数控滚齿加工零编程技术的研究与开发
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摘要
现有的齿轮加工数控机床，一般都采用手工编程方法，即通过人工来进行工艺处理、数值计算、编写程序、键盘输入程序、程序校验等各步骤。手工编程方法主要的不足之处是：①对编程人员的职业技术要求比较高；②编程时容易出错，特别是计算和键盘输入程序环节更容易出错，从而影响齿轮的加工质量；③效率比较低，生产周期长。在现有少数自动编程方法中，大部分是通过对绘图软件进行二次开发实现的，这种方法只能在计算机上实现，而且生成的NC程序还要再通过联网传输给数控机床。
本文根据齿轮的特殊性，对齿轮数控加工零编程技术进行了可行性分析，并建立了齿轮数控加工编程的数学模型，在此基础上研制了一套齿轮数控加工NC程序自动生成技术，即通过输入一定的工件参数、刀具参数、工艺参数等参数，然后对这些参数进行校验和计算，最后按照数控系统的代码格式自动生成该齿轮数控加工的NC程序。利用西门子840D数控系统的开放性，本文把零编程技术嵌入到西门子840D数控系统中，研发了一套基于西门子840D数控系统的齿轮零编程系统；针对不开放的数控系统，本文提出了把零编程技术应用到嵌入式系统中，利用嵌入式系统来辅助数控齿轮加工机床编写NC程序，并对该方案的实现进行了分析和阐述。
应用零编程技术后，不仅能缩短齿轮生产周期、提高数控齿轮加工机床的利用率，降低机床操作人员的劳动强度和职业技术门槛，提高齿轮加工的工艺成熟度和齿轮加工的质量稳定性，而且也能提升该齿轮数控机床的市场竞争力。
The manual programming method, which uses manpower to carry on processing procedure, computing, compiling programs, inputting programs, checking programs and so on, is the most common programming method of the numerical control machine for gear producing. The main deficiencies of manual programming method are: needing high qualification of programmers' professional specification; being prone to make mistakes when programming, especially when calculating and inputting the NC programs, which may affects the quality of gear; having lower efficiency and longer production period. Developed based on cartography software, most of the existing automatic programming methods only can realize on a computer, which means that the generated NC programs have to be transported to the numerical control machine through network among computers and the numerical control machines.
The feasibility of the auto-programming method is analyzed and the mathematical model of NC programming for gear numerical control producing is developed in this paper. The NC program automatically generating technology is studied on the above foundation. Certain parameters like work piece parameter, cutting tool parameter, procedure parameter, are inputted, then are verified and computed, finally the gear's NC program is generated according to the code format of the numerical control system. The auto-programming technology is embedded into SINUMERIK 840D numerical control system by use of the openness of the system, a set of gear auto-programming system based on SINUMERIK 840D numerical control system is studied and developed. As to the non-open numerical control systems, the auto-programming technology applied to embedded system is presented being a assistant equipment for NC programming, and the realization of scheme is analyzed and stated in this paper.
After applying the auto-programming technology, not only the gear's production period can be shortened, the efficiency of the gear producing numerical control machine be improved, the operator's labor intensity and the professional technical threshold be reduced, the gear's quality stability and the craft maturity be enhanced, but also the market competitive power of this kind of gear producing numerical control machine can be promoted.
本文根据齿轮的特殊性，对齿轮数控加工零编程技术进行了可行性分析，并建立了齿轮数控加工编程的数学模型，在此基础上研制了一套齿轮数控加工NC程序自动生成技术，即通过输入一定的工件参数、刀具参数、工艺参数等参数，然后对这些参数进行校验和计算，最后按照数控系统的代码格式自动生成该齿轮数控加工的NC程序。利用西门子840D数控系统的开放性，本文把零编程技术嵌入到西门子840D数控系统中，研发了一套基于西门子840D数控系统的齿轮零编程系统；针对不开放的数控系统，本文提出了把零编程技术应用到嵌入式系统中，利用嵌入式系统来辅助数控齿轮加工机床编写NC程序，并对该方案的实现进行了分析和阐述。
应用零编程技术后，不仅能缩短齿轮生产周期、提高数控齿轮加工机床的利用率，降低机床操作人员的劳动强度和职业技术门槛，提高齿轮加工的工艺成熟度和齿轮加工的质量稳定性，而且也能提升该齿轮数控机床的市场竞争力。
The manual programming method, which uses manpower to carry on processing procedure, computing, compiling programs, inputting programs, checking programs and so on, is the most common programming method of the numerical control machine for gear producing. The main deficiencies of manual programming method are: needing high qualification of programmers' professional specification; being prone to make mistakes when programming, especially when calculating and inputting the NC programs, which may affects the quality of gear; having lower efficiency and longer production period. Developed based on cartography software, most of the existing automatic programming methods only can realize on a computer, which means that the generated NC programs have to be transported to the numerical control machine through network among computers and the numerical control machines.
