时变周期性参考输入的自适应重复控制系统设计

在凸轮研磨加工应用中,为符合特定加工条件,凸轮需要操作在变转速条件,这将使得输入信号变成所谓的时变周期信号,即是位置或角度的周期信号.因此,为降低时变周期信号的跟踪误差,提出了一种基于重复控制理论设计的具有线性时变特性的自适应重复控制器,使得角位移域内的时变周期信号得到衰减.采用自适应重复控制理论将定义在时域内的所有的控制信号转换成定义在角位移域内的信号,以使输入信号变成周期函数.针对直线伺服电机驱动的凸轮加工中心进行了仿真研究,结果表明所提出的控制方案是有效的,提高了系统跟踪精度,大大减小了跟踪误差.     

Application of grey predictor and fuzzy speed regulator in controlling a retrofitted machining table

In this work, the control plant is an a.c. servo motor retrofitted traditional manually operated milling machine with a lead-screw transmission system. This obsolescent milling machine has non-linear time-varying behavior due to obvious backlash and irregular coulomb friction of the sliding surfaces. The system model is difficult to derive and identify for classical control design. In order to achieve the objectives of reducing the tracking error and path error and increasing the motion speed, a combination of PI control with grey prediction, cross-coupling and feedforward control loops and fuzzy speed regulator is proposed to control this machining table. The grey prediction loop is employed to improve the robustness and tracking accuracy of the control system. The fuzzy speed regulator is used to achieve the maximum machining speed under a specified error tolerance. The experimental results show that this control method achieves satisfactory performance of transient response, tracking and robustness under the influence of about 0.4 mm backlash on each axis and large stick-slip friction. This performance verifies the applicability of this economical approach to the automation of traditional milling machines.     

电液伺服系统的模糊自适应复合控制研究

电液位置伺服系统的阻尼比较低,造成电液位置伺服系统响应速度慢及跟踪性能较差。为解决此问题,提出一种模糊自适应控制与速度正反馈、加速度负反馈相结合的复合控制策略。通过速度正反馈来提高系统的开环增益,加速度负反馈提高阻尼比,从而提高系统动态响应速度并减小位置误差。利用前馈控制拓宽系统频宽,进一步减小位置跟踪误差。对传统PI控制、模糊PI控制、模糊PI复合控制算法下的系统响应性能进行仿真分析,结果表明:采用所提出的复合控制策略时,系统动态响应速度比模糊PI控制提高约76.9%,比传统PI控制提高约84.2%,其位置跟踪误差几乎为0。     

基于多轴运动控制方法的高速切削复合轨迹研究

为了解决复杂曲面数控加工中的高速数控加工问题,从过程集成控制的角度构建了多轴平滑运动模型、插补控制、位置跟踪等。速度优化模型采用数学方法,构造了加、减速控制。速度预处理中通过简化优化模型,提出了柔性加减速控制算法,并对其进行了优化设计。为了克服高速进给系统的非线性影响,通过引入新的加速度和速度的前馈控制,提出了高速位置跟踪算法;实现了基于双核处理器的嵌入式数控系统,且该结构能保证六轴插补周期的要求。现场数据显示该系统在高速运动平稳性好,能满足叶轮复杂轨迹控制要求等。     

基于模糊时变滑模的永磁同步电机调速系统设计

针对永磁同步电机突然加入负载时存在的转速波动和不稳定问题,提出一种基于积分时变滑模面和新型模糊增益趋近律的滑模调速方法。采用积分时变滑模面,在传统积分滑模面中加入一个时变项,借此提升系统的响应速度。改进传统的指数趋近律,加入非线性函数来削弱系统的抖振,同时根据不同的系统状态用模糊算法整定趋近律增益参数,着重于提升趋近速度和系统抗扰动能力。最后,使用李雅普诺夫稳定性判据证明了该控制系统的稳定性。在MATLAB/Simulink环境下将此控制策略与传统滑模控制策略进行对比,仿真结果表明：采用此控制方法的系统响应速度更快、抑制系统扰动和抖振的能力更强,具备更好的综合性能。     

基于H∞反馈的直接驱动XY平台切向轮廓控制设计

为了提高XY平台的轮廓加工精度,在分析系统轮廓误差的基础上,提出将H∞速度反馈控制器和切向-轮廓控制器(TCC)相结合的控制策略.在速度环内采用H∞鲁棒控制理论设计反馈控制器,在具有模型摄动及外部干扰的情况下,保证了闭环系统的鲁棒稳定性和鲁棒性能,TCC使得XY平台之间的耦合作用消除,且轮廓控制器设计变得更加直接和简单.单轴系统采用IP(积分-比例)控制与速度前馈控制相结合的复合控制器.仿真结果表明所设计控制系统在保证具有较好的跟踪性能、鲁棒性能的同时轮廓精度大大提高.     

