[37]John M.Stockie.The Geometry of Intersecting Tubes Applied to Controlling a Robotic Welding Torch[J].MapleTech.1998,6:2.
[38]王令其.相贯线插补方式的研究[J].机械工程师,2003,2:21.
[39]边广韬.相贯线焊接数控机床研究[J].机械设计与制造,2001,4(8):82.
[40]李小刚.相交双管焊接坡口的数据化处理[J].中国机械工程,2004,15(4):355-356.
[41]李树楫.异径圆管相贯线数学模型的建立与应用[J].起重运输机械,2005,2:51.
[42]孟霍友.相贯线接缝自动焊接实时插补控制算法与仿真[J].机电一体化,2006,3:23-24.
[43]朱鼎勋.空间解析几何学[M].武汉:武汉大学出版社,2006:195-196.
[44]中华人民共和国建设部.结构钢设计规范GB50017-2003[Z].2003:102.
[45]谢新房,王国栋.多管相贯焊接坡口数控切割研究[J].工程图学学报,2007,4:151-152.
[46]刘科.海洋平台导管架构件自动切割系统研究与开发[D].天津大学硕士学位论文,2005:24-26.
[47]郑宝东.线性代数与空间解析几何[M].北京:高等教育出版社,2001:74.
[48]John Fuller.OpenGL Reference Manual[M].Addison Wesley Publishing Company,2001:12-13.
[49]Dave Shreiner,Ed Angel.An Interactive Introduction To Opengl Programming[M]. Wordware Publishing,2001:7-8.
[50]Richard S.Wright,Jr.Micheal Sweet.OpenL超级宝典[M].北京:人民邮电出版社,2002:24.
[51]隋刚,刘国栋.CSG方法在建筑物三维建模中的应用研究[J].太原理工大学学报,2003,34(6):691-693.
[52]Edward Angel.OpenGL:A Primer Second Edition[M].李桂琼,张文祥.OpenGL程序设计指南.北京:清华大学出版社,2005:25-26.
[53]Samuel R.Buss.3D Computer Graphics—A Mathematical Introduction with OpenGL[M].California:CAMBRIDGE UNIVERSITY PRESS,2003:67-69.
[54]Tom McReynolds.Advanced Graphics Programming Using OpenGL[M].CA:Morgan Kaufmann Publishers,2005:40-43.
[55]Mason Woo,Jackie Neider.OpenGL Programming Guide[M].Addison Wesley Longman,2001:79-81.
[56]Dave Astle,Kevin Hawkins.Beginning OpenGL Game Programming[M].Premier Press,2004:99-104.
[2]冯兴财,郭艳玲.多类型管切割数控轨迹建模与仿真[J]新技术新工艺,2006,2:50.
[3]陆启祥.中国切割机具行业现状及未来市场的需求[J].焊接,2006,9:10.
[4]李莉.管件相贯线数控切割数学模型及其自动编程系统的研发[J].组合机床与自动化加工技术,2001,12:34-35.
[5]季钟,刘韧.管管相交数学模型及其在数控加工中的应用[J].工程图学学报,2002,2:139.
[6]董桂西,赵文霞.多边形钢管相贯线的计算机放样研究[J].广东电力,2006,19(5):25.
[7]向平.具有误差补偿的五轴联动数控管切割机控制系统开发[D].武汉大学硕士学位论文,2005:2.
[8]韩传华.数控圆管切割机自动编程系统的开发[D].武汉大学硕士学位论文,2004:2.
[9]吴萍.方、圆管两用五轴数控切割机控制系统开发[D].武汉大学硕士学位论,2005:2.
[10]李爱平,张建国.NC嵌入PC型开放式数控系统的研究[J].组合机床与自动化加工技术,2001,12:31-32.
[11]郭艳玲.数控发展的趋势——开放式体系结构数控系统[J].东北林业大学学报,2000,28(5):148-149.
[12]Altintas Y.Munasinghe WK.A Hierarchichal Open Architechture CNC System for Machine Tools.Annals of the CIRP.1994,43(1):349-354.
[13]王成元,郭雨梅.开放式数控系统的发展现状及其趋势[J].沈阳工业大学学报,2007,29(1):61-62.
[14]彭子龙.基于IPC的数控火焰切割机数控系统开发[D].哈尔滨理工大学硕士学位论文,2006:5-6.
[15]王睿鹏.基于PC的开放式数控系统[J].宁夏机械,2006,2:18-19.
[16]杨晓京.开放式微机数控系统实现技术研究[J].昆明理工大学学报.2002,27(1):50-51.
[17]Zhu Tong-xing.The development tendency of home and overseas NC technology[J].Numerical Control Technique and Application,2001(3):10-11.
[18]房淑红.PMAC卡在数控火焰切割机上的应用研究[J].中国科技信息,2005,3:14.
