基于IPC和FPGA的滚齿加工运动控制系统研究

发布时间：2019-06-08 18:22

【摘要】：齿轮是机械传动中的重要组件,特别是非圆齿轮,能够实现普通齿轮无法替代的功能。然而传统的滚齿机床对于非圆齿轮的加工,存在加工困难,精度和效率低的问题,另外,目前齿轮加工的数控系统大部分是在机床的配套数控系统基础上实现二次开发,但是不能嵌入自主研发的控制算法,从而限制了系统的控制精度。为解决这些问题,现研究并设计一款用于数控滚切加工非圆齿轮的基于IPC、以PCIE总线连接上下位机、将FPGA作为主控单元的专用运动控制系统。其中,FPGA运动控制卡是连接上位机与伺服机构的重要组成部分,发挥着关键性的作用。本文主要研究内容如下:首先,论文分析了滚齿机床的运动联动关系以及建立了滚齿需要的数学模型,并根据数学模型研究了非圆齿轮在滚切加工时的运动特性,为非圆齿轮在设计阶段对阶数和偏心率的选取提供参考。此外,分析了分齿运动方式,采用了滚刀角速度恒定,工件角速度变化的方案,为电子齿轮箱的设计做准备。其次,论文采用FPGA运动控制卡实现电子齿轮箱功能。在电子齿轮箱的设计过程中,采用主从式结构;为提高齿轮箱的响应精度,采用锁相环和脉冲分频技术;为实现速度、位置等控制精度,采用前馈+PID控制。此外,为缓解FPGA运动控制卡的压力,达到高速、高精度运动控制,在工控机IPC上设计应用程序实现速度、位移等实时数据的预处理(粗插补)。最后,根据功能目标,规划了运动控制卡总体方案,选取了FPGA开发板的型号,并给出了电子齿轮箱部分功能模块的时序仿真;采用了PCIE作为通讯接口总线插入IPC卡槽内;为提高控制卡的硬件集成度和可靠度,设计了FPGA外部接口功能,有编码器接口、D/A转换接口等,并给出了电路图和时序仿真。
[Abstract]:Gear is an important component in mechanical transmission, especially non-circular gear, which can not be replaced by ordinary gear. However, for the machining of non-circular gears, the traditional gear roller machine tool has the problems of difficult machining, low accuracy and low efficiency. In addition, most of the CNC systems of gear machining are developed on the basis of the supporting CNC system of the machine tool. However, the self-developed control algorithm can not be embedded, which limits the control accuracy of the system. In order to solve these problems, a special motion control system based on IPC, to connect upper and lower computer with PCIE bus and FPGA as main control unit is studied and designed for NC rolling machining of non-circular gears. Among them, FPGA motion control card is an important part of connecting upper computer and servo mechanism, and plays a key role. The main contents of this paper are as follows: firstly, the motion linkage relationship of gear roller machine tool is analyzed and the mathematical model of gear hobbing is established, and the motion characteristics of non-circular gear in rolling machining are studied according to the mathematical model. It provides a reference for the selection of order and eccentricity of non-circular gears in the design stage. In addition, the tooth separation movement mode is analyzed, and the scheme of constant hob angular velocity and workpiece angular velocity is adopted to prepare for the design of electronic gearbox. Secondly, the FPGA motion control card is used to realize the function of electronic gearbox. In the design process of electronic gearbox, master-slave structure is adopted; in order to improve the response accuracy of gearbox, phase-locked loop and pulse frequency division technology are adopted; in order to realize the control accuracy of speed and position, feedforward PID control is adopted. In addition, in order to relieve the pressure of FPGA motion control card and achieve high speed and high precision motion control, an application program is designed on the industrial control computer IPC to realize the preprocessing of real-time data such as speed and displacement (rough interpolation). Finally, according to the functional goal, the overall scheme of the motion control card is planned, the model of FPGA development board is selected, and the timing simulation of some functional modules of the electronic gearbox is given, and PCIE is used as the communication interface bus to insert into the IEC card slot. In order to improve the hardware integration and reliability of the control card, the external interface function of FPGA, encoder interface, D 鈮，

本文编号：2495479