圆弧刃金刚石刀具刃磨机摆轴控制系统设计
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摘要
金刚石超精密切削技术是超精密加工技术的一个重要组成部份,在合适的机床和环境条件下,用圆弧刃金刚石刀具车削可以加工出超光滑表面,在国防和民用等领域得到广泛应用。圆弧刃金刚石刀具的质量是影响加工质量的重要因素,然而,我国的圆弧刃金刚石刀具研磨设备还无法与国际上的尖端设备相比,刀具的进口不仅价格昂贵,高水平的刀具还受到国外的禁运。所以,依靠自己的力量来研制高水平的圆弧刃金刚石刀具刃磨设备,开发控制系统提高控制性能,对我国金刚石超精密切削领域的发展具有重要意义。
本文针对“圆弧刃金刚石刀具刃磨机摆轴”控制,参考目前国内外流行的数控系统,考虑刃磨机的具体功能需求,提出了上下位机控制方案,并对具体的实施方案进行了研究。
首先,参考国内外先进的数控机床和刃磨机床的数控系统,采用“PC+运动控制器”的控制方案,PC机采用工控机,运动控制器采用功能强大的UMAC控制器,并对系统的硬件进行了设计。
其次,伺服驱动设计了经典的三环控制系统,采用直流力矩电机直接驱动空气静压轴系,降低传动误差。为了提高系统的指令跟踪能力,采用加前馈的复合PID控制策略,建立基于MATLAB/Simulink模块的伺服系统仿真模型,证明前馈PID伺服控制的优越性。
然后,基于UMAC运动控制器的编程环境,包括PEWIN执行程序、变量、指令、程序的应用,以及利用Pcomm.dll与UMAC的通讯方式,编写了人机交互软件,对各个模块的实现方法进行了详细阐述。
最后,通过提出速度/加速度前馈的复合PID控制的参数的调节方法,进行了参数调节实验。通过实验结果表明与仿真结果一致,带有速度/加速度前馈的伺服控制策略可以显著减小系统的跟随误差,提高系统跟踪指令信号的能力。
The diamond ultra-precision machining is an important part of ultra-precision machining. With the ultra-precision machine and stable machining environment, diamond ultra-precision machining can process super smooth surface, widely applied in filed of civil and national defense. The quality of diamond tools is an important factor which influences the machining quality. However our equipment is backward compared with international high sophisticated equipments. The price is expensive for cutting tool’s import and the high level cutting tool is embargoed for us. So it will have great significance for us to develop high level lapping machine and its Control system.
With the reference of domestic and national popular numerical control system and the consideration for lapping machine's concrete function demand, we propose an CNC system of upper and lower computerfor lapping machine’s pendulum shaft axis.
First, with the reference of domestic and national CNC system for lapping machine,‘PC + controller’CNC system is proposed. PC machine adopts IPC and controller adopts UMAC controller. And designed for the system hardware .
Secondly, the design of servo control system adopts three loop control system. And the error is reduced because the air static pressure shafting is directly driven by the DC torque motor. To improve the control performance of command tracking ability, the compound PID servo-control principle of feed-forward is put to use. The model of servo-control is carried out by MATLAB/Simulink, which proves that the feed-forward control has superiority.
Next, this paper introduces the environment of making programs, including PEWIN, variables, commands, programs and the method of communication to UMAC by Pcomm.dll. Man-machine interface is designed and the method that how to realize the model is introduced in detail.
Last, how to adjust the compound PID servo-control principle of feed-forward is introduced and the experiments are made. The experimental result indicated that the compound PID of feed-forward is consistent with the simulation result. And this servo-control principle can reduced the error remarkably and enhances the ability of the system trace command signal.
