Research of contour error compensation control for X-C non-circular grinding in polar coordinates

In the X-C linkage grinding of non-circular parts,the computation and control method of contour error in polar coordinates platform is different with that in the XY coordinates platform.To solve this problem,the analysis of the definition and computation methods for contour error and track error in polar coordinates platform will be made.Through the relative lead-lag relation of the linkage axes in the grinding process,the range of the estimation contour error is narrowed and a contour error calculation model is constructed.Then the contour compensation controllers along contour error direction and trajectory tracking error direction are designed respectively,and the error compensation decoupling matrix of the X-C linkage axes is given as well.In the end of this paper,we take the machining of the cylinder contour in Wankel rotary piston engine as an example.A simulation experiment of contour error compensation control based on relative lead-lag quantity is made.The result shows that the designed contour compensation controller can increase the contour machining accuracy effectively.

Research on Contour Error Based on CNC Multi-axis Motion Control System

The contour error was analyzed based on CNC multi-axis motion control, the contour error model was obtained focused on beeline and different radius of curvature and common contour of curve, for a CNC biaxial motion control system and the mechanism of producing contour error and the relationship between tracking error and contour error were presented. The theoretical and practical significance of modeling error and controlling error in motion control systems was carried out.

TWO-COORDINATE DUAL-SERVO CONTOURERROR COMPENSATION TECHNOLOGY FOR ULTRA-PRECISION MANUFACTURING

A technology of two-coordinate dual-servo(TCDS) is proposed. Using this technology which is based on error compensation, workpieces of higher contour accuracy could he turned on ultra-precision machine tool with Poor dynamic performances. The principle, constitute and operation of a TCDS system are described. Mathematical proof and experiments are achieved in addition.

Chord error constraint based integrated control strategy for contour error compensation

As the traditional cross-coupling control method cannot meet the requirements for tracking accuracy and contour control accuracy in large curvature positions, an integrated control strategy of cross-coupling contour error compensation based on chord error constraint, which consists of a cross-coupling controller and an improved position error compensator, is proposed. To reduce the contour error, a PI-type cross-coupling controller is designed, with its stability being analyzed by using the contour error transfer function. Moreover, a feed rate regulator based on the chord error constraint is proposed, which performs speed planning with the maximum feed rate allowed by the large curvature position as the constraint condition, so as to meet the requirements of large curvature positions for the chord error. Besides, an improved position error compensation method is further presented by combining the feed rate regulator with the position error compensator, which improves the tracking accuracy via the advance compensation of tracking error. The biaxial experimental results of non-uniform rational B-splines curves indicate that the proposed integrated control strategy can significantly improve the tracking and contour control accuracy in biaxial contour following tasks.

Interpolation-based contour error estimation and componentbased contouring control for five-axis CNC machine tools

High accuracy contour error estimation and direct contour error control are two major approaches to reduce the contour error.However, two key factors make them complex for five-axis machine tools: the nonlinear kinematics and the coupling between the tool position and orientation. In this study, by finding the reference point nearest to the current actual position, and interpolating the point with two neighboring reference points and using the distance ratio, a new contour error estimation method for five-axis machine tools is proposed, which guarantees high accuracy while depending on only the reference points. By adding a weighted contour error on the tracking error in the workpiece coordinate system, and specifying a desired second-order error dynamics based on the error variable, an effective contouring control method is proposed, which can alleviate the problem: when the contour error components are introduced into the controller, the contour errors increase instead in some regions of the tracking trajectory. A series of experiments are performed on a tilting-rotary-table(TRT) type five-axis machine tool. The results reveal that the proposed estimation method has high accuracy, and compared with the case without contour error control, the proposed control approach can reduce the contour error along the whole trajectory.

