STEP-NC车削工艺信息提取和参数优化的研究与开发
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摘要
近年来欧、美、韩等工业发达国家面向现代计算机数控系统提出一种新的数据接口规范,即STEP-NC,用以取代沿用已久的ISO 6983(G代码)。它于1996年制定的,迄今己完成了部分标准化工作,其中的铣削和车削的数据模型己基本完善。STEP-NC基于制造特征(manufacturing features)进行编程,而不是直接对刀具运动进行编程。它包含了工件的所有加工任务,通过这一系列加工任务,对从零件毛坯到最终成品所有的操作加以描述,提供了更高层次的信息给加工车间。
本文从总体上介绍了基于Linux-RTAI实时操作系统对开发STEP-NC数控系统在实时性方面的优势,分析了STEP-NC数控系统的用户层、控制层、内核层三层软件结构以及每一层的特点。其中重点介绍了用户层中STEP-NC各功能模块的特点并简要阐述了内核层RTAI实时内核的抢占式调度算法。
对STEP-NC信息提取的方法进行了分析比较,简单分析了基于ROSE C++类库开发的ST-Developer软件在信息提取方面的优缺点。本文采用的方法是以EXPRESS语言向C++语言的映射为基础,建立了C++类库,作为STEP-NC的C++数据模型,详细描述信息提取的流程。同时,也对面向STEP-NC加工工步的车削轨迹的规划以及生成方法进行了一定的讨论。
针对基于STEP-NC特征的切削参数优化问题,以切削速度和进给量为优化变量,以加工时间和加工成本综合优先建立多目标函数,并且从刀具和机床多方面对数学模型加入约束,建立切削参数优化模型。分析认为在数学模型中,切削长度L是对优化结果影响最大的参数,因此根据STEP-NC中关于几何轮廓的数据结构的定义,将切削优化数学模型和STEP-NC加工特征结合起来,并用基因遗传算法求解。
最后在STEP-NC车削原型系统上对本文中所阐述的STEP-NC车削系统的功能模块进行验证,并给出了相关模块的实例。
In recent years, Europe, America and Korea etc industrial developed country put forward a new criterion of data interface, namely, STEP-NC (ISO 14649), in order to replace ISO 6983 (G code) that have already used in a long time. It was drew up in 1996, and part work of standardize has been completed heretofore, in which data model of milling and turning have approximately completed. STEP-NC carries on program according to manufacturing features, but not to movement of tool directly. It includes all processing mission of workpiece, through a series of processing mission, describing all operation from the part of rough to final product and providing higher level information to the workshop of machining.
This thesis introduces the advantage in real-time as developing the STEP-NC based on the Linux-RTAI real-time OS and analyzes the three-layer structure of STEP-NC, which contained User Layer, Control Layer and Kernel Layer. Among which the characteristic of STEP-NC modules embed in the User Layer is mainly discussed, at the same time, describing the preemption scheduling of RTAI kernel.
Comparing the common method of information extraction, this thesis simply analyzes the advantage and disadvantage of ST-Deveploer based on ROSE class lib. The way to extract information in this thesis is based on the mapping form EXPRESS to C++, building a C++ lib as the STEP-NC mathematics model, and describing the process of information extraction. At the same time, this thesis also discusses the plan and generation of turning toolpath facing working-steps.
Aiming at the optimization of cutting parameters based on STEP-NC features, the cutting speed and feedrate are regarded as the variables,and the cutting parameters optimization model can be built though using muti-objective function consists of less machining time function and less machining cost function, and the constraints mainly come from the tools and machines. According to analysis, the cutting distance L is regarded as the parameter which has most influence on the optimization result. So according to the description of geometry profile in STEP-NC, the cutting parameter model and the STEP-NC features can be contacted, and the using the Genetic algorithm to get the results.
The realization of the related modules in the STEP-NC turning prototype system is discussed in the end.