本文针对“圆弧刃金刚石刀具刃磨机摆轴”控制,参考目前国内外流行的数控系统,考虑刃磨机的具体功能需求,提出了上下位机控制方案,并对具体的实施方案进行了研究。
首先,参考国内外先进的数控机床和刃磨机床的数控系统,采用“PC+运动控制器”的控制方案,PC机采用工控机,运动控制器采用功能强大的UMAC控制器,并对系统的硬件进行了设计。
其次,伺服驱动设计了经典的三环控制系统,采用直流力矩电机直接驱动空气静压轴系,降低传动误差。为了提高系统的指令跟踪能力,采用加前馈的复合PID控制策略,建立基于MATLAB/Simulink模块的伺服系统仿真模型,证明前馈PID伺服控制的优越性。
然后,基于UMAC运动控制器的编程环境,包括PEWIN执行程序、变量、指令、程序的应用,以及利用Pcomm.dll与UMAC的通讯方式,编写了人机交互软件,对各个模块的实现方法进行了详细阐述。
最后,通过提出速度/加速度前馈的复合PID控制的参数的调节方法,进行了参数调节实验。通过实验结果表明与仿真结果一致,带有速度/加速度前馈的伺服控制策略可以显著减小系统的跟随误差,提高系统跟踪指令信号的能力。
The diamond ultra-precision machining is an important part of ultra-precision machining. With the ultra-precision machine and stable machining environment, diamond ultra-precision machining can process super smooth surface, widely applied in filed of civil and national defense. The quality of diamond tools is an important factor which influences the machining quality. However our equipment is backward compared with international high sophisticated equipments. The price is expensive for cutting tool’s import and the high level cutting tool is embargoed for us. So it will have great significance for us to develop high level lapping machine and its Control system.
With the reference of domestic and national popular numerical control system and the consideration for lapping machine's concrete function demand, we propose an CNC system of upper and lower computerfor lapping machine’s pendulum shaft axis.
First, with the reference of domestic and national CNC system for lapping machine,‘PC + controller’CNC system is proposed. PC machine adopts IPC and controller adopts UMAC controller. And designed for the system hardware .
Secondly, the design of servo control system adopts three loop control system. And the error is reduced because the air static pressure shafting is directly driven by the DC torque motor. To improve the control performance of command tracking ability, the compound PID servo-control principle of feed-forward is put to use. The model of servo-control is carried out by MATLAB/Simulink, which proves that the feed-forward control has superiority.
Next, this paper introduces the environment of making programs, including PEWIN, variables, commands, programs and the method of communication to UMAC by Pcomm.dll. Man-machine interface is designed and the method that how to realize the model is introduced in detail.
Last, how to adjust the compound PID servo-control principle of feed-forward is introduced and the experiments are made. The experimental result indicated that the compound PID of feed-forward is consistent with the simulation result. And this servo-control principle can reduced the error remarkably and enhances the ability of the system trace command signal.
引文
1杨桂霞,梁鑫.国内外超精密加工技术与机床的发展状况.机械工程师. 2009(1):9~11
2王大伟,崔宇,杨坤等.精密和超精密加工技术的发展.科技资讯. 2008(14):12
3 Youngchan Song, Kentaro Nezu, Chunhong Park, et al. Tools wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method. International Journal of Machine Tools & Manufacture. 2009, (49): 339~343
4袁哲俊,王先逵.精密和超精密加工技术(第二版).机械工业出版社, 2007: 10~11
5 P. A. Mckeown. The Role of Precision Engineering in Manufacturing of the Future. Annals of the CIRP. 1987, 36(2): 495~501
