摘要
数控技术在制造业中起着非常重要的作用,其发展水平关系着一个国家制造业的水平。随着生产要求的不断提高,传统的数控系统逐渐不能满足生产的要求,分析可归结为数控系统软件的开放性、加工数据模型的开放性以及硬件实施平台的开放性三个问题。软件的开放性包括两个方面:开放的支持二次开发的软件体系结构和友好的设计方法。加工数据模型的开放性是指使用与上游CAD/CAM数据格式兼容的加工数据模型STEP-NC,替代传统的ISO6983(G、M代码),以充分利用上游的设计制造信息对数控系统智能自治能力提供支持,从而解决ISO6983信息量不足的问题。硬件实施平台的开放性主要体现在硬件的柔性配置能力方面,用以实现对整个系统柔性和二次开发能力的硬件层支持。以上三个问题即STEP-Compliant数控平台的设计方法问题。针对STEP-Compliant数控平台的实施方法,本文以上述三个问题为主线进行了深入的研究。
首先是开放式数控系统软件结构和设计方法的研究。本文针对数控系统交互式事件驱动的特点,基于Statecharts建模理论,提出了功能分离的设计方法和结构,并给出了其实施方案。在功能分离的结构中,数控系统软件部分被分为机器接口、功能描述数据、非交互功能函数动态链接库和事件处理器四部分。机器接口是软件层与硬件层交互的接口,其根据从硬件层获取的信息或设计者定义的规则产生事件处理器的驱动事件并将事件处理器产生的控制命令映射到底层硬件层。功能描述数据是对事件处理规则的描述,其包括行为描述数据和动作函数动态链接库。非交互功能函数动态链接库是数控系统中复杂计算和数据处理等具有非交互特点的功能函数的集合,这些函数根据功能描述数据中描述的规则被调用。事件处理器受机器接口送来的事件的驱动,根据功能描述数据中的处理规则进行处理,处理过程中在必要的情况下通过功能描述数据的动作函数调用非交互功能函数,得出的处理结果由机器接口映射至底层硬件层。
此结构将数控功能设计为功能描述数据和非交互功能函数动态链接库,在系统中分离出来作为数控功能开发的接口。数控功能通过Statecharts进行图形化建模并仿真后,由本文设计的功能描述数据生成器(FDD Generator)将Statecharts模型自动生成功能描述数据。非交互功能函数动态链接库可由数控系统生产厂商或第三方提供,也可由用户自行设计修改。这种结构保证了数控系统软件的开放性,其友好的数控功能图形化设计和仿真方法简便易行,既减轻了数控功能的设计负担,又保证了用户级的二次开发能力。
其次是在数控系统加工数据模型方面的研究。本文对STEP-NC加工数据模型与开放式软件结构的集成,即STEP-Compliant开放式控制器的构建方法进行了研究。首先对它的工作方式进行了分析,然后在功能分离方法的框架下,设计了STEP-Compliant智能控制器的结构并给出了其工作方法。通过此开放的结构可方便地对STEP-Compliant控制器相应模块的功能进行测试和更新,为其后续研发提供一个快速开发平台。
最后是在开放式数控硬件实施平台方面的研究。最近几年,基于工业总线的硬件结构成为发展的趋势。工业以太网由于其较高的性价比和与上游的设计、管理单元网络的纵向一致性而成为工业现场总线发展的主流。本文对课题组自主研发的以太网总线技术EtherMC进行了改进和完善,作为系统的硬件实施平台。给出了EtherMC的拓扑结构和同步方案,并将树形结构引入到从站拓扑结构中,给出了树形结构下系统主站和从站的设计方法和配置方法。在以上设计中,通过FPGA中设计的并行收发机制和数据控制机制,可以实现各子树中高效的数据并行传输和处理,并可将指定的子树设计为高速自治子系统,解决了工业控制总线超小周期控制的问题。提供的配置方法保证了硬件平台的柔性和可重构性,为整个系统的柔性和可重构型提供了硬件层的支持。
为验证以上方法的正确性,本文进行了系统原型机的开发和运行验证。通过机床手动功能的实现,验证了功能分离的方法以及EtherMC硬件平台的可行性和有效性。通过对手动功能进行的二次开发(增加第四轴、第五轴功能),验证了系统的二次开发能力和EtherMC硬件平台的开放性。通过以STEP-NC加工数据模型为支持的智能决策功能的实施范例,示范了在功能分离的设计方法下构建STEP-Compliant智能控制器的方法。
本研究的成功实施,为解决数控系统软件、加工数据模型和硬件实施平台中存在的问题提供了一个解决方案,进而为STEP-Compliant开放式数控平台的实施提供了一条有效的途径。
Computer Numerical Control (CNC) technology plays a very important role in the development of manufacturing industry. Its development level is a very essential point in the manufacturing industry of a country. With the development of manufacturing, the drawbacks of traditional CNC system make it gradually unable to fulfill the demands. It can be clarified to three problems: open ability of software, open machining data model and open hardware platform. The open ability of software has two aspects: open software structure which can support secondary development and friendly software design method. The open machining data model is to use STEP-NC data model instead of ISO6983. Then the design and manufacturing information of upstream CAD/CAM units can be used to support intelligent autonomous functions. The open hardware platform means flexible reconfigurabilty of hardware platform. It ensures the flexibility and secondary development ability of the whole system at the hardware level. These three problems can be summarized to the problems of STEP-Compliant open CNC platform design method. In this dissertation, a deep research on the realization method of STEP-Compliant open CNC platform is put forward through the three problems above.
