基于遗传神经网络的直线伺服系统定位误差补偿

针对数控直线伺服系统的定位误差补偿,采用激光干涉仪测量工作台的定位误差,建立基于RBF算法的神经网络误差模型.提出遗传算法的训练方案优化RBF的网络参数,为了评价优化后RBF网络预测的精度,运用部分误差样本进行训练和仿真.构建了以DSP为核心的直线电机定位误差实验平台,根据误差校正值进行误差实时补偿实验.仿真和实验结果表明:经过遗传算法训练的神经网络模型对工作台的误差具有良好的学习能力和泛化能力,工作台定位精度显著提高.     

基于PMAC快速PID整定与精度补偿研究

数控系统中动态性能与定位精度决定了加工质量及效率,为满足磨床数控系统控制要求及加工精度,研究快速整定PID方法及提高定位精度补偿方式,基于PMAC运动控制器搭建五轴数控工具磨床的全闭环伺服系统。针对伺服系统动态性能差、跟随误差较大等问题,阐述了基于PMAC的前馈-PID陷波滤波器伺服算法,提出了快速PID整定方法。针对定位精度差的问题,论述了定位补偿原理及方式,使用激光干涉仪进行目标点测量后制作螺距补偿和反向间隙补偿表。结果表明,PID整定方法得当,五轴磨床的动态响应性能良好,跟随误差大幅度减小;定位补偿措施合理,定位精度和重复定位精度大幅度提高,达到设计要求的3μm以内。     

基于PMAC开放式数控系统的定位精度控制

伺服控制方法是影响机床定位精度的关键因素之一，要保证数控系统的高定位精度，应采用合理的伺服控制方法。文章分析了在基于PMAC的开放式数控系统中提高定位精度的具体方法，对PMAC所提供的“PID＋速度／加速度前馈＋陷波滤波器”的伺服控制算法和误差补偿功能进行了阐述，将螺距误差补偿和间隙误差补偿应用于航空航天领域某型测控系统的系统误差补偿中，取得了良好效果。     

数控玻璃钻孔加工技术应用

普通的玻璃钻孔机床靠人工定位,误差大、工效低、劳动强度高.新型数控玻璃钻孔加工设备,将工作台设计为X-Y二坐标联动的滑台,用数控装置和侍服系统驱动,并增设刀具自动补偿功能,实现了高精度自动化加工.     

带有摩擦前馈补偿的伺服控制器设计的研究

为了克服系统摩擦给系统带来的稳态误差和低速爬行问题，利用控制策略来补偿摩擦非线性对系统运动的负面影响是降低摩擦非线性负面影响的有效且节俭的途径。首先对交流伺服驱动的工作台进给系统进行了摩擦力测量实验，根据实验数据，建立了用于摩擦补偿控制的简化Stribeek摩擦力模型：由于XY工作台进给传动机构中存在的伺服滞后和摩擦是降低工作台位置跟踪精度两个主要因素，所以一个完整的前馈补偿方案应该包括两个部分：摩擦前馈补偿器和命令前馈补偿器。分别对命令前馈控制器和摩擦前馈补偿控制器进行了理论设计，借助于现有的GT-400运动控制器的功能，添加摩擦力补偿模块提升了工作台的跟踪精度，并和没有前馈补偿的传统控制器进行了对比研究，实验结果表明带有命令前馈和摩擦前馈的控制方案能取得更好的控制性能。     

BF-850B立式高速数控机床精度检测及误差补偿研究

机床在加工的过程中会因为物理变形和热变形,使得加工零件的精度难以保证,因此必须对运动中的影响机床精度的误差源进行误差分析及实时补偿。利用激光干涉仪和球杆仪对数控机床定位精度进行检测,并建立了关于机床变形的检测数据的数学模型,确定了定位误差补偿方法,同时以具体的数控机床为例进行了定位精度检测与误差补偿,最后对补偿效果进行了分析。结果表明：该定位误差检测及补偿方法具有可行性与实用性,使数控机床的定位精度得到了显著的提高。     

精密工作台直线电机推力波动补偿研究

为了抑制直线电机推力波动的影响,提高精密工作台的轨迹跟踪精度,采用了基于跟踪误差分离的方法,将由推力波动引起的跟踪误差分量取出,设计推力波动前馈补偿器,构成PD 推力波动前馈补偿的运动控制结构.通过实验,与没有推力波动补偿的PD控制相比较,以50mm/s的速度匀速运动时工作台的轨迹跟踪精度提高了1μm,以120mm/s的速度匀速运动时工作台的轨迹跟踪精度提高了4μm.结果表明,该控制方法可以较好的抑制直线电机的推力波动.     