6袁哲俊.精密和超精密加工技术的新进展.工具技术. 2006, 40(3): 3~8
7宗文俊.高精度金刚石刀具的机械刃磨技术及其切削性能优化研究.哈尔滨工业大学博士学位论文. 2008: 3~4
8新一代天然金刚石刀具刃磨设备.航空精密制造技术. 2007, 43(2): 1~2
9李增强.圆弧刃金刚石刀具刀尖圆弧的机械研磨及其检测技术.哈尔滨工业大学工学博士学位论文. 2008: 1~20
10李东飞.于PMAC下数控系统的设计与实现.燕山大学硕士学位论文. 2006: 4~10
11文立伟,王永章,路华等.基于开放结构控制器的可重构数控系统.计算机集成制造系统. 2003, 9(11): 1018~1021
12梁宏斌,王永章,李霞.开放式数控系统与标准化.计算机集成制造系统. 2004, 10(9): 1134~1138
13 Guo Wei, Chen Zongyu, Li Congxin. Investigation on full stribution CNC system based on SERCOS bus. Journal of Systems Engineering and Electronics. 2008, 19(1): 52~57
14 Dong Yu, Yi Hu, Xun W. Xu, et al. An Open CNC System Based on Component Technology. IEEE Transactions on Automation Science and Engineering, 2009, 6(2): 302~308
15林峰,黄云峰,吴明明.基于工业PC机的开放式CNC系统研究.机械. 2004,31(7): 27~29
16王睿鹏.基于PC的开放式数控系统.计算机技术与应用. 2006, (2): 18~23
17 Li Bin, Zhou Yun-fei, Tang Xiao-qi . A research on open CNC system based on architecture/component software reuse technology. Computers in Industry. 2004, (55): 73~85
18张志燕.基于运动控制器的开放式数控系统关键技术研究与应用.华中科技大学硕士学位论文. 2005: 2~10
19 J. Ortmann, A. Kahmen, S. Kaierle, et al. Open architecture control for laser materials processing. Proceedings of SPIE. 2001, (4563): 37
20王世寰,王永章,付云忠.开放式软CNC发展趋势及其体系结构的研究.机床与液压. 2004, (2): 7~9
21沙玉.基于PC开放式数控系统的现状和展望.上海大学学报. 2001, 7: 10~12
22李斌.基于构架/构件复用的开放式数控系统研究.华中科技大学博士学位论文. 2004: 1~16
23钱星.国家“十五”数控攻关项目“网络化、开放式数控系统开发及示范应用”通过验收.产品信息. 2004(1): 62
24 J. P. Khatait, W. Lin and W. J. Lin. Design and development of orifice-type aerostatic thrust bearing. SIMTech technical reports. 2005, 6(1): 7
25付坤霞,朱煜,张鸣.基于非等温条件的空气静压轴承润滑问题研究.润滑与密封. 2007, 32(1): 117-119
26杨晓京,张仲彦,李浙昆等.几种开放式微机数控系统比较.制造自动化. 2002, 24(1): 18~21
27 Turbo PMAC User Manul. Delta Tau Data Systems Inc. 2008, 9: 1~40
28 Xi Chen, Yanbo Chen, K. W. E Cheng Motion Controller and the Application of PMAC in AC Servo CNC. 2009 3rd International Conference on Power Electronics Systems and Applications. 2009: 5
29 Zhao Xiaolong, Yang Yonggang, Zhang Zhiyuan, et al. PMAC principle and It's Application to Cell Winding. Journal of Rare Earths. 2004, 22: 352~354
30 Liang Lihua, Tian Jun, Zhang Songtao. Control System Design of 6-DOF Platform Based on PMAC. Proceedings of ISFP‘2007: 5th International Symposium on Fluid Power Transmission and Control. Beidaihe, China. 2007: 703~708
31 Chen Zhiyu, Qin Xiansheng. Research and Development of a CNC System Based on NC+PC Architecture. Machine Tool & Hydraulics. 2007, (9) : 107~110
32 Mi Fangwei, Chen Gongfu. The Application of Electromechanical IntegratedExperimental Device. Machine Tool & Hydraulics. 2004, (12): 129~131
33 UMAC Product Selection Guide. Delta Tau Data Systems Inc. 2004: 1~52
34 Xinqi Xu, Shihai Yang. Motion control for Lamost focal plane. Farrokh Janabi-Sharifi, Proc. of SPIE. 2005, 6052: 1~7
35 Accessory 11E User Manual. Delta Tau Data Systems Inc. 2007: 1~43
36 Accessory 24E2A User Manual. Delta Tau Data Systems Inc. 2006: 1~63
37陶桂林.大功率永磁无刷直流电机及其系统研究.华中科技大学博士学位论文. 2004: 1~20
38胡文静.永磁无刷直流电动机的发展及展望.微电机. 2002, 35(4): 37~38
39李丹,周波,方斯琛等.伺服电机用超高分辨率码盘分频接口设计.电机与控制学报. 2007, 11(5): 477~483
