柔性电子齿轮箱设计及精度控制方法研究

发布时间：2018-02-23 23:27

本文关键词： 电子齿轮箱数控齿轮加工滚齿插齿展成运动多轴联动非圆齿轮柔性　出处：《合肥工业大学》2014年博士论文　论文类型：学位论文

【摘要】：电子齿轮箱是一种特殊的多轴同步运动控制技术,可以实现复杂的多轴耦合联动关系,具有传动比范围宽、传动精度高、调整方便等特点。电子齿轮箱的基本功能是代替机械传动链,实现两个或多个运动的定速比或变速比控制,保证各轴运动之间严格的同步关系。在数控齿轮加工机床中,采用电子齿轮箱控制模块,可以实现多坐标轴按照给定的约束关系进行同步运动。采用软件式电子齿轮箱控制策略,不仅可以实现滚齿机和插齿机等齿轮机床加工常规圆柱齿轮对多轴联动的要求,还能实现非圆齿轮加工的变比传动要求。在齿轮的展成加工过程中,齿轮形状的产生依赖于刀具与工件的耦合运动及进给附加运动的多轴联动关系,该运动关系由电子齿轮箱控制实现,其精度控制不仅包含刀具路径轨迹本身的轮廓精度,还包含从运动轴与主运动轴之间的同步精度。本文设计了适用于齿轮数控展成加工的柔性电子齿轮箱结构,使其在自主研发的齿轮加工数控系统中实现,并深入研究了电子齿轮箱的精度控制方法。论文的主要研究内容如下： 1.通过对滚齿、插齿及非圆齿轮加工原理的分析和研究,推导出滚齿加工数学模型、插齿加工数学模型及非圆齿轮加工数学模型,构建了一种主从式复合结构的柔性电子齿轮箱,通过电子齿轮箱控制系数和数控轴定义的改变,形成滚齿加工电子齿轮箱、插齿加工电子齿轮箱(电子螺旋导轨)及非圆齿轮加工电子齿轮箱,提出柔性电子齿轮箱的概念,充分展现了软件式电子齿轮箱具有易改变、可重构的柔性特征。 2.提出将柔性电子齿轮箱与插补模块相结合,形成柔性电子齿轮箱插补模块,在嵌入式多CPU数控系统硬件平台上,采用模块化可重构思想,设计了数控系统总体架构,详细剖析了数控系统软件内部的信息流向,将柔性电子齿轮箱无缝地嵌入在齿轮加工数控系统中。在自行开发的嵌入式齿轮加工数控系统中实现了柔性电子齿轮箱的NC控制,通过程序运行实验数据与理论计算数据的对比分析,说明了柔性电子齿轮箱软件执行的正确性。 3.详细研究了数控系统常用轮廓精度和跟踪精度的基本控制策略,分析其控制结构和试用条件,建立了柔性电子齿轮箱的基本控制模型。根据柔性电子齿轮箱的结构特点,选择合适的增益匹配方式,推导出增益匹配数学模型,并在闭环数控实验平台上验证了增益匹配模型的有效性。考虑到增益匹配在一定程度上会带来跟踪精度的降低,结合柔性电子齿轮箱运动过程中刀具轨迹的特点,将交叉耦合控制模型应用在有多轴联动要求的进给轴之间,建立其交叉耦合补偿模型,并在闭环数控实验平台上验证了交叉耦合控制模型的有效性。由于本文所提出的电子齿轮箱控制模型对工作台回转轴的跟踪精度有较高要求,故研究了零相前馈控制方法,可以在精确建立系统模型并且系统超前信号已知的情况下实现单轴的高精度跟踪控制。 4.研究了由前馈控制器和交叉耦合控制器构成的复合式交叉耦合控制器的实现原理,并详细分析了该控制结构的设计步骤及系统稳定性,证明该控制器可以同时提高系统的轮廓精度和跟踪精度。以圆柱斜齿轮的轴向滚切为例,从加工工艺和几何的角度分析了电子齿轮箱控制误差的产生原因,并对相关误差的计算公式进行推导,结合主从式电子齿轮箱的结构特点与复合式交叉耦合控制器的设计原理,构建了复合式交叉耦合柔性电子齿轮箱结构模型,采用Matlab仿真的形式验证了复合式交叉耦合柔性电子齿轮箱具有较好的控制效果。.研究了模糊控制原理和生物免疫调节机理,将两者与PID控制相结合,构成模糊免疫PID控制器,并将这种智能控制算法应用在复合式交叉耦合电子齿轮箱的位置控制环节,仿真结果表明该控制方法可以进一步提高电子齿轮箱的控制精度。 5.将复合式交叉耦合柔性电子齿轮箱模型与主从式电子齿轮箱模型分别嵌入齿轮加工数控系统中,采用轴向滚切法进行实验,实验结果表明复合式交叉耦合柔性电子齿轮箱具有较好的控制精度,并在此基础上做了对角滚切实验及电子齿轮箱控制精度分析,验证了圆柱齿轮滚切加工电子齿轮箱软件具有精确的控制功能；采用电子螺旋导轨实现圆柱斜齿轮插齿加工运动控制实验,并对运动过程中各轴的位置轨迹及各轴的跟踪误差进行采集和分析,结果表明电子螺旋导轨可以精确实现圆柱斜齿轮的插齿加工运动控制；采用非圆滚齿加工电子齿轮箱实现一阶椭圆齿轮的加工运动控制,采用非圆插齿电子齿轮箱实现三阶椭圆齿轮的加工运动控制,并分别对运动过程数据进行了采样分析,实验结果表明柔性电子齿轮箱可以精确实现非圆齿轮加工所要求的多轴联动运动控制关系。 6.最后本文将电子齿轮箱控制软件成功的应用于自主研发的齿轮加工数控系统中,并将该数控系统与重庆机床厂生产的YS3118CNC5滚齿机床及天津第一机床总厂生产的YK5132B插齿机床配套。在自主研发的滚齿数控系统的控制下,完成了标准测试齿轮的加工,其中滚齿机床所加工的标准直齿轮精度可达5级,标准斜齿轮精度可达7级,插齿机床所加工的标准直齿轮精度可达6级。充分证明了本文所提出的柔性电子齿轮箱在实际加工应用中的高精度、可靠性和实用性。
[Abstract]:The electronic gear box is a kind of special multi axis synchronous motion control technology, multi axis coupling relationship can realize complex, with a wide range of transmission ratio, high transmission precision, easy adjustment and so on. The basic functions of electronic gear box is used instead of mechanical transmission chain, to achieve two or more fixed ratio or a variable motion than the control, ensure strict synchronous relation between each axis. In NC gear machine, electronic gear box control module, can realize multi axis according to the constraints of the given synchronous movement. By using the software of electronic gear box control strategy can not only achieve the requirements of gear hobbing machine and gear slotting machine etc. conventional machining of cylindrical gear of multi axis linkage, can realize the transmission ratio of noncircular gear machining requirements. In gear machining process, which depends on the shape of gear cutter and workpiece The multi axis linkage relationship between coupling motion and feed additional motion is realized by electronic gearbox control. The accuracy control includes not only the contour accuracy of tool path itself, but also the synchronization accuracy between the motion axis and the main motion axis.