本文从总体上介绍了基于Linux-RTAI实时操作系统对开发STEP-NC数控系统在实时性方面的优势,分析了STEP-NC数控系统的用户层、控制层、内核层三层软件结构以及每一层的特点。其中重点介绍了用户层中STEP-NC各功能模块的特点并简要阐述了内核层RTAI实时内核的抢占式调度算法。
对STEP-NC信息提取的方法进行了分析比较,简单分析了基于ROSE C++类库开发的ST-Developer软件在信息提取方面的优缺点。本文采用的方法是以EXPRESS语言向C++语言的映射为基础,建立了C++类库,作为STEP-NC的C++数据模型,详细描述信息提取的流程。同时,也对面向STEP-NC加工工步的车削轨迹的规划以及生成方法进行了一定的讨论。
针对基于STEP-NC特征的切削参数优化问题,以切削速度和进给量为优化变量,以加工时间和加工成本综合优先建立多目标函数,并且从刀具和机床多方面对数学模型加入约束,建立切削参数优化模型。分析认为在数学模型中,切削长度L是对优化结果影响最大的参数,因此根据STEP-NC中关于几何轮廓的数据结构的定义,将切削优化数学模型和STEP-NC加工特征结合起来,并用基因遗传算法求解。
最后在STEP-NC车削原型系统上对本文中所阐述的STEP-NC车削系统的功能模块进行验证,并给出了相关模块的实例。
In recent years, Europe, America and Korea etc industrial developed country put forward a new criterion of data interface, namely, STEP-NC (ISO 14649), in order to replace ISO 6983 (G code) that have already used in a long time. It was drew up in 1996, and part work of standardize has been completed heretofore, in which data model of milling and turning have approximately completed. STEP-NC carries on program according to manufacturing features, but not to movement of tool directly. It includes all processing mission of workpiece, through a series of processing mission, describing all operation from the part of rough to final product and providing higher level information to the workshop of machining.
This thesis introduces the advantage in real-time as developing the STEP-NC based on the Linux-RTAI real-time OS and analyzes the three-layer structure of STEP-NC, which contained User Layer, Control Layer and Kernel Layer. Among which the characteristic of STEP-NC modules embed in the User Layer is mainly discussed, at the same time, describing the preemption scheduling of RTAI kernel.
Comparing the common method of information extraction, this thesis simply analyzes the advantage and disadvantage of ST-Deveploer based on ROSE class lib. The way to extract information in this thesis is based on the mapping form EXPRESS to C++, building a C++ lib as the STEP-NC mathematics model, and describing the process of information extraction. At the same time, this thesis also discusses the plan and generation of turning toolpath facing working-steps.
Aiming at the optimization of cutting parameters based on STEP-NC features, the cutting speed and feedrate are regarded as the variables,and the cutting parameters optimization model can be built though using muti-objective function consists of less machining time function and less machining cost function, and the constraints mainly come from the tools and machines. According to analysis, the cutting distance L is regarded as the parameter which has most influence on the optimization result. So according to the description of geometry profile in STEP-NC, the cutting parameter model and the STEP-NC features can be contacted, and the using the Genetic algorithm to get the results.
The realization of the related modules in the STEP-NC turning prototype system is discussed in the end.
引文
[1]杨叔子,丁洪.智能制造技术与智能制造系统的发展与研究.中国机械工程,1992,3(2):15~18
[2]李圣怡.智能制造技术与智能制造系统.国防科技大学学报,1995,6(2): 1~10
[3]赵东标,朱剑英.智能制造技术与系统的发展与研究.中国机械工程,1999,10 (8): 927~931
[4] Mark Albert. STEP-NC——The end of G codes?. Http:/ /www. mmsonline. com/ articles/, 2001.11.9.