40 Xuhui Zhang, Hongwei Ma, Juan Tong. Developing Full-digital Servo System for RSP Based on PMAC. Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation. Harbin, China. 2007: 2404~2408
41 Zuo Jin-ping, Tang Shu-jin. Research on 6-DOF motion platform on PMAC. Second International Workshop on Knowledge Discovery and Data Mining. 2009: 941~943
42张维玺.巴特沃斯数字陷波滤波器的设计.现代电子技术. 2008, (18): 129
43楚子林,伍丰林.传动系统速度实际值信号的陷波滤波器及其仿真研究.电气传动. 2008, 38(8): 14~16
44尔桂花,窦曰轩.运动控制系统.清华大学出版社. 2002: 10~326
45 Pewin32 PRO Software reference manual. Delta Tau Data Systems, 1999
46 Delta Tau Data System Inc. Turbo PMAC Software Reference Manual. USA: Delta Tau Data System Inc, 2003
47 Wang Jun. Study on ARM-based Embedded NC System. 2009 International Conference on Artificial Intelligence and Computational Intelligence. 2009: 538~544
48 J. P. Wang, A. Wang, Z. L. Jing, et al. Design and Application of an Anti-Windup State Feedback Controller. Journal of Xi'an Jiaotong University. 2002, 36(4): 365~368
49 Liu Xiangquan, Yun Chao, Zhang Zhiqiang, et al. Development of Mixed-connection Stacking Robot Based on PMAC. International Conference on Computer Science and Information Technology 2008. 2008: 362~366
50 Da Liu, Li Nancong, Jingmeng Liu, et al. The Research on the Control System of the Minimally Invasive Surgical Robot. Restrictions Apply. 2008: 592~597
2王大伟,崔宇,杨坤等.精密和超精密加工技术的发展.科技资讯. 2008(14):12
3 Youngchan Song, Kentaro Nezu, Chunhong Park, et al. Tools wear control in single-crystal diamond cutting of steel by using the ultra-intermittent cutting method. International Journal of Machine Tools & Manufacture. 2009, (49): 339~343
4袁哲俊,王先逵.精密和超精密加工技术(第二版).机械工业出版社, 2007: 10~11
5 P. A. Mckeown. The Role of Precision Engineering in Manufacturing of the Future. Annals of the CIRP. 1987, 36(2): 495~501
6袁哲俊.精密和超精密加工技术的新进展.工具技术. 2006, 40(3): 3~8
7宗文俊.高精度金刚石刀具的机械刃磨技术及其切削性能优化研究.哈尔滨工业大学博士学位论文. 2008: 3~4
8新一代天然金刚石刀具刃磨设备.航空精密制造技术. 2007, 43(2): 1~2
9李增强.圆弧刃金刚石刀具刀尖圆弧的机械研磨及其检测技术.哈尔滨工业大学工学博士学位论文. 2008: 1~20
10李东飞.于PMAC下数控系统的设计与实现.燕山大学硕士学位论文. 2006: 4~10
11文立伟,王永章,路华等.基于开放结构控制器的可重构数控系统.计算机集成制造系统. 2003, 9(11): 1018~1021
12梁宏斌,王永章,李霞.开放式数控系统与标准化.计算机集成制造系统. 2004, 10(9): 1134~1138
13 Guo Wei, Chen Zongyu, Li Congxin. Investigation on full stribution CNC system based on SERCOS bus. Journal of Systems Engineering and Electronics. 2008, 19(1): 52~57
14 Dong Yu, Yi Hu, Xun W. Xu, et al. An Open CNC System Based on Component Technology. IEEE Transactions on Automation Science and Engineering, 2009, 6(2): 302~308
15林峰,黄云峰,吴明明.基于工业PC机的开放式CNC系统研究.机械. 2004,31(7): 27~29
16王睿鹏.基于PC的开放式数控系统.计算机技术与应用. 2006, (2): 18~23
17 Li Bin, Zhou Yun-fei, Tang Xiao-qi . A research on open CNC system based on architecture/component software reuse technology. Computers in Industry. 2004, (55): 73~85
18张志燕.基于运动控制器的开放式数控系统关键技术研究与应用.华中科技大学硕士学位论文. 2005: 2~10
19 J. Ortmann, A. Kahmen, S. Kaierle, et al. Open architecture control for laser materials processing. Proceedings of SPIE. 2001, (4563): 37
20王世寰,王永章,付云忠.开放式软CNC发展趋势及其体系结构的研究.机床与液压. 2004, (2): 7~9
21沙玉.基于PC开放式数控系统的现状和展望.上海大学学报. 2001, 7: 10~12
22李斌.基于构架/构件复用的开放式数控系统研究.华中科技大学博士学位论文. 2004: 1~16