In this paper, a flexible electronic gearbox structure suitable for gear NC generating process is designed, which is implemented in a self-developed gear manufacturing CNC system, and the accuracy control method of electronic gearbox is further studied.
1. through the hobbing, inserted and non analysis and Research on circular gear hobbing machining principle, mathematical model, mathematical model and slotting machining of noncircular gear machining model, builds a flexible electronic gear box a master-slave type composite structure, control coefficient and NC axis defined by electronic gear box change, the formation of hobbing electronic gear box, gear shaping electronic gear box (electronic spiral rail) and noncircular gear machining electronic gear box, put forward the concept of flexible electronic gear box, full software type electronic gear box is easy to change, flexible features can be reconstructed.
2. the flexible electronic gear box and the interpolation module combination, form a flexible electronic gear box interpolation module in the hardware platform of embedded multi CPU CNC system, modular reconfigurable idea, designed the overall architecture of the CNC system, a detailed analysis of the CNC system software in the information flow, will be seamlessly embedded flexible electronic gear the box in gear machining CNC system. In embedded gear machining CNC system developed by the realization of flexible electronic gear box NC control, through the program of experimental data and the calculated data comparative analysis, illustrate the correctness of the flexible electronic gearbox software implementation.
3. a detailed study of the basic control strategy commonly used contour accuracy and tracking accuracy of CNC system, analyzes its control structure and operating conditions, establish the basic control model of flexible electronic gear box. According to the structure characteristics of flexible electronic gear box, select the appropriate gain matching, derived gain matching mathematical model, and verify the effectiveness gain matching model in closed loop NC experimental platform. Considering the gain, to a certain extent will reduce the tracking precision, combined with the characteristics of the tool path of flexible electronic gear box in the process of movement, the cross coupling control is applied in Multi Axis axis requirements, establish the cross coupling compensation model, and to verify the effectiveness of the proposed control model of cross coupling in closed loop NC experimental platform. Because the electronic gear box control model proposed in this paper to rotary table The accuracy of axis tracking is high, so the zero phase feedforward control method is studied. It can achieve single axis high precision tracking control under the condition of accurately establishing the system model and the system's leading signal is known.