The feasibility of the auto-programming method is analyzed and the mathematical model of NC programming for gear numerical control producing is developed in this paper. The NC program automatically generating technology is studied on the above foundation. Certain parameters like work piece parameter, cutting tool parameter, procedure parameter, are inputted, then are verified and computed, finally the gear's NC program is generated according to the code format of the numerical control system. The auto-programming technology is embedded into SINUMERIK 840D numerical control system by use of the openness of the system, a set of gear auto-programming system based on SINUMERIK 840D numerical control system is studied and developed. As to the non-open numerical control systems, the auto-programming technology applied to embedded system is presented being a assistant equipment for NC programming, and the realization of scheme is analyzed and stated in this paper.
After applying the auto-programming technology, not only the gear's production period can be shortened, the efficiency of the gear producing numerical control machine be improved, the operator's labor intensity and the professional technical threshold be reduced, the gear's quality stability and the craft maturity be enhanced, but also the market competitive power of this kind of gear producing numerical control machine can be promoted.
引文
[1] 孙建东．机械设计学基础．机械工业出版社．2004年
[2] 申永胜．机械原理教程．清华大学出版社．1999年
[3] 重庆机床厂．YKS318／YKS3112数控高速滚齿机使用说明书．1999年
[4] 熊海洋．齿轮加工图形参数化自动编程系统的开发与研究．兰州理工大学硕士论文．2004年3月
[5] 殷包祖．参数化数控编程技术及应用．电子机械工程．2005，Vol．21(3)，60～64
[6] 辜志刚．基于AutoCAD的数控自动编程系统研究．西南科技大学硕士论文．2004年4月
[7] 郭剑锋．基于网络和Auto CAD的数控自动编程系统开发技术的研究．西安石油学院硕士论文．2003年5月
[8] Jean J．Labrosse著 邵贝贝等译．嵌入式实时操作系统μC／OS—Ⅱ(第二版)．北京航空航天大学出版社．2003年9月
[9] 王田苗．嵌入式系统设计与实例开发．清华大学出版社．2003年10月
[10] Wang Shilong, Liu Fei. System of communicationg based on DNC pluggedprogram. China Mechanical Engineering. 99.3(35)51～54
[11] 拉伯罗斯，邵贝贝．嵌入式实时操作系统uC／OS-Ⅱ．北京航空航天大学出版．2003年5月
[12] 王金刚，田捷，陈翌．嵌入式软件开发技术．国防工业出版社．2003年
[13] 布鲁克曼，张君施．嵌入式软件测试．电子工业出版社．2004年
[14] 杨玉芳，林大钧，付掌印．齿轮加工仿真技术．东华大学学报．2005．8，Vol31(4)
[15] 肖本贤，韩江，王治森．一种基于灵活制造的齿轮NC系统体系．机械与电子．1995年第5期，6～8
[16] 陈国平．不同数控系统编程的比较和应用．机床与液压．2003，No．1．242～243
[17] 李胜涛，石冰心，刘启文．动态数据交换(DDE)协议及应用．电脑学习．1994年6月．第3期，2～3
[18] 李大琪．使用Visual Basic建立DDE链接．实践与技巧．1996年9月，62～63
[19] 江效尧，罗传松．Visual Basic下数据共享技术及实现．1998年8月．Vol4(3)，26～30
[20] 鲍尔，苏建平，刘谦．嵌入式微处理器系统设计实例．电子工业出版社．2004年
[21] 范炳炎．数控加工程序编制．航空工业出版社．2000年
[22] 李福生．数控机床程序编制．机械工业出版社．1998年
[23] 刘斌，王明德，黄树愧．一种适合于滚齿加工机床CNC系统的参数编程方法．组合机床与自动化加工技术．1995，6～8
[24] 梁永芳．数控滚齿机德对刀计算．甘肃工业大学学报．1997，Vol23(3)，46～48
[25] 何满才．数控编程与加工．人民邮电出版社．2004年
[26] 北京机械学校．数控技术．机械工业出版社．1999年
[27] 张永杰．滚齿切削过程的计算机仿真．哈尔滨工业大学硕士论文．2004年6月
[28] 朱映远．滚齿加工过程的计算机仿真．哈尔滨工业大学硕士论文．2002年7月
[29] 王田苗．嵌入式系统设计与实例开发．清华大学出版社．2003年