机床工作台滚珠丝杠高速驱动系统精密定位机械特性研究

文章提出了机床工作台高速运动定位过程中，存在着加速状态时由滚珠丝杠驱动时工作台弹性变形和工作台与滚珠丝杠联结件刚度引起定位精度误差的问题。对滚珠丝杠和工作台结构在高速运动下受力状态进行分析建立了力学模型。     

数控机床定位精度检测及补偿方法研究

为了提高数控机床的定位精度,保证加工工件质量,需辨识影响机床精度的误差源并对误差进行补偿。论述了利用激光干涉仪对数控车床定位精度进行检测的原理,建立了检测数据处理的数学模型,确定了定位精度误差补偿方法,结合具体的数控车床实例进行了定位精度的检测与分析,根据分析结果实现了反向间隙误差与丝杠螺距误差补偿,最后对定位精度的补偿效果进行了评价。实际应用结果表明：该定位精度检测及补偿方法具有可行性,数控车床的定位精度得到了显著地提高。     

极坐标数控铣齿机回转台运动精度干涉测量

根据极坐标数控铣齿机床回转工作台的运动特点,采用Renishaw双频激光干涉仪测量回转台的运动精度,对干涉仪角度测量原理和光路调节方法进行了详细探讨,获得了准确的回转台定位精度和重复定位精度数据,最后根据已建立的几何误差模型,并利用辨识得到的误差数据,可以准确计算出机床的各项几何误差,为误差补偿提供了理论依据。     

Geometric error measurement and identification for rotary table of multi-axis machine tool using double ballbar

In this paper, comprehensive geometric errors, including linkage errors and volumetric errors, of a rotary table are measured totally by employing a double ballbar and obtained by a two-step identification procedure. The derivations of the center of the ball installed on the table are measured in the error sensitive directions with newly developed serial of two axes controlled circular paths. Hence, there are nine results measured from three mounting positions of the ball at the same rotation angle. These results are used to form the identification model based on the homogeneous transformation. Moreover, a sensitivity analysis method is applied to select the optimum installation parameters of the ballbar to diminish the influence of the inaccuracy of the measurement parameters. As the mounting position errors of the socket on the table are inevitable during the installation of the balls, a new correction procedure is developed as well. Finally, an experiment is conducted on the four-axis machining center. The comparison results between the predicted errors and the measured results are shown to verify the proposed method.     

Construction of an error map of rotary axes on a five-axis machining center by static R-test

This paper proposes an efficient and automated scheme to calibrate error motions of rotary axes on a five-axis machining center by using the R-test. During a five-axis measurement cycle, the R-test probing system measures the three-dimensional displacement of a sphere attached to the spindle in relative to the machine table. Location errors, defined in ISO 230-7, of rotary axes are the most fundamental error factors in the five-axis kinematics. A larger class of error motions can be modeled as geometric errors that vary depending on the angular position of a rotary axis. The objective of this paper is to present an algorithm to identify not only location errors, but also such position-dependent geometric errors, or “error map,” of rotary axes. Its experimental demonstration is presented.     

Identification and compensation of geometric errors of rotary axes on five-axis machine by on-machine measurement

The geometric errors of rotary axes are the fundamental errors of a five-axis machine tool. They directly affect the machining accuracy, and require periodical measurement, identification and compensation. In this paper, a precise calibration and compensation method for the geometric errors of rotary axes on a five-axis machine tool is proposed. The automated measurement is realized by using an on-the-machine touch-trigger technology and an artifact. A calibration algorithm is proposed to calibrate geometric errors of rotary axes based on the relative displacement of the measured reference point. The geometric errors are individually separated and the coupling effect of the geometric errors of two rotary axes can be avoided. The geometry error of the artifact as well as its setup error has little influence on geometric error calibration results. Then a geometric error compensation algorithm is developed by modifying the numeric control (NC) source file. All the geometric errors of the rotary errors are compensated to improve the machining accuracy. The algorithm can be conveniently integrated into the post process. At last, an experiment on a five-axis machine tool with table A-axis and head B-axis structure validates the feasibility of the proposed method.     

Analysis of circular trajectory equivalent to cone-frustum milling in five-axis machining centers using motion simulator

The present paper describes the effect of the half apex angle of the cone-frustum on the motion trajectory under simultaneous five-axis motion and the effect of the sensitive direction of the ball bar when the motion trajectory is measured along the three-dimensional circular conical path. In the present paper, simulation of the measurement by means of a ball bar instrument is mainly conducted using a motion simulator developed previously. In particular, a precise mathematical model was developed to express the pitch errors of the axes of rotation of the five-axis machining center having a tilting rotary table driven by worm gears. In the experiment and simulation, primarily the center position and half apex angle of the cone-frustum were varied. In addition, two sensitive directions of the ball bar were investigated. The motion simulator incorporating the pitch error model can express the detailed trajectories obtained by the ball bar, even if the half apex angle and center position of the cone-frustum and the sensitive direction of the ball bar were changed. Then, the influence of the frictional force of the linear axes of motion, and the backlash and pitch error of the axes of rotation on the circular trajectories were analyzed. In particular, for the case of a half apex angle of 45°, the trajectory due to the errors of the axis of rotation is strongly affected by the sensitive direction of the ball bar.     