Cross-coupled controller design for triaxial motion systems based on second-order contour error estimation

The cross-coupled control(CCC)is widely applied to reduce contour errors in contour-following applications.In such situation,the contour error estimation plays an important role.Traditionally,the linear or second-order estimation approach is adopted for biaxial motion systems,whereas only linear approach is available for triaxial systems.In this paper,the second-order contour error estimation,which was presented in our previous work,is utilized to determine the variable CCC gains for motion control systems with three axes.An integrated stable motion control strategy,which combines the feedforward,feedback and CCC controllers,is developed for multiaxis CNC systems.Experimental results on a triaxial platform indicate that the CCC scheme based on the second-order estimation,compared with that based on the linear one,significantly reduces the contour error even in the conditions of high tracking feedrate and small radius of curvature.

永磁直线电机驱动XY平台精密轮廓跟踪控制

为了减少高速进给率条件下轮廓跟踪过程中产生的轮廓误差,提出了一种将PDFF位置控制器与模糊交叉耦合控制器相结合的控制策略。首先,通过调节前馈增益,PDFF位置控制器可以综合利用PDF控制和PI控制的优点;其次,基于自由曲线轮廓误差模型来计算轮廓误差,并且提出一种以两轴的位置跟踪误差以及轮廓误差为输入的模糊交叉耦合器来减少轮廓跟踪过程中产生的轮廓误差;最后,空载与负载实验结果表明,与传统的交叉耦合结构相比,该方法在高速进给率条件下可以有效降低XY平台的轮廓误差,并且可以提高轮廓跟踪系统的鲁棒性。

基于线结构光扫描的工件高精度三维测量方法

为了提高工业中对复杂轮廓工件的测量精度和效率,设计了一套高精度非接触三维测量系统,并提出了一种基于线结构光扫描的工件轮廓三维测量方法。首先,利用高精度相机和三轴移动平台采集线结构光图像。然后,通过基于差分区间的灰度质心算法,精确而高效地提取出线结构光中心线,并生成原始点云模型。接着,对采集到的点云数据进行必要的点云滤波和精简预处理。最后,将预处理后的点云数据与CAD模型精确配准,进行工件表面轮廓的测量与误差评定。实验结果表明:测量工件轮廓高度的绝对误差小于0.07 mm,相对误差小于0.5%。所提出的三维测量系统及方法测量误差较低,能够实现工件的高精度三维测量,具有一定的工业应用价值。

直线拟合椭圆轮廓曲线数控加工误差分析

数控编程中,不仅要关注程序语句逻辑正确,还要关注加工精度问题。用直线拟合法编制椭圆轮廓数控加工程序时,首先要计算逼近误差,然后根据逼近误差确定各节点步距。通过数学推导,得到等间距和等角度直线逼近椭圆轮廓曲线时的逼近误差计算公式,可用于编制椭圆轮廓数控加工程序时确定循环语句或条件跳转语句的步距,提高椭圆轮廓加工精度。给出了确定步距的一些技巧。

基于神经网络的双轴音圈电机驱动系统智能控制

在双轴或多轴驱动伺服系统中,各轴之间的动态特性互相耦合,严重影响了平台的定位精度和轮廓精度,而传统控制方法运算量大,寻找最优值困难。该文在基于设定值前向补偿的交叉耦合控制方法的基础上,提出了一种基于神经网络的智能控制策略。利用S函数实现了神经网络的在线调整、参数自动调整寻优。改变了系统学习速度,增强了其自适应能力,简化了操作复杂度,实现了系统的智能跟踪控制。用Matlab对文中方法进行仿真,并且与其它方法进行比较,结果表明,改进后的方法在减小轮廓误差和提高定位精度等方面有很好的效果,且在实验平台上进一步验证了该控制策略的可行性和有效性。

基于指数增益迭代学习三轴运动平台轮廓控制

为了得到三轴运动平台精确的轮廓误差估计值,提出了一种基于指数增益型迭代学习的轮廓控制方法。以永磁直线同步电机驱动的三轴运动平台为研究对象,建立三轴运动平台的数学模型,采用泰勒扩展轮廓误差估计法对轮廓误差进行估计,并设计了基于指数增益的PD型迭代学习控制器。采用交叉耦合控制策略,选取按比例的分配方式将轮廓误差补偿到原始参考轮廓上。仿真结果表明,针对给定马鞍形和心形曲线采用指数增益迭代学习比传统迭代学习控制的轮廓误差最大值以及均方差值均有所减小,可证明该方法能够有效减小系统轮廓误差,提升轮廓控制精度。