4. realization of the principle of the composite cross coupling controller consists of feedforward controller and cross coupled controller, and a detailed analysis of the stability of the control system design steps and structure, proved that the controller can improve system accuracy and tracking accuracy. The contour to the axial helical gear hobbing as an example, analysis of the electronic gear the causes of the error control box from the machining process and geometry, and the calculation formula of relative error was derived, the design principle of master-slave structure according to the characteristics of electronic gear box and composite cross coupling controller, constructed a composite cross coupled flexible electronic gear box structure model, using Matlab simulation to verify the composite form cross coupled flexible electronic gear box has a better control effect. On the principle of fuzzy control and immune regulation mechanism, the two Combined with PID control, a fuzzy immune PID controller is constructed, and the intelligent control algorithm is applied to the position control part of the compound cross coupled electronic gearbox. The simulation results show that the control method can further improve the control accuracy of the electronic gearbox.
5. composite cross coupled flexible electronic gear box model and master-slave electronic gear box model are respectively embedded CNC gear machining, the axial hobbing method, the experimental results show that the composite cross coupling flexible electronic gear box has better control accuracy, and on the basis of the diagonal roll cutting experiment and electronic gear box control precision analysis, verify the cylindrical gear hobbing electronic gearbox software has accurate control function; using electronic spiral helical gear tooth movement guide insert process control experiment, and to collect and analyze the trajectory of the movement of the shaft in the process and the axis of the tracking error, the results show that the electronic spiral guide can to achieve precise motion control inserted tooth machining cylindrical helical gear; non circular gear hobbing machining electronic gear box movement order elliptic gear control For non circular gear electronic gear box realization of three order elliptic gear machining motion control, and the movement process of data were collected and analyzed, the experimental results show that the flexible electronic gear box can accurately realize multi axis motion non circular gear machining control system.
6. finally the gear machining CNC system of electronic gear box control application software is successful in the independent research and development, and the CNC system and Chongqing machine tool factory production of YS3118CNC5 rolling factory of machine tool and the Tianjin first machine tool production YK5132B machine. In the control gear hobbing CNC system developed under the complete the processing standard test of gear hobbing machine, the processing precision can reach 5 level standard spur gear, helical gear standard precision can reach 7, slotting machine processing standard spur gear precision can reach 6. Fully demonstrated the high accuracy in the actual processing and application of flexible electronic gear box is proposed in this paper, the reliability and practicability.

【学位授予单位】：合肥工业大学
【学位级别】：博士
【学位授予年份】：2014
【分类号】：TH132.4

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