多轴联动电火花加工数控系统开发

Development of multi-axis electro-discharge machining CNC System

为加工具有复杂几何结构或者材料较难加工的零件,开发了多轴联动电火花加工数控系统。为了增强系统的实时性、稳定性和可靠性,采用RT-Linux技术,提出双核结构概念来分别处理实时任务和非实时任务。确立数控系统由实时控制模块、驱动模块、用户管理模块和模块间的通信所组成。提出了线程承载法解决实时任务间协调控制问题,以及循环选择法解决任务调度问题。给出了平面二轴联动插补派生法构建适合电火花加工机床的多轴联动插补控制算法,提出内存映射法构建硬件实时驱动方式以增强系统驱动的实时性,提出线程-处理器模式构建用户管理模块,以使复杂的管理任务清晰化和易于管理,选择最优的通信方式来增强数控系统的实时性能。开发出了五轴联动电火花加工数控系统,并运用该系统进行了带冠整体式涡轮盘的加工实验。实验结果表明,该系统具有实时性强、稳定性好和可靠性高等特点。

To process geometrically complex or hard material parts,a new kind of multi-axis Electro-Discharge Machining （EDM） Computer Numerical Control （CNC） system was developed. To strengthen the real-time performance,stability and reliability of the system,based on RT-Linux,dual-kernel structure was proposed to realize real-time task and time-sharing task separately. CNC system was composed of real-time control module,drive module,CNC user module and communications among modules. Thread-carrying method was put forward to solve collaborative control of real-time tasks. Circulation-selection method was presented to solve scheduling problem,and plan interpolation deriving method was proposed to construct multi-axis interpolation algorithm. To strengthen the real-time performance of drivers,memory-mapping method was advanced. To simplify management tasks,thread-processor mode was advanced. To strengthen real-time performance of the system,the optimal communication methods were adopted. Five-axis EDM CNC system was developed and turbine blisk processing experiment was carried out to validate the performance. Experimental results indicated that the system was stable and reliable with good real-time performance.