[5] Martin Hardwick, David Loffredo. STEP into NC. Manufacturing Engineering, 2001(6): 38~50
[6] Martin Hardwick, STEP-NC Frequently Asked Questions, http://www.steptools/library/stepnc/faq/fqa.html, 2003.8
[7]李佳特. NC技术发展的历史回顾与展望.世界制造技术与装备市场, 2000(2): 29~34
[8]李佳特.数控技术的现状发展趋势.世界制造技术与装备市场,2001(1): 34~37
[9]李伟光,张金,张秀娟,李勇,黄文波.基于STEP-NC的数控技术.机床与液压, 2005 (02): 17~20
[10]张承瑞,刘日良等. CNC技术的最新进展——STEP-NC.制造技术与机床, 2002, (02): 28~30
[11]彭海涛. CNC系统的全新数据输入标准STEP-NC.航空制造技术,2004,(3):58~61
[12]李伟光.新型STEP-NC数控加工方式.CAD/CAM与制造业信息化,2004,(4):90~94
[13]张承瑞,刘日良,王恒.STEP-NC-新一代机床控制器.组合机床与自动化加工技术,2002(12):34~40
[14] Michael Weyrick. The ultimate STEP. American Machinist, 2001(5):350~362
[15] Martin Hardwick. What you should know about STEP. Machine Design, 2000(6): 98~102
[16] Suh S H, D.h.Chung, B.E.Lee, et al. Developing an integrated STEP-compaint CNC prototype. Journal of Manufacturing
[17] SUCH-HWAN SUH ,DAE-HYUCK CHUNG, BYEONG-EON LEE SEUNGJUN SHIN etc. Step-compliant cnc system for turning: data model, architecture,and implementation[J]. Computer-Aided Design,2006,38:677~688
[18]陈凯云,叶佩清,汪劲松.基于STEP-NC数控系统的研究.中国机械工程, 2003,14(9):721~723
[19]刘日良,张承瑞. STEP_NC 2_5D铣削工步的运动特征及其数据模型.机械科学与技术, 2005(01):90~93
[20]刘日良,张承瑞,张元才,王锐.面向STEP_NC控制器的数控加工工艺规划模型.中国机械工程, 2004(04):325~328
[21]张元才.基于STEP-NC数据模型的信息提取与处理技术研究.[硕士学位论文].济南:山东大学,2004.
[22]彭芳瑜,罗忠诚,李斌等. STEP-NC数控加工程序解析方法的研究与实践[J].华中科技大学学报,2005,08:75~77
[23]朱萍.基于STEP-NC的解释器模型研究. [硕士学位论文].哈尔滨:哈尔滨工程大学,2004.
[24]轩传桃.基于STEP-NC的CAD/CAM集成接口的研究. [硕士学位论文].哈尔滨:哈尔滨工程大学,2002.
[25]轩传桃,张家泰,祝海涛.基于STEP-NC标准的CAD/CAM集成接口的研究.应用科技, 2003,3 (30-3):6~8
[26]杜娟,田锡天,朱名铨等.基于STEP-NC的CAD/CAM/CNC系统集成的研究.组合机床与自动化加工技术,2004(10):23~26
[27]杜娟,田锡天,朱名铨等.基于STEP和STEP-NC的CAD/CAPP/CAM/CNC系统集成技术研究计算机集成制造系统. 2005(04):0487~0491
[28] ISO 10303-11E2: tobe published. The EXPRESS language reference manual. 2 edition
[29] ISO/TC184/SC1/WG7. ISO14649-10 Data Model for Computerized Numerical Controllers , 2003
[30] ISO/TC184/SC1/WG7. ISO14649-12 Data Model for Computerized Numerical Controllers , 2003
[31] POSTGRESQL-DOC-8.0-ZH_CN
[32] PostgreSQL实用实例参考
[33] Barry Stinson著.云巅工作室译PostgreSQL必备参考手册北京:人民邮电出版社, 2002
[34]彭晓明等. PostgreSQL对象关系数据库开发北京:人民邮电出版社, 2001.
[35]许宏松编. PostgreSQL 7数据库开发指南北京:机械工业出版社, 2001.
[36]蒋德军.数控车床CAD/CAM系统中走刀路线的设计计算分析.电气开关, 1996(5):29~30
[37]冯之敬.机械制造工程原理.清华大学出版社(第一版),1999
[38] Dufuaa S.O, Shuaib A.N, Alan M.. Evaluation of Optimization methods for machining economics models, Computers and Operations Research, 1992 Feb V20 n2227~237
[39] M. Cemaal Cakir, Adam Gurarda. Optimization and representation of machining conditions in muti-pass turning operations, Computer Integrated Manufacturing System, 1998 July V11 n2 P157~70
[40] J. Wang, Computer-aided economic optimization of end-milling operation, International Journal of production Economics, 1998 may P307~320
[41]解放,柯文等.基于专家系统的NC程序切削参数检验的方法研究.中国制造业信息化. 2003, (03): 86~87,90
[42]刘战强,黄传真等.切削数据库的研究现状与发展.计算机集成制造系统-CIMS. 2003, (11): 937~943
[43]张元才,余卓平等. STEP-NC数控程序信息提取和数控加工数据库初步规划.中国制造业信息化. 2006 (01):62~66
[44]武美萍,翟建军等.数控加工切削参数优化研究.中国机械工程.2004, (03): 235~237
[45]姜彬,杨树财等.数控切削加工工艺参数的多目标优化.工具技术.2002, (07): 22~25
[46]姜彬,郑敏利等.数控车削用量优化切削力约束条件的建立.机械工程师, 2002, (08): 38~40
[47]胡毓达.实用多目标最优化.上海科学技术出版社(第一版),1990.