[30] 王学龙．嵌入式Linux系统设计与应用．清华大学出版．2001年8月
[31] 肖踞雄，翁铁成，宋中庆编著．USB技术及应用设计．清华大学出版社．2003
[32] SIEMENS. SINUMERIK 840D/810D/FM-NC Description of Functions Basic Machine (Part 1) Description of Functions[M]. German:Siemens, 1998
[33] SIEMENS. SINUMERIK 840D/S10D/FM-NC/611D Lists[M]. German:Siemens, 2000
[34] 北京博创兴业科技有限公司．嵌入式系统实验指导书．2004年1月
[35] Wang Shilong, Liu Fei. The present and future research subjects in the field of DNC integrated technology. China Mechanical Engineering. 1998, Vol9(2), 54～56
[36] Wang Shilong , Liu Fei . The Development of DNC Integrated Technology. Computer Integrated Manufacturing Systems. 1998, (3), 45～47
[37] SIEMENS. SINUMERIK 840D/840Di/810D/FM-NC HMI Enviroment User's Manual. German:Siemens, 02.2001 Edition
[38] SIEMENS. SINUMERIK 810D/840D 简明调试手册. 2002
[39] SIEMENS. HMI Programming Package for COM and OPC Client. German:Siemens, 02.2001 Edition
[40] SIEMENS. DOConCD Installation and Operation User Instructions. German:Siemens, Edition 03.2004
[41] SIEMENS. SINUMERIK 810D/FM-NC Installation Guide HMI Programming Package. German:Siemens, 02.2001 Edition
[42] SIEMENS. HMI Programming Package Regie Com Server Interface. German:Siemens, 02.2001 Edition
[43] SIEMENS. OLE for Process Control Data Access Standard (UPDATED). German: Siemens, September 11, 1997
[44] SIEMENS. HMI Programming Package Installation Guide. German:Siemens , 02.2001 Edition
[45] SIEMENS. HMI Programming Package ASCII Editor Control. German:Siemens , 02.2001 Edition
[46] SIEMENS. HMI Programming Package FileViewer Control. German:Siemens , 02.2001 Edition
[47] SIEMENS. HMI Programming Package Command Interfaces. German:Siemens , 02.2001 Edition
[48] SIEMENS. HMI Programming Package IMcEventList IMcEventCreation. German: Siemens, 02.2001 Edition
[49] SIEMENS. HMI Programming Package Interfaces for Accessing File. German:Siemens , 02.2001 Edition
[50] SIEMENS. HMI Programming Package Regie Corn Server Interface. German:Siemens , 02.2001 Edition
[51] SIEMENS. HMI Programming Package MMC Controls. German:Siemens, 02.2001 Edition
[52] Daniel W.Lewis. Fundamentals of embedded software. Higher Educatiion Press. 2004.8
[2] 申永胜．机械原理教程．清华大学出版社．1999年
[3] 重庆机床厂．YKS318／YKS3112数控高速滚齿机使用说明书．1999年
[4] 熊海洋．齿轮加工图形参数化自动编程系统的开发与研究．兰州理工大学硕士论文．2004年3月
[5] 殷包祖．参数化数控编程技术及应用．电子机械工程．2005，Vol．21(3)，60～64
[6] 辜志刚．基于AutoCAD的数控自动编程系统研究．西南科技大学硕士论文．2004年4月
[7] 郭剑锋．基于网络和Auto CAD的数控自动编程系统开发技术的研究．西安石油学院硕士论文．2003年5月
[8] Jean J．Labrosse著 邵贝贝等译．嵌入式实时操作系统μC／OS—Ⅱ(第二版)．北京航空航天大学出版社．2003年9月
[9] 王田苗．嵌入式系统设计与实例开发．清华大学出版社．2003年10月
[10] Wang Shilong, Liu Fei. System of communicationg based on DNC pluggedprogram. China Mechanical Engineering. 99.3(35)51～54
[11] 拉伯罗斯，邵贝贝．嵌入式实时操作系统uC／OS-Ⅱ．北京航空航天大学出版．2003年5月
[12] 王金刚，田捷，陈翌．嵌入式软件开发技术．国防工业出版社．2003年
[13] 布鲁克曼，张君施．嵌入式软件测试．电子工业出版社．2004年
[14] 杨玉芳，林大钧，付掌印．齿轮加工仿真技术．东华大学学报．2005．8，Vol31(4)
