高速数控加工的前瞻控制理论及关键技术研究
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摘要
针对加工路径尖锐拐角及高曲率而导致高速数控加工中的加工过切、机床异常振动及数据饥饿现象,提出了高速数控加工前瞻控制新算法。相对于传统加工控制过程,前瞻控制具有自动分析加工路径、自动发现路径危险点及自动处理路径危险点的能力,有效保证较高的加工效率及加工精度。根据前瞻控制的实现过程及实现目的,本文结合863高技术研究发展计划资助项目“面向微流控芯片的微模具制造装备研究”(2002AA421150)和浙江省重大机电装备专项项目“中高档数控机床控制系统”(2006C11067)等任务,系统研究了前瞻控制加减速算法、前瞻控制离散路径插值算法、前瞻控制参数曲线插补算法及前瞻控制过程中的误差补偿算法,最后论述了前瞻控制算法的具体实现过程。
前瞻控制算法的组成构架中,加减速算法是基础,离散路径的插值算法、参数曲线的插补算法是必要手段,而误差补偿算法则是必须的配件。论文首先深入研究了传统数控系统加减速算法的实现原理和数控加工过程中离散加工路径段的速度矢量混和算法,基于多项式的多样性与实用性,针对性地论述了多项式通用加减速算法的实现,并基于特定加减速特性创新的提出了微小线段的速度光滑衔接算法。
根据前瞻控制中路径分析及实际插补的需要,将离散加工路径的插值应用划分为局部插值及全局插值两种,基于求解线性方程组的追赶法和求解高次多项式方程的牛顿迭代法,详细阐述了常用参数式曲线插值算法。由于参数曲线插补在高速数控加工中应用越来越普遍,为了保证前瞻控制算法应用的广泛性,论文阐述了泰勒展开式插补方法和预测校正插补方法,并深入研究了参数曲线自适应插补算法。为了保证前瞻控制算法的系统与完整性,在数据缓冲指令产生算法硬件结构的基础上,结合传统数控系统误差补偿算法,创新的提出了前瞻控制中的误差均匀补偿算法。
论文最后给出了高速加工中的前瞻控制实现过程,以离散加工路径和参数曲线加工路径为对象,结合伺服系统的特点,实现了路径危险点的分析、离散路径插补点的增加、参数曲线路径的加减速划分、危险点优化速度的求解及路径加减速的规划。实验结果表明,前瞻控制是高速数控加工的必要组成部分,是加工效率和加工精度的有效保证。
To deal with overshooting, mechanical harmful vibrations and data starvation caused by sharp corner or high curvature of tool path, a new look-ahead algorithm for high speed cutting machining is proposed by this paper. Compared to traditional numerical control, look-ahead control can analyze tool path、find dangerous points and deal with dangerous situations in machining automatically. Therefore machining productivity and accuracy can be improved efficiently. According to the goal of look-ahead control and considering both discrete and parametric curve tool path, this paper places emphases on acceleration and deceleration algorithm, discrete points interpolation algorithm, parametric curve interpolation algorithm and error compensation algorithm combined with the research of the National High Technology Research and Development Program (863 Program):"Microfluidic chip-oriented micromold manufacure equipments research" (2002AA421150) and the Special Project for Key Mechatronic Equipment of Zhejiang Province: "Medium and high class numerical control system" (2006C11067). At last, new look-ahead algorithm is proposed.
In terms of configuration of look-ahead algorithm, the basic is acceleration and deceleration algorithm. Discrete points interpolation algorithm and parametric curve interpolation algorithm are necessary tools. Error compensation algorithm is necessary accessory. The paper firstly researches the principle of acceleration and deceleration algorithm and velocity blending algorithm for discrete tool path used in traditional numerical control system. Then according to the multiformity and practicality of polynomial, the acceleration and deceleration construction algorithm of polynomial is proposed. Under specific polynomial construction method, innovative velocity link method for small short straight lines is proposed.
For the necessity of data analysis and parametric curve interpolation, the partial and overall interpolations algorithms for discrete tool path are used. Chasing method and Newton iterative method are applied in parametric curve interpolation algorithm. Due to the wider and wider use of parametric curve in high speed cutting machining and to guarantee the universality of look-ahead control, interpolation methods based on Taylor series and predictor-corrector are expatiated. Furthermore, interpolator adapted to tool path is introduced. To guarantee the systemic and integrality of look-ahead control algorithm and based on buffer command generation method, error even compensation algorithm is proposed.