Direct adaptive control of end milling process

A direct adaptive control algorithm, which is spindle speed and drive dynamics independent, has been developed for machining operations. The combined dynamics of feed motion and cutting process are modelled as a third order system whose parameters may vary with spindle speed and part geometry changes during machining. The algorithm does not use any specific time interval, thus sampling time dependent discrete transfer functions and pole assignments are avoided. The adaptive controller is designed to have a closed loop characteristic function which behaves like an open loop regular and stable machining operation. The proposed direct adaptive controller is practical, can be used in any multi-axes machining, and can be combined with chatter suppression techniques which require spindle speed regulation. The algorithm is applied to the adaptive control of milling. Satisfactory results are obtained in constraining the maximum cutting forces and dimensional surface errors in milling experiments.     

Application of self-tuning feed-forward and cross-coupling control in a retrofitted milling machine

In this work, a traditional manually operated milling machine with a lead screw transmission system is retrofitted to AC servo motor control. This obsolescent milling machine has nonlinear time-varying behaviors due to obvious backlash and irregular Coulomb friction of the sliding surfaces. Classical digital control cannot assure the required stability and accuracy of a closed loop system. Hence, a pole placement self-tuning control strategy is proposed for this nonlinear time-varying system by introducing an on-line estimator of system parameters to adjust the feedback gains. Concepts of feed-forward and cross-coupling control are employed to improve the accuracy of trajectory tracking control. The experimental results show that this control method achieves satisfactory performance of stability, transient response, tracking and robustness under the influence of about 0.4 mm backlash on each axis and large stick-slip friction. This performance verifies the applicability of this economical approach to automation of traditional milling machines.     

A new approach to stability analysis of variable speed machining systems

This paper presents a new method for the stability analysis of variable speed machining systems. By using spindle angular position as the independent variable, the system dynamics are modeled as a linear periodic time-varying system with fixed delay. This representation is proven much easier to analyze and to numerically simulate than the time-varying delay representation, which traditionally uses the real-time as the independent variable. With a finite difference scheme, the infinite dimensional periodic time-varying system is approximated by a finite dimensional periodic time-varying discrete system, which in turn is converted to a time-invariant system by multiplying the time-varying state transition matrix over one period of speed variation. System-relative stability becomes tractable by spectral radius analysis. This approach makes possible the quantitative characterization of system stability as a function of variable speed profiles as well as other system parameters such as stiffness and damping of the cutting process and the tool/workpiece structure. Verifications for the face milling process by numerical simulation and experiment for both constant and variable speed are given.     

活塞数控加工的预期迭代学习控制研究

在高速精密非圆加工中,伺服刀架系统的幅值衰减产生较大的刀具轨迹跟踪误差,从而降低加工精度.针对活塞外圆数控加工数据控制,设计了一种预期迭代学习控制方法.推导该控制算法在频域下的收敛条件,经仿真实验验证,这种控制方法运用于活塞外圆加工中可以取得良好的控制效果.     

Control of ball screw drives based on disturbance response optimization

This paper presents a new method for designing control laws for ball screw drives by directly optimizing the load side disturbance response against cutting forces. The design applies, concurrently, the principles of pole placement and loop shaping, and is easy to implement in practice. In addition to good low frequency disturbance rejection, the control law provides active vibration damping, which reduces the magnification of tracking errors near the drive's mechanical resonance. Effectiveness of the proposed strategy is demonstrated in machining and high speed tracking experiments, where its performance is compared to the industry standard P-PI cascade control law.     

电火花块反拷加工控制系统设计与实验

对电火花块反拷加工的运动控制系统进行了设计,提出了可行的数据采集策略与运动控制策略。基于LabView开发的运动控制系统主要包括初始化模块、粗对刀模块、精确对刀模块、加工控制模块与坐标实时显示模块。应用设计的控制系统对碳化钨工具电极进行了反拷加工实验,正交实验结果得出:材料去除率随着脉宽的增大先增加后减小,脉宽有一个最佳值,脉宽小了能量不足,脉宽大了容易产生电弧放电,影响了材料去除。材料去除率随着脉间相对于脉宽倍数、主轴转速与进给率的增大而增大,足够大的脉间以及主轴转速,有利于电火花加工区域的消电离与加工产物的排除,在材料能够有效去除的前提下,进给速度越快材料去除率越高。     

基于人工神经网络和遗传算法的平面铣削加工参数自适应优化

机械加工最优自适应控制的关键在于自适应加工模型的建立和实时优化策略的制定。本文提出用人工神经网络方法建立加工过程模型 ,用遗传算法实现在线优化。基于以上算法 ,构造了平面铣削加工参数自适应优化系统 ,可使加工系统在不违反加工约束的前提下 ,总是获得最大材料去除率。     

Virtual High Performance Milling

The goal of future manufacturing is to design, test and manufacture parts in a virtual environment before they are manufactured on the shop floor. This paper presents a generalized process simulation and optimization strategy for 2 1/2 axis milling operations to increase Material Removal Rate (MRR) while avoiding machining errors. The process is optimized at two stages. Optimal spindle speed, radial and axial depth of cut are recommended to process planner by considering the chatter, and spindle's torque/power limits. The cutter-part engagement conditions are extracted from CAD system by geometrically processing the NC program and part geometry. Long tool path segments are broken into smaller segments whenever the geometry varies. The spindle speed and feed fields of the NC program are automatically optimized by constraining maximum torque, power, tool deflection and chip load set by the user. The acceleration and speed limits of the machine tool feed drives are considered to prevent frequent variations of the feed unnecessarily. The optimization is experimentally verified by milling a helicopter gear box cover on a high speed, horizontal machining centre.     

