误差输入前馈补偿控制方法及其在滚珠丝杠磨削中的应用

为提高精密滚珠丝杠磨削精度，在激光反馈螺纹磨床误差补偿系统中提出了一种误差输入前馈补偿控制方法。理论分析表明，该方法能显著提高系统的控制精度，改善系统的动态性能。该方法应用于滚珠丝杠磨削中，使加工精度得到明显提高。     

床身导轨的变形法磨削

提高床身导轨磨削精度的方法主要分为两种,第一种是对影响磨削精度的各种因素分别进行修正或控制;第二种方法是对加工总误差进行综合控制和修正,或者根据加工工件的实测总误差进行综合补偿或修正。     

轴对称非球面模具加工中的补偿技术研究

研究精密磨削以及超精研磨轴对称非球面模具中 ,磨削力和速度变化对加工表面精度的影响因素 ,提出一种使用软件技术对加工误差进行补偿控制以提高加工精度的方法。     

导轨磨削精度软件补偿

导轨磨精度软件补偿是将计算机用于控制直线度误差的补偿磨削系统,它主要具有下列功能:1)误差的在线测试;2)数据的实时处理和数学模型的建立;3)计算机控制的补偿磨削加工。实验室和车间现场加工试验表明,系统的补偿加工是成功的。本文阐述补偿系统的工作原理、装置、计算机控制和磨削试验。     

磨加工主动测量控制仪尺寸预报功能研究

磨加工主动测量控制仪应用于磨削中,提高了磨削精度、磨加工效率与磨削的自动化水平。在深入研究主动测量与误差补偿控制的基础上,研究拓展主动测量控制仪的磨加工尺寸预报功能,预报磨加工过程中的超差,为机床系统修正加工状态提供指引。通过对磨加工过程进行分析,对尺寸预报理论的适用性进行研究,构建了磨加工尺寸灰色补偿式滑动平均组合预报模型。通过实验验证分析,模型平均相对误差为0.0067,均方根误差为0.3173,关联度为0.7682,尺寸预报应用于磨加工主动测量控制仪中,提高了主动量仪的精度与智能化程度,提高了磨加工系统地尺寸测量、预报与误差补偿控制的精度。     

基于多体系统理论的非球面磨削误差模型与补偿技术

为提高大中型非球面的磨削精度,从而提高非球面的加工效率,研究轴对称非球面磨削过程的误差模型,并对误差进行补偿.运用多体系统理论,基于一阶线性模型,建立非球面磨削成形的统一误差模型,并且推导各种误差对于最终面形误差的传递函数.基于传递函数特征相似误差集中补偿的方法,将所有趋势项误差转化为砂轮对刀误差以及砂轮形状误差进行补偿,并建立实用补偿模型,从而避免求解、校正各项具体误差.试验结果表明,建立的误差模型和辨识模型正确,可以使面形误差收敛到预期范围,从而解决了轴对称非球面磨削中的精度控制问题.     

精密磨削加工的神经网络误差补偿技术

通过对磨削加工过程中的误差信息进行综合分析,运用人工神经网络的基本方法,建立了基于神经网络理论的精密磨削加工误差补偿模型,并从结构和算法方面进行了详细阐述。给出了对磨削加工进行实时误差补偿的硬件实现方法,并通过样本的合理选择及系统的学习过程提高了该误差补偿系统的补偿能力。     

数控随动磨床加工凸轮方法及其精度补偿策略

针对凸轮随动磨削中因工件轴转速差、伺服系统响应偏差、硬件制造误差等重复性误差影响因素造成的零件制造精度下降问题,将在线测量技术和Sinumerik 840D数控系统的插补表与电子齿轮功能应用到机床运动控制系统中,开展了随动磨削工艺的运动轨迹和控制方案分析,提出了由内嵌在系统PCU上的VB程序来处理在线测量获得的360个离散误差补偿数值,自动生成带插补表与电子齿轮功能的专用加工程序,利用同轴运动叠加控制方法,把补偿值叠加到进给轴上,使带误差补偿数据的凸轮加工NC程序不断根据实际加工状态更新,最后在工程样机上进行了磨削试验。试验结果表明,发动机凸轮轴的廓型最大加工误差降到了2.6μm以下,残余误差主要来源为机械振动、非线性摩擦扰动等随机性偏差。该运动控制和误差补偿方法能在实际加工中较好地补偿重复性误差因素对工件精度产生的影响。     

精密磨削加工的神经网络误差补偿技术

通过对磨削加工过程中的误差信息进行综合分析,运用人工神经网络的基本方法,建立了基于神经网络理论的精密磨削加工误差补偿模型,并从结构和算法方面进行了详细阐述.给出了对磨削加工进行实时误差补偿的硬件实现方法,并通过样本的合理选择及系统的学习过程提高了该误差补偿系统的补偿能力.     

凸轮廓形误差力位融合预测与补偿控制研究

廓形误差是凸轮最重要的精度指标,由于磨削过程复杂,廓形误差通常通过离线抽检获得,难以实现在线补偿控制。提出了一种基于BP神经网络与镜面补偿凸轮磨削力-伺服滞后信息融合廓形误差预测、补偿方法。通过对凸轮磨削过程中影响廓形误差的主要因素分析,将X轴跟随误差、C轴跟随误差、磨削力三项传感器信息作为输入特征,凸轮廓形误差作为输出特征,利用BP神经网络的逼近性能和全局最优特性,建立了凸轮廓形误差预测模型,并提出了凸轮廓形误差镜面补偿方法。进行了预测模型训练与补偿验证,结果表明,该方法能够有效预测凸轮廓形误差,并提高凸轮加工廓形精度。     

滚珠丝杠在线检测及模糊PID补偿算法研究

为提高大型精密滚珠丝杠磨削精度及效率,将在线检测和误差补偿技术应用到丝杠磨削过程中.介绍了系统的构成和主要模块的工作原理,提出了在线综合动态测量及模糊PID补偿方法.开发了基于VC++的滚珠丝杠检测补偿软件,以型号60×06×420-P03R(公称直径mm×公称导程mm×螺纹长度mm-类型·标准公差等级·旋向)的丝杠螺...     