[19]谭民,景奉水.开放式先进机器人控制器开发[J].http://www.cas.ac.cn/html/dir/2001/10/19/2023.htm.
[20]康文惠.基于工业PC机的数控火焰切割机控制系统的开发[J].科技情报开发与经济,2003,13(10):177.
[21]赵海军.开放式数控火焰切割机系统设计与开发[J].自动化技术与应,2007,26(7)97:98.
[22]邱润生.基于PC运动控制卡的开放式数控系统的研究[J].宁夏工程技术,2006,5(4):351-352.
[23]李显,王明红.基于开放式运动控制器PMAC的数控系统的研究[J].控制工程,2007,14(7):151-152.
[24]肖会军,黄健.基于PMAC的数控管切割机的开发[J].石油机械,2004,32(2):32-33.
[25]刘梅清,张锁山.基于PMAC的数控管切割机的开发[J].数控技术与装备,2004,4:101-102.
[26]章生.基于PMAC的数控火焰切割机数控系统的开发[J].航空制造技术,2004,4:74-75.
[27]陈金成.基于工业PC机的数控火焰切割机数控系统开发[J].机床与液压,1999,5:18.
[28]余建军.燃气管道在线智能切割的研究[D].华中科技大学硕士学位论文,2005:33-35.
[29]Delta Tau Data System Inc Installation Manual[Z].January 29,2003.
[30]章生.基于PMAC的数控火焰切割机数控系统开发[J].机电工程,2002,19(2):38-39.
[31]PMAC Pcomm32PRO Software Reference Manua.Delta Tau Data System Inc,2003.
[32]黄振山,王国栋.管端相贯焊接坡口数控切割研究[J].制造业自动化,2005,17(9):34-36.
[33]王国栋,肖聚亮.管端相贯线坡口切割割炬位姿控制[J].天津大学学报,2005,38(8):685.
[34]4 and 5-Axis Microprocessor Pipe Machine Instruction Manual[Z].USA:Vernon Tool Company,2003.
[35]王国栋.管环相贯焊接坡口数控切割研究[J].中国机械工,2005,16(6):561-563.
[36]肖聚亮.火焰数控切管机割炬轨迹研究及仿真[J].机械工程学报 2005,41(4):234.
[37]John M.Stockie.The Geometry of Intersecting Tubes Applied to Controlling a Robotic Welding Torch[J].MapleTech.1998,6:2.
[38]王令其.相贯线插补方式的研究[J].机械工程师,2003,2:21.
[39]边广韬.相贯线焊接数控机床研究[J].机械设计与制造,2001,4(8):82.
[40]李小刚.相交双管焊接坡口的数据化处理[J].中国机械工程,2004,15(4):355-356.
[41]李树楫.异径圆管相贯线数学模型的建立与应用[J].起重运输机械,2005,2:51.
[42]孟霍友.相贯线接缝自动焊接实时插补控制算法与仿真[J].机电一体化,2006,3:23-24.
[43]朱鼎勋.空间解析几何学[M].武汉:武汉大学出版社,2006:195-196.
[44]中华人民共和国建设部.结构钢设计规范GB50017-2003[Z].2003:102.
[45]谢新房,王国栋.多管相贯焊接坡口数控切割研究[J].工程图学学报,2007,4:151-152.
[46]刘科.海洋平台导管架构件自动切割系统研究与开发[D].天津大学硕士学位论文,2005:24-26.
[47]郑宝东.线性代数与空间解析几何[M].北京:高等教育出版社,2001:74.
[48]John Fuller.OpenGL Reference Manual[M].Addison Wesley Publishing Company,2001:12-13.
[49]Dave Shreiner,Ed Angel.An Interactive Introduction To Opengl Programming[M]. Wordware Publishing,2001:7-8.
[50]Richard S.Wright,Jr.Micheal Sweet.OpenL超级宝典[M].北京:人民邮电出版社,2002:24.
[51]隋刚,刘国栋.CSG方法在建筑物三维建模中的应用研究[J].太原理工大学学报,2003,34(6):691-693.
[52]Edward Angel.OpenGL:A Primer Second Edition[M].李桂琼,张文祥.OpenGL程序设计指南.北京:清华大学出版社,2005:25-26.
[53]Samuel R.Buss.3D Computer Graphics—A Mathematical Introduction with OpenGL[M].California:CAMBRIDGE UNIVERSITY PRESS,2003:67-69.
[54]Tom McReynolds.Advanced Graphics Programming Using OpenGL[M].CA:Morgan Kaufmann Publishers,2005:40-43.
[55]Mason Woo,Jackie Neider.OpenGL Programming Guide[M].Addison Wesley Longman,2001:79-81.
[56]Dave Astle,Kevin Hawkins.Beginning OpenGL Game Programming[M].Premier Press,2004:99-104.