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.
引文
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