[15] 肖本贤，韩江，王治森．一种基于灵活制造的齿轮NC系统体系．机械与电子．1995年第5期，6～8
[16] 陈国平．不同数控系统编程的比较和应用．机床与液压．2003，No．1．242～243
[17] 李胜涛，石冰心，刘启文．动态数据交换(DDE)协议及应用．电脑学习．1994年6月．第3期，2～3
[18] 李大琪．使用Visual Basic建立DDE链接．实践与技巧．1996年9月，62～63
[19] 江效尧，罗传松．Visual Basic下数据共享技术及实现．1998年8月．Vol4(3)，26～30
[20] 鲍尔，苏建平，刘谦．嵌入式微处理器系统设计实例．电子工业出版社．2004年
[21] 范炳炎．数控加工程序编制．航空工业出版社．2000年
[22] 李福生．数控机床程序编制．机械工业出版社．1998年
[23] 刘斌，王明德，黄树愧．一种适合于滚齿加工机床CNC系统的参数编程方法．组合机床与自动化加工技术．1995，6～8
[24] 梁永芳．数控滚齿机德对刀计算．甘肃工业大学学报．1997，Vol23(3)，46～48
[25] 何满才．数控编程与加工．人民邮电出版社．2004年
[26] 北京机械学校．数控技术．机械工业出版社．1999年
[27] 张永杰．滚齿切削过程的计算机仿真．哈尔滨工业大学硕士论文．2004年6月
[28] 朱映远．滚齿加工过程的计算机仿真．哈尔滨工业大学硕士论文．2002年7月
[29] 王田苗．嵌入式系统设计与实例开发．清华大学出版社．2003年
[30] 王学龙．嵌入式Linux系统设计与应用．清华大学出版．2001年8月
[31] 肖踞雄，翁铁成，宋中庆编著．USB技术及应用设计．清华大学出版社．2003
[32] SIEMENS. SINUMERIK 840D/810D/FM-NC Description of Functions Basic Machine (Part 1) Description of Functions[M]. German:Siemens, 1998
[33] SIEMENS. SINUMERIK 840D/S10D/FM-NC/611D Lists[M]. German:Siemens, 2000
[34] 北京博创兴业科技有限公司．嵌入式系统实验指导书．2004年1月
[35] Wang Shilong, Liu Fei. The present and future research subjects in the field of DNC integrated technology. China Mechanical Engineering. 1998, Vol9(2), 54～56
[36] Wang Shilong , Liu Fei . The Development of DNC Integrated Technology. Computer Integrated Manufacturing Systems. 1998, (3), 45～47
[37] SIEMENS. SINUMERIK 840D/840Di/810D/FM-NC HMI Enviroment User's Manual. German:Siemens, 02.2001 Edition
[38] SIEMENS. SINUMERIK 810D/840D 简明调试手册. 2002
[39] SIEMENS. HMI Programming Package for COM and OPC Client. German:Siemens, 02.2001 Edition
[40] SIEMENS. DOConCD Installation and Operation User Instructions. German:Siemens, Edition 03.2004
[41] SIEMENS. SINUMERIK 810D/FM-NC Installation Guide HMI Programming Package. German:Siemens, 02.2001 Edition
[42] SIEMENS. HMI Programming Package Regie Com Server Interface. German:Siemens, 02.2001 Edition
[43] SIEMENS. OLE for Process Control Data Access Standard (UPDATED). German: Siemens, September 11, 1997
[44] SIEMENS. HMI Programming Package Installation Guide. German:Siemens , 02.2001 Edition
[45] SIEMENS. HMI Programming Package ASCII Editor Control. German:Siemens , 02.2001 Edition
[46] SIEMENS. HMI Programming Package FileViewer Control. German:Siemens , 02.2001 Edition
[47] SIEMENS. HMI Programming Package Command Interfaces. German:Siemens , 02.2001 Edition
[48] SIEMENS. HMI Programming Package IMcEventList IMcEventCreation. German: Siemens, 02.2001 Edition
[49] SIEMENS. HMI Programming Package Interfaces for Accessing File. German:Siemens , 02.2001 Edition
[50] SIEMENS. HMI Programming Package Regie Corn Server Interface. German:Siemens , 02.2001 Edition
[51] SIEMENS. HMI Programming Package MMC Controls. German:Siemens, 02.2001 Edition
[52] Daniel W.Lewis. Fundamentals of embedded software. Higher Educatiion Press. 2004.8