[48]袁亚湘.非线性规划数值方法.上海科学技术出版社(第一版),1993.
[49]胡毓达.多目标规划有效性理论.上海科学技术出版社(第一版),1994.
[50]王启平.机械制造工艺学.哈尔滨工业大学出版社, 1995.
[51]周明,孙树栋.遗传算法原理及应用(第一版).北京:国防工业出版社, 1999
[52]陈国良等.遗传算法及其应用(第一版).人民邮电出版社, 1996.
[53] Goldberg D E. Genetic Algorithms in Search, Optimization and Machine Learning. Addison-Wesley, 1989.
[54]徐寺群.简明机械加工工艺手册(第一版).上海科学技术出版社, 1991.
[55]张维纪.车工实用手册(第一版).浙江科学技术出版社, 1996
[2]李圣怡.智能制造技术与智能制造系统.国防科技大学学报,1995,6(2): 1~10
[3]赵东标,朱剑英.智能制造技术与系统的发展与研究.中国机械工程,1999,10 (8): 927~931
[4] Mark Albert. STEP-NC——The end of G codes?. Http:/ /www. mmsonline. com/ articles/, 2001.11.9.
[5] Martin Hardwick, David Loffredo. STEP into NC. Manufacturing Engineering, 2001(6): 38~50
[6] Martin Hardwick, STEP-NC Frequently Asked Questions, http://www.steptools/library/stepnc/faq/fqa.html, 2003.8
[7]李佳特. NC技术发展的历史回顾与展望.世界制造技术与装备市场, 2000(2): 29~34
[8]李佳特.数控技术的现状发展趋势.世界制造技术与装备市场,2001(1): 34~37
[9]李伟光,张金,张秀娟,李勇,黄文波.基于STEP-NC的数控技术.机床与液压, 2005 (02): 17~20
[10]张承瑞,刘日良等. CNC技术的最新进展——STEP-NC.制造技术与机床, 2002, (02): 28~30
[11]彭海涛. CNC系统的全新数据输入标准STEP-NC.航空制造技术,2004,(3):58~61
[12]李伟光.新型STEP-NC数控加工方式.CAD/CAM与制造业信息化,2004,(4):90~94
[13]张承瑞,刘日良,王恒.STEP-NC-新一代机床控制器.组合机床与自动化加工技术,2002(12):34~40
[14] Michael Weyrick. The ultimate STEP. American Machinist, 2001(5):350~362
[15] Martin Hardwick. What you should know about STEP. Machine Design, 2000(6): 98~102
[16] Suh S H, D.h.Chung, B.E.Lee, et al. Developing an integrated STEP-compaint CNC prototype. Journal of Manufacturing
[17] SUCH-HWAN SUH ,DAE-HYUCK CHUNG, BYEONG-EON LEE SEUNGJUN SHIN etc. Step-compliant cnc system for turning: data model, architecture,and implementation[J]. Computer-Aided Design,2006,38:677~688
[18]陈凯云,叶佩清,汪劲松.基于STEP-NC数控系统的研究.中国机械工程, 2003,14(9):721~723
[19]刘日良,张承瑞. STEP_NC 2_5D铣削工步的运动特征及其数据模型.机械科学与技术, 2005(01):90~93
[20]刘日良,张承瑞,张元才,王锐.面向STEP_NC控制器的数控加工工艺规划模型.中国机械工程, 2004(04):325~328
[21]张元才.基于STEP-NC数据模型的信息提取与处理技术研究.[硕士学位论文].济南:山东大学,2004.