23钱星.国家“十五”数控攻关项目“网络化、开放式数控系统开发及示范应用”通过验收.产品信息. 2004(1): 62
24 J. P. Khatait, W. Lin and W. J. Lin. Design and development of orifice-type aerostatic thrust bearing. SIMTech technical reports. 2005, 6(1): 7
25付坤霞,朱煜,张鸣.基于非等温条件的空气静压轴承润滑问题研究.润滑与密封. 2007, 32(1): 117-119
26杨晓京,张仲彦,李浙昆等.几种开放式微机数控系统比较.制造自动化. 2002, 24(1): 18~21
27 Turbo PMAC User Manul. Delta Tau Data Systems Inc. 2008, 9: 1~40
28 Xi Chen, Yanbo Chen, K. W. E Cheng Motion Controller and the Application of PMAC in AC Servo CNC. 2009 3rd International Conference on Power Electronics Systems and Applications. 2009: 5
29 Zhao Xiaolong, Yang Yonggang, Zhang Zhiyuan, et al. PMAC principle and It's Application to Cell Winding. Journal of Rare Earths. 2004, 22: 352~354
30 Liang Lihua, Tian Jun, Zhang Songtao. Control System Design of 6-DOF Platform Based on PMAC. Proceedings of ISFP‘2007: 5th International Symposium on Fluid Power Transmission and Control. Beidaihe, China. 2007: 703~708
31 Chen Zhiyu, Qin Xiansheng. Research and Development of a CNC System Based on NC+PC Architecture. Machine Tool & Hydraulics. 2007, (9) : 107~110
32 Mi Fangwei, Chen Gongfu. The Application of Electromechanical IntegratedExperimental Device. Machine Tool & Hydraulics. 2004, (12): 129~131
33 UMAC Product Selection Guide. Delta Tau Data Systems Inc. 2004: 1~52
34 Xinqi Xu, Shihai Yang. Motion control for Lamost focal plane. Farrokh Janabi-Sharifi, Proc. of SPIE. 2005, 6052: 1~7
35 Accessory 11E User Manual. Delta Tau Data Systems Inc. 2007: 1~43
36 Accessory 24E2A User Manual. Delta Tau Data Systems Inc. 2006: 1~63
37陶桂林.大功率永磁无刷直流电机及其系统研究.华中科技大学博士学位论文. 2004: 1~20
38胡文静.永磁无刷直流电动机的发展及展望.微电机. 2002, 35(4): 37~38
39李丹,周波,方斯琛等.伺服电机用超高分辨率码盘分频接口设计.电机与控制学报. 2007, 11(5): 477~483
40 Xuhui Zhang, Hongwei Ma, Juan Tong. Developing Full-digital Servo System for RSP Based on PMAC. Proceedings of the 2007 IEEE International Conference on Mechatronics and Automation. Harbin, China. 2007: 2404~2408
41 Zuo Jin-ping, Tang Shu-jin. Research on 6-DOF motion platform on PMAC. Second International Workshop on Knowledge Discovery and Data Mining. 2009: 941~943
42张维玺.巴特沃斯数字陷波滤波器的设计.现代电子技术. 2008, (18): 129
43楚子林,伍丰林.传动系统速度实际值信号的陷波滤波器及其仿真研究.电气传动. 2008, 38(8): 14~16
44尔桂花,窦曰轩.运动控制系统.清华大学出版社. 2002: 10~326
45 Pewin32 PRO Software reference manual. Delta Tau Data Systems, 1999
46 Delta Tau Data System Inc. Turbo PMAC Software Reference Manual. USA: Delta Tau Data System Inc, 2003
47 Wang Jun. Study on ARM-based Embedded NC System. 2009 International Conference on Artificial Intelligence and Computational Intelligence. 2009: 538~544
48 J. P. Wang, A. Wang, Z. L. Jing, et al. Design and Application of an Anti-Windup State Feedback Controller. Journal of Xi'an Jiaotong University. 2002, 36(4): 365~368
49 Liu Xiangquan, Yun Chao, Zhang Zhiqiang, et al. Development of Mixed-connection Stacking Robot Based on PMAC. International Conference on Computer Science and Information Technology 2008. 2008: 362~366
50 Da Liu, Li Nancong, Jingmeng Liu, et al. The Research on the Control System of the Minimally Invasive Surgical Robot. Restrictions Apply. 2008: 592~597