基于轮廓误差灵敏度函数的增益匹配研究

现有数控系统和伺服驱动系统开放性有限,实时轮廓误差控制策略难以实现,为避免加工设备二次开发,研究了精密加工轮廓误差的离线补偿方法,本文提出了一种以减少轮廓误差为目的的跟踪误差匹配方法。首先在构建各进给系统的机电混合控制模型的基础上,推导轮廓误差关于参考轨迹的灵敏度函数;然后以轮廓误差灵敏度函数为理论依据,针对数控加工过程中常用的G01直线和G02/G03圆弧指令,分析伺服参数在不同运动学参数下对加工轨迹的影响;最后通过调整各伺服轴的控制参数,匹配动态误差系数,提高轮廓精度。此方法可在不增加控制系统复杂性的同时减小各轴动态特性导致的误差,对提高多轴联动加工轮廓精度具有参考价值。

层次多叉树映射布尔体廓后验误差的自适应层切

在给定构建方向下,层切厚度影响熔融沉积成型零件表面的阶梯效应,层切轮廓及其层次关系是路径规划的研究基础.为此,提出基于布尔体廓运算的自适应层切方法,在零件模型不同高度层切面上构建局部轮廓拓扑并计算内核域,根据内核点连线与轮廓环的交点,将轮廓环数据映射到一维坐标轴,基于拓扑映射判定轮廓环层次关系.建立层次关系多叉树,以树高映射体廓特征变化的布尔运算,根据层变阈值设计自适应层厚,通过体廓后验误差估计任意层厚的体积误差,验证自适应层切的有效性.实例打印及不同自适应层切方法对比结果表明,采用体廓后验误差计算的层切体积误差精度比牙尖高度法的更高;通过控制体廓特征部位的层厚来减小体积误差,有助于提高模型特征部位的表面成型精度.

五轴机床运动学建模与几何误差补偿

相对三轴机床,五轴机床包含三个线性轴和两个旋转轴,轴数和轴类型的增加使得五轴机床的几何误差建模更加复杂。本文基于齐次坐标变换理论,构建各线性轴和旋转轴的DH矩阵和误差矩阵,通过运动链配置关系获得考虑几何误差的五轴机床的运动学模型;基于梯度方法,构建轴空间和笛卡尔空间的微分运动映射雅克比矩阵;结合考虑误差的正运动学和误差映射模型,获得末端位姿偏差与轴端位置偏差的补偿量映射关系;实现考虑误差的通用五轴机床逆运动学迭代求解。仿真和分析证明所提方法可以有效改善机床各运动轴装配偏差引起的加工轮廓误差。

基于在机测量点集配准的工件位姿自适应调整算法

针对工件位姿变化所导致的加工轮廓误差控制问题,设计一种基于在机测量点集的配准算法。在理论测量面与实际测量面上分别选取参考测量点建立对应的局部坐标系,通过坐标系重合实现初始配准;通过初配准后的测量点集建立基于最小二乘距离的目标函数,利用自适应差分进化算法获得精确配准矩阵。根据两次配准结果计算工件位姿的调整矩阵。通过实例对算法进行验证,结果表明:所提算法可以较好地实现加工坐标系的调整,有利于加工轮廓误差控制。