Time-varying positioning error modeling and compensation for ball screw systems based on simulation and experimental analysis

Thermal expansion of ball screw systems affects the machining accuracy of machine tools significantly. This paper intends to provide a comprehensive error compensation method for the time-varying positioning error of machine tools. To confirm the thermal deformation mechanism of ball screw systems, experiments have been designed to study the thermal behaviors of a ball screw system under varying temperature conditions. An exponential algorithm is proposed to predict the temperature variation pattern of the ball screw based on finite element analysis, and the actual thermal boundary conditions of the ball screw system are exactly defined according to the proposed algorithm and the experimental results. Then, a comprehensive compensation model is established based on the decomposition of the initial geometric error and thermal error components. Finally, a real-time error compensation system is developed for machine tools based on the function of external machine original coordinate shift and fast Ethernet data interaction, and satisfactory results have been achieved for the compensation experiments on a machining center.     

误差补偿技术在可持续制造中的应用

可持续制造技术是基于现代的多学科的先进科技成果的综合技术,基于信息技术的现代误差补偿技术,为应用低档次的设备制造高档次零部件提供了一条可行的技术途径.通过对精密丝杠磨削过程误差补偿系统--磨削过程卡补偿系统的功能装置及实现策略的分析,表明该补偿系统具有实用性.     

Geometric error modeling and compensation for large-scale grinding machine tools with multi-axes

Synthesis modeling of a geometric error-based traditional method for large-scale grinding machine tools with six axes is too complicated to perform in a real-time compensator with a built-in position control system, and it is difficult to obtain all of the error elements corresponding to the model. This paper proposed a novel strategy in which a machine may be considered as translation axes and rotary axes, and geometric errors of the translation axes and rotary axis are modeled and the geometric error models of the machine are very simple for real-time error compensation. The volumetric errors of the translation axes are measured using spatial circular curve ball bar test, and every element of the rotary axis is also obtained by a series of considerate ball bar tests. According to the characteristics of a position controller used in the machine, a synthesis error compensation system based on the NUM numerical control system was developed. Error compensation experiments were carried out, and the results show that the accuracy of the machine is improved significantly.     

滚珠丝杠精磨误差的实时补偿与控制

介绍滚珠丝杠精磨误差的实时测量、补偿和控制的原理和方法。由直线感应同步器尺及数显表和微机数据处理与控制系统实现了对滚珠丝杠精磨过程误差的在线精密测量,并由计算机控制补偿机构对磨削过程的误差进行实时补偿。     

高精度滚珠丝杠磨床的设计与开发

针对高精度滚珠丝杠的滚道特点,分析了该机床主要零部件的结构特点和工作原理。结合实际生产,着重阐述主要零部件的有限元分析、表面质量的在线监测方法、热误差分析及补偿技术等方面的研究,这些措施是机床可靠性及安全性的重要保证,为高精度滚珠丝杠磨床的设计制造提供了参考依据。     

Development of a new lapping method for high precision ball screw (2nd report): Design and experimental study of an automatic lapping machine with in-process torque monitoring system

This paper presents a new approach in lapping process in making appropriate condition to improve the manufacturing operations for ball screw. After grinding, high precision ball screw is lapped by highly skilled operators. These operators have the ability to control and maintain the lapping conditions by sensing the lapping torque manually. Prior to lapping process, the effective diameter must be measured to find out the effective threaded profile along the screw shaft. The section which has a large effective diameter will be primarily lapped wherein the lapping torque is high. The aim of this study is to establish a control scheme on the automatic lapping machine for high precision ball screw in both measuring and finishing process. A prototyped horizontal lapping machine with in-process torque monitoring system has been designed, built, and tested. This is to determine the relationship among lapping torque, effective diameter, and error on travel to establish the measurement system to control the finishing operations efficiently and eventually improve and eliminate the various sorts of error components in a ball screw. The experimental results showed that the new lapping method could adequately predict the effective diameter and error on travel by observing the lapping torque.     

The effect of dynamic behavior on surface roughness of ball screw under the grinding force

The dynamic behavior of a ball screw under a moving grinding force and the resulting ball screw surface roughness are investigated. The system includes a ball screw, a headstock, a tailstock, a steady rest, a grinding wheel, and a wheel head. Equations of motion of the system are derived through Lagrangian approach combined with global assumed mode method in this study. The transient responses of the system due to a moving force are evaluated using Runge?CKutta method. Results show that the steady rest can reduce 90% vibration in a grinding process. An equation is proposed to predict the maximum response by the cutting depth. Then we simulate the grain height distribution on the grinding wheel, considering transient response on the ball screw and the grinding wheel. Lastly, the ball screw surface roughness could be simulated via calculating the depth of all working grains. The purpose of using grinding process is that the ball screw needs fine surface roughness. The ball screw surface roughness is influenced by the grain size more than the structure numbers can be.     

丝杠磨削加工热变形误差分析

对于导热问题的求解常用两种方法:有限差分法和有限元法。在丝杠磨削加工中,由磨削热引起的热变形误差是影响丝杠精度的一个主要误差。本文利用有限差分和有限元两种方法对磨削热引起的误差进行了分析,并对理论数据进行了对比。