First is the research on the CNC software structure and design method. In this dissertation, according to the reactive characteristic of the CNC system, an open CNC software design method, Function Separated Design (FSD) method and its structure was proposed based on Statecharts modeling theory. The implementing strategy is also given. With FSD method, CNC software is divided to Machining Interface, Function Description Data (FDD), Non-reactive Function Library and Event processor. Machining Interface provides an interface between software level and hardware level. It generates driving signal and reflects control data to the hardware level. FDD is a description of event processing rules. Non-reactive function library is the collection of complex calculation and data processing functions, which have non-reactive characteristics. They can be called according to the rules described in FDD. Event processor is driven by the events sent from Machine interface. It processes the events according to the rules described in FDD, and then sends the control data to Machine Interface.
With this structure, CNC Functions are separated from the complex systems as the FDD and Non-reactive Function Library. After graphical Statecharts modeling and simulation of CNC functions, it can be converted to FDD automatically via FDD Generator, which is developed in this dissertation. This structure ensures the open ability of the software, and its friendly graphical design and simulation method is very convenient. The design burden can be eased and the user-level secondary development ability can be guaranteed.
Second is the research on the open machining data model. In this dissertation, a research on the implementing method of STEP-NC under the framework of open software design method is put forward. First the working mode of intelligent STEP-Compliant CNC system is analyzed. Under the framework of Function Separated Design method, the STEP-Compliant intelligent CNC system structure is proposed and its working procedure is given. With this design, the test and upgrading of the STEP-NC related module can be done easily. A rapid development platform can be provided to fulfill the further development demands of STEP-Compliant CNC system.
Third is the research on the hardware implementing platform. Recent years, because of the good consistency with upstream design and management unit, industrial Ethernet becomes a mainstream in fieldbus development. In this dissertation, EtherMC, which was developed by our research group, was improved and built as the hardware implementing platform. The topology and synchronization method of EtherMC was given. A tree-shape topology is adopted. Under this topology, the design specification of both Master and Slave node was given. Based on the design specifications, the implementation of high speed autonomous sub-system was given to solve the ultra-short period control problems in the fieldbus system. The configuration method based on the design specification was illustrated to ensure the flexibility and reconfigurability of the hardware platform. The flexibility and reconfigurability of the whole system was guaranteed at the hardware level.
In order to verify the methods proposed above, a prototype is developed in this dissertation. In the realization of manual operation functions, the feasibility and validity of Function Separated Design method and hardware platform was proven. The open ability and shop-floor level secondary design ability of the system was proven by the secondary development of the previously designed manual operation functions (adding the fourth and fifth axis function). The implementation method of STEP-Compliant intelligent machine controller under the framework of Function Separated Design method was showed through an implementing demo of STEP-NC supported intelligent decision making module.
The successful implementation of this research gives a solution to the problems existed in the CNC software, machining data model and hardware implementing platform. It provides an effective way to the STEP-Compliant open CNC platform implementation.
引文
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