Finally look-ahead control algorithm is proposed based on analysis of dangerous points、complement of points on discret tool path、partition of parametric tool path according to acceleration and deceleration、solution of optimal feedrate at dangerous points and arrangement of acceleration and deceleration for machining. On-line experiments shows look-ahead control is necessary for high speed cutting machining and guarantees productivity and accuracy efficiently.
前瞻控制算法的组成构架中,加减速算法是基础,离散路径的插值算法、参数曲线的插补算法是必要手段,而误差补偿算法则是必须的配件。论文首先深入研究了传统数控系统加减速算法的实现原理和数控加工过程中离散加工路径段的速度矢量混和算法,基于多项式的多样性与实用性,针对性地论述了多项式通用加减速算法的实现,并基于特定加减速特性创新的提出了微小线段的速度光滑衔接算法。
根据前瞻控制中路径分析及实际插补的需要,将离散加工路径的插值应用划分为局部插值及全局插值两种,基于求解线性方程组的追赶法和求解高次多项式方程的牛顿迭代法,详细阐述了常用参数式曲线插值算法。由于参数曲线插补在高速数控加工中应用越来越普遍,为了保证前瞻控制算法应用的广泛性,论文阐述了泰勒展开式插补方法和预测校正插补方法,并深入研究了参数曲线自适应插补算法。为了保证前瞻控制算法的系统与完整性,在数据缓冲指令产生算法硬件结构的基础上,结合传统数控系统误差补偿算法,创新的提出了前瞻控制中的误差均匀补偿算法。
论文最后给出了高速加工中的前瞻控制实现过程,以离散加工路径和参数曲线加工路径为对象,结合伺服系统的特点,实现了路径危险点的分析、离散路径插补点的增加、参数曲线路径的加减速划分、危险点优化速度的求解及路径加减速的规划。实验结果表明,前瞻控制是高速数控加工的必要组成部分,是加工效率和加工精度的有效保证。
To deal with overshooting, mechanical harmful vibrations and data starvation caused by sharp corner or high curvature of tool path, a new look-ahead algorithm for high speed cutting machining is proposed by this paper. Compared to traditional numerical control, look-ahead control can analyze tool path、find dangerous points and deal with dangerous situations in machining automatically. Therefore machining productivity and accuracy can be improved efficiently. According to the goal of look-ahead control and considering both discrete and parametric curve tool path, this paper places emphases on acceleration and deceleration algorithm, discrete points interpolation algorithm, parametric curve interpolation algorithm and error compensation algorithm combined with the research of the National High Technology Research and Development Program (863 Program):"Microfluidic chip-oriented micromold manufacure equipments research" (2002AA421150) and the Special Project for Key Mechatronic Equipment of Zhejiang Province: "Medium and high class numerical control system" (2006C11067). At last, new look-ahead algorithm is proposed.
In terms of configuration of look-ahead algorithm, the basic is acceleration and deceleration algorithm. Discrete points interpolation algorithm and parametric curve interpolation algorithm are necessary tools. Error compensation algorithm is necessary accessory. The paper firstly researches the principle of acceleration and deceleration algorithm and velocity blending algorithm for discrete tool path used in traditional numerical control system. Then according to the multiformity and practicality of polynomial, the acceleration and deceleration construction algorithm of polynomial is proposed. Under specific polynomial construction method, innovative velocity link method for small short straight lines is proposed.
For the necessity of data analysis and parametric curve interpolation, the partial and overall interpolations algorithms for discrete tool path are used. Chasing method and Newton iterative method are applied in parametric curve interpolation algorithm. Due to the wider and wider use of parametric curve in high speed cutting machining and to guarantee the universality of look-ahead control, interpolation methods based on Taylor series and predictor-corrector are expatiated. Furthermore, interpolator adapted to tool path is introduced. To guarantee the systemic and integrality of look-ahead control algorithm and based on buffer command generation method, error even compensation algorithm is proposed.
Finally look-ahead control algorithm is proposed based on analysis of dangerous points、complement of points on discret tool path、partition of parametric tool path according to acceleration and deceleration、solution of optimal feedrate at dangerous points and arrangement of acceleration and deceleration for machining. On-line experiments shows look-ahead control is necessary for high speed cutting machining and guarantees productivity and accuracy efficiently.
引文
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