A novel simple and low cost 4 degree of freedom angular indexing calibrating technique for a precision rotary table

For calibrating an angular rotary table, either a high precision standard table or a laser interferometer and related optics are normally employed at high cost. This paper establishes a novel, simple and low cost technique to calibrate the 4-degrees-of-freedom (DOF) errors of a rotary table (three angular position errors and one linear position error) for a 360° full circle by employing one reference rotary table, one 1 dimensional (1D) grating and two 2 dimensional (2D) position-sensing-detectors (PSD). With this technique, no highly accurate reference rotary table, but with good repeatability is needed. After two full circle tests, the 4-DOF errors of both the target rotary table and the reference rotary table could be obtained. The system calibration, stability test, system verification and full circle test were completed. The angular stability of this system was less then 2 arc sec, while the displacement stability was less than 1.2 μm.     

Measurement methods for the position errors of a multi-axis machine. Part 1: principles and sensitivity analysis

Accurate measurement of errors is an essential part of error compensation. By using telescoping ball-bars, two measurement methods, characterized by low cost, simplicity of setup, and quick measurements are developed to directly identify the total position errors at the tip of the tool of a multi-axis machine tool without the use of an error model. The first method uses the well known triangulation principle that requires three reference points. The second, referred to as the single socket method, utilizes a single reference point, offering thereby a higher degree of dexterity and flexibility. In addition, sensitivity analysis is used to investigate the accuracy of the two methods with respect to two error factors: errors of the ball-bar system, and location errors of the reference point.     

基于旋量理论的打磨机器人位置精度分析

为建立各误差源与打磨机器人的末端位置误差的对应关系,在基于旋量理论建立了打磨机器人的运动学模型的同时,对可能产生的主要误差源进行了分析,通过误差源之间的几何关系建立误差旋量,从而得到静态误差模型;分析了各单项误差对机器人末端执行器位置误差的影响及各误差源对末端位置误差的显著性影响,为机器人精度优化方案的提出提供可靠的分析参考。分析结果表明:结构误差及传动误差是机器人静态位置精度的主要影响因素,其中结构误差为稳态误差,可以通过精度设计减小或补偿,传动误差需要通过后期的标定来解决。     

带标准分度转台的激光角度干涉仪的不准直误差模型

为了探讨带标准分度转台的激光角度干涉仪在测量过程中的安装不准直误差对测量结果的影响,在分析回转轴转角误差测量原理的基础上,根据测量光路的几何特征变化规律,提出测量系统的不准直误差模型。研究不准直误差变化对转角误差测量结果的影响,明确了为保证最终测量结果的精度在±1″内宜采取的误差控制措施。通过与自准直仪配合高精度多面棱体方法进行比对实验,并利用不准直误差模型对测量结果进行修正后,可以将测量结果的最大差值减小为-0.52″。结果表明所建立的误差模型的正确性,在准确评估和提高测量系统的精度上有一定的推广价值。     

视觉测量在机器人加工过程手眼标定中的应用

针对高精度测量辅助机器人加工的手眼标定,提出一种基于三维视觉测量的精确手眼标定方法,该方法考虑了非线性优化和初值计算中建模误差的影响。为了提高求解精度,在传感器框架中建立了具有更精确参考点的非线性标定模型,提出一种结合传感器测量和机器人位置随机误差的迭代权重优化解。在初值解中,建立考虑基础参考测量误差的测量平差模型,并使用拉格朗日乘子进行求解。仿真对比结果表明：该方法在估计手眼变换参数方面比其他典型方法具有更高的精度。最后通过搭建实验平台,进一步验证了所提方法在求解精度测试上的优越性。     

6UPS并联机构杆长误差标定及其对动平台运动的影响分析

分析了不同误差对并联机构的影响,尤其是杆长误差对动平台姿态误差的影响.建立了采用并联机构运动学反解模型的矢量法误差求解模型;针对6UPS并联刀具机构的结构特点,使用支链分析方法,对由杆长误差引起的动平台误差变化趋势及变化的敏感性方向进行了分析.使用激光干涉仪完成了误差测量实验,使用多组姿态数据的不同组合进行误差计算,获得了优化的杆长误差数据.完成了杆长误差对动平台误差变化影响的数值分析与矢量合成两种方法的验证.