Repetitive control design and implementation for linear motor machine tool

The goal of this paper is to eliminate the period tracking error via the design of discrete-time domain repetitive controller. It increases the stabilizing range and enhances the robust performance by adopting the prototype repetitive controller design principle to compensate repetitive control. Furthermore, with the concept of command feedforward, it introduces the feedforward gains of speed and acceleration, which can forcefully enhance the tracking ability of the repetitive controller and improve on the errors of the system. Finally, it puts into practice the theory on a gantry type machinery platform with linear motors. The results prove that the theory can reduce period tracking error successfully.     

铣削加工颤振稳定域影响参数研究及优化

建立圆柱形铣刀铣削加工动态切削数学模型,采用一种解析法计算并绘制稳定域图,获取加工稳定性随工艺参数变化的规律。分析系统参数对铣削加工颤振稳定特性的影响,提高固有频率、增大系统刚度和阻尼有助于提高系统加工稳定性。基于动态变化的稳定域图及共振功率半频带频率,提出一种铣削稳定性约束下铣削参数优化模型,获取最大加工效率下的主轴转速、径向进给量及轴向进给量参数的最优值。开发铣削稳定性分析仿真软件,实现铣削颤振稳定域分析、共振区域分析、铣削参数优化等功能。将复杂设计分析过程工程实用化,具有工程应用价值。该方法同样可推广到磨削、车削的颤振分析。     

The influence of cryogenic cooling on milling stability

Cryogenic cooling is emerging as an effective process for high performance machining. However, the influence of cryogenic cooling on milling stability is seldom reported. This paper involves experimental study on the effect of cryogenic cooling on milling stability, using a dedicated cryogenic cooling system to applying liquid nitrogen (LN2) jet to the cutting zone. We observe that cryogenic cooling leads to higher stability limit compared with conventional milling operations, which indicates that the cutting efficiency can be improved greatly in LN2 environment as opposed to the conventional one. The stability improvement is explained from the perspective of machining dynamics parameters variation between the two conditions. Cutting force coefficients and modal parameters of spindle-tool system are identified during cryogenic machining, then milling stability lobe diagrams are predicted by time domain and frequency domain methods. On the basis of milling stability analysis, the enhancement of stability boundary is attributed to the significant reduction of cutting force coefficients during cryogenic cooling. Additionally, the experiment result indicates that cryogenic cooling decreases the dominant modal frequency of the spindle-tool system, which shifts the milling stability boundary slightly to lower spindle speed range. The explanations are verified by a plenty of cutting tests.     

基于高速加工的加减速控制方法研究及实现

加减速控制是CNC系统开发的关键技术之一,文章通过对高速加工过程中轮廓误差和加、减速引起的滞后误差进行了详细分析,提出了一种基于数据库的采用不同形状的加、减速曲线插补前加减速控制方法,适合于高速加工的柔性自动加减速控制,CNC能根据实际情况改变升降速控制曲线,有效改善机床运行的平稳性,减少加减速引起的滞后误差,实现快速、精确的位置伺服控制,使机床运动的动态特性达到最佳,文章对高速CNC系统开发具有重要的参考意义。     

直行工况下分布式电动汽车四轮转速同步控制

多电机同步控制系统是车辆安全行驶的核心内容之一.为了提高分布式电动汽车在直线行驶时的可靠性以及控制精度,提出一种采用转矩状态观测器的改进型偏差耦合多电机同步控制策略.结合矢量控制算法,分析了偏差耦合结构中速度补偿器的特点并进行改进.根据多电机同步系统中同步误差与跟踪误差的控制要求,进一步给出多电机同步转矩状态观测器的设...     

Model-based chatter stability prediction for high-speed spindles

The prediction of stable cutting regions is a critical requirement for high-speed milling operations. These predictions are generally made using frequency response measurements of the tool/holder/spindle set, obtained from a non-rotating spindle. However, significant changes in system dynamics occur during high-speed rotation. In this paper, a dynamic model of a high-speed spindle-bearing system is elaborated on the basis of rotor dynamics predictions, readjusted with respect to experimental modal identification. Variations in dynamic behaviour according to speed range are then investigated and determined with accuracy. Dedicated experiments are carried out in order to confirm model results. By integrating the proposed speed-dependant transfer function into the chatter vibration stability approach of Budak–Altintas [S. Tobias, W. Fishwick, Theory of regenerative machine tool chatter, The Engineer February (1958)] a dynamic stability lobes diagram is predicted. The proposed method enables a new stability lobes diagram to be established that takes into account the effect of spindle speed on dynamic behaviour. Significant variations are observed and allow the accurate prediction of cutting conditions. Finally, experiments are performed in order to validate chatter boundary predictions in practice. The proposed modelling approach can also be used to qualify a spindle design in a given machining process and can easily be extended to other types of spindle.