高速高精度电子齿轮箱自抗扰控制研究

针对展成法加工齿轮切削力呈周期性变化引起刀具与工件的相对位姿偏差,导致工件齿轮加工误差的问题,文章提出一种基于自抗扰控制(active disturbance rejection control,ADRC)的主从式电子齿轮箱(electronic gearbox,EGB)控制方法。首先,分析滚齿加工过程中机床各运动轴之间的联动关系,建立斜齿轮加工运动控制数学模型,确立主从式EGB结构模型;其次,建立EGB中各轴跟踪误差与工件齿轮齿廓偏差、齿距偏差和螺旋线偏差之间的数学关系,采用交叉耦合控制(cross-coupling control,CCC)补偿方式求解出各运动轴的补偿量,对从动轴进行补偿;然后,构建基于传统比例积分微分(proportional integral derivative,PID)控制和扩张状态观测器(extended state observer,ESO)的ADRC-EGB,评估EGB从动轴所受的干扰并进行补偿,提高其同步精度和鲁棒性。最后,在开放式实时半实物仿真平台开展滚齿加工运动模拟实验。结果表明该EGB控制结构相较于传统EGB具有更高的同步控制精度和抗干扰能力。

基于LSTM与牛顿迭代的两轴系统轮廓误差控制

针对轮廓误差影响运动系统精度的问题,提出结合长短期记忆神经网络(LSTM)和牛顿迭代法对轮廓误差进行预测、通过转换任务坐标系对轮廓误差进行补偿的方法.在运动平台上提取特征轮廓与数据,将牛顿迭代法应用于对轮廓误差的计算,通过计算出的轮廓误差对优化后的LSTM神经网络进行训练,建立更准确的轮廓误差预测模型.通过转换任务坐标系,将预测的轮廓误差作为前馈补偿到参考轮廓中,提高轮廓控制性能.通过试验对比PID、迭代法和神经网络法,利用随机NRBUS轨迹验证泛化性,表明提出的方法能够有效地预测并控制轮廓误差,在精密运动控制领域有良好的应用前景.

直线电机进给系统轮廓误差预测控制方法及仿真研究

为提高永磁同步直线电机驱动的进给系统轮廓轨迹跟踪精度和系统的动态性能,提出了一种显式模型预测交叉耦合控制方法(Explicit model predictive cross-coupled control, EMPCCC)。该方法结合显式预测控制原理与交叉耦合控制思想,对单轴电流和速度信号进行多步预测,将轮廓误差作为反馈量来修正预测控制的给定轨迹,达到轮廓误差预测控制的目的。基于MATLAB/Simulink搭建仿真模型,结果表明,所提EMPCCC方法能快速实现不同转速波形的无超调跟踪控制,且可以实时估计并补偿轮廓误差,提升不同轨迹的轮廓精度。

五轴联动数控刀具切削加工误差非线性插补方法研究

在五轴联动数控刀具切削加工过程中,机床摆心运动轨迹和刀具运动轨迹之间的误差导致加工精度难以保持较高水平,为此提出五轴联动数控刀具切削加工误差非线性插补方法。分析刀具切削加工误差产生的原因,获得理想刀轴矢量,通过插值处理两旋转轴的运动角度,获得实际刀轴矢量误差。通过计算刀轴控制点的距离偏移值,调整刀位和刀闸位置,并使用线性补偿位移调整刀具的位移。同时,根据角度变化计算误差插补量,进一步优化刀具运行轨迹,以确保刀具轨迹始终与理想轨迹保持一致,从而实现五轴联动数控刀具运行轨迹的位移补偿。经实验验证,采用所提方法开展误差插补后,五轴联动数控刀具运行误差小,且运行轨迹贴近理想轨迹。

多轴数控机床伺服参数优化方法研究

数控机床在实际生产中,各轴伺服参数调整不好将影响机床的加工精度。为提高多轴联动中各轴伺服参数的匹配性,推导三轴数控机床加工轮廓误差的计算方法,分析三轴数控机床各轴进给系统伺服参数对轮廓误差的影响,提出2个进给轴之间伺服参数匹配方法。以人字齿的加工为例,对比了参数优化前后的实际加工轨迹,参数优化后人字齿的轮廓误差由优化前的300μm减小到100μm,各轴伺服参数匹配能够有效提高数控机床的加工精度。