[22]彭芳瑜,罗忠诚,李斌等. STEP-NC数控加工程序解析方法的研究与实践[J].华中科技大学学报,2005,08:75~77
[23]朱萍.基于STEP-NC的解释器模型研究. [硕士学位论文].哈尔滨:哈尔滨工程大学,2004.
[24]轩传桃.基于STEP-NC的CAD/CAM集成接口的研究. [硕士学位论文].哈尔滨:哈尔滨工程大学,2002.
[25]轩传桃,张家泰,祝海涛.基于STEP-NC标准的CAD/CAM集成接口的研究.应用科技, 2003,3 (30-3):6~8
[26]杜娟,田锡天,朱名铨等.基于STEP-NC的CAD/CAM/CNC系统集成的研究.组合机床与自动化加工技术,2004(10):23~26
[27]杜娟,田锡天,朱名铨等.基于STEP和STEP-NC的CAD/CAPP/CAM/CNC系统集成技术研究计算机集成制造系统. 2005(04):0487~0491
[28] ISO 10303-11E2: tobe published. The EXPRESS language reference manual. 2 edition
[29] ISO/TC184/SC1/WG7. ISO14649-10 Data Model for Computerized Numerical Controllers , 2003
[30] ISO/TC184/SC1/WG7. ISO14649-12 Data Model for Computerized Numerical Controllers , 2003
[31] POSTGRESQL-DOC-8.0-ZH_CN
[32] PostgreSQL实用实例参考
[33] Barry Stinson著.云巅工作室译PostgreSQL必备参考手册北京:人民邮电出版社, 2002
[34]彭晓明等. PostgreSQL对象关系数据库开发北京:人民邮电出版社, 2001.
[35]许宏松编. PostgreSQL 7数据库开发指南北京:机械工业出版社, 2001.
[36]蒋德军.数控车床CAD/CAM系统中走刀路线的设计计算分析.电气开关, 1996(5):29~30
[37]冯之敬.机械制造工程原理.清华大学出版社(第一版),1999
[38] Dufuaa S.O, Shuaib A.N, Alan M.. Evaluation of Optimization methods for machining economics models, Computers and Operations Research, 1992 Feb V20 n2227~237
[39] M. Cemaal Cakir, Adam Gurarda. Optimization and representation of machining conditions in muti-pass turning operations, Computer Integrated Manufacturing System, 1998 July V11 n2 P157~70
[40] J. Wang, Computer-aided economic optimization of end-milling operation, International Journal of production Economics, 1998 may P307~320
[41]解放,柯文等.基于专家系统的NC程序切削参数检验的方法研究.中国制造业信息化. 2003, (03): 86~87,90
[42]刘战强,黄传真等.切削数据库的研究现状与发展.计算机集成制造系统-CIMS. 2003, (11): 937~943
[43]张元才,余卓平等. STEP-NC数控程序信息提取和数控加工数据库初步规划.中国制造业信息化. 2006 (01):62~66
[44]武美萍,翟建军等.数控加工切削参数优化研究.中国机械工程.2004, (03): 235~237
[45]姜彬,杨树财等.数控切削加工工艺参数的多目标优化.工具技术.2002, (07): 22~25
[46]姜彬,郑敏利等.数控车削用量优化切削力约束条件的建立.机械工程师, 2002, (08): 38~40
[47]胡毓达.实用多目标最优化.上海科学技术出版社(第一版),1990.
[48]袁亚湘.非线性规划数值方法.上海科学技术出版社(第一版),1993.
[49]胡毓达.多目标规划有效性理论.上海科学技术出版社(第一版),1994.
[50]王启平.机械制造工艺学.哈尔滨工业大学出版社, 1995.
[51]周明,孙树栋.遗传算法原理及应用(第一版).北京:国防工业出版社, 1999
[52]陈国良等.遗传算法及其应用(第一版).人民邮电出版社, 1996.
[53] Goldberg D E. Genetic Algorithms in Search, Optimization and Machine Learning. Addison-Wesley, 1989.
[54]徐寺群.简明机械加工工艺手册(第一版).上海科学技术出版社, 1991.
[55]张维纪.车工实用手册(第一版).浙江科学技术出版社, 1996