工业机械臂交流伺服控制系统关键技术研究

发布时间：2018-01-09 15:03

本文关键词：工业机械臂交流伺服控制系统关键技术研究　出处：《中国农业机械化科学研究院》2017年博士论文　论文类型：学位论文

【摘要】：交流伺服控制系统在现代工业自动化运动控制领域具有无可代替的地位,工业应用主要包括机器人、高精度数控机床和其他高精度运动控制机械。尤其在机器人领域,交流伺服系统得到了大量的应用,工业机器人是拥有多自由度的工业机械臂的集合体,每个运动关节至少需要一套交流伺服系统,由于机器人应用场合对伺服系统通讯的实时性及同步性、系统可靠性及精度提出了更高的要求,以及我国机器人专用交流伺服系统起步晚,应用经验少等原因,工业机械臂交流伺服系统的大部分市场被国外品牌所占领。本文针对工业机械臂交流伺服系统的关键技术进行深入研究,通过对工业机械臂专用伺服控制系统的应用特点的分析,在交流伺服系统转矩观测器、在线参数变数、通信总线及伺服系统全数字化设计等方面做了大量的理论分析和试验研究,并研发了基于EtherCAT总线通信的高性能全数字化工业机械臂双轴交流伺服控制系统。本文的主要研究内容包括:(1)提出了空间矢量脉宽调制矢量控制算法在现场可编程门阵列(Field-Programmable Gate Array,FPGA)中的实现方法。在对交流永磁同步电机(PMSM)的数学模型进行分析的基础上,对交流伺服电机坐标变换原理及基本思路进行了详细的阐述,并对交流伺服系统中的应用最为广泛的电压空间矢量脉宽调制技术(Space Vector Pulse Width Modulation,SVPWM)原理进行了论述,完成了基于FPGA的SVPWM矢量控制算法的研究及实现。(2)设计了交流伺服控制系统的三闭环数学模型。根据现代控制理论分析了交流伺服控制系统各环节的传递函数,为文中负载转矩观测器及基于辨识结果参数自整定的实现提供理论依据,并依此建立了交流伺服控制系统电流环、速度环和位置环三闭环串级控制结构中各环路的数学模型,讨论分析了电流、速度和位置控制调节器的设计方法,并且通过仿真试验对控制器设计的正确性进行了验证,为后文中为进一步提高系统性能研究提供基础。(3)提出了基于李雅普诺夫Lyapunov原理负载转矩观测器的设计方法以及基于负载转矩辨识结果速度环参数在线优化设计方法。由于工业机械臂在不同的应用场合中负载转矩不同,会影响交流伺服系统的控制性能,为了提高系统的可靠性,利用永磁同步电机定子转轴电流和转速方程构建的电机机械运动动力学方程,设计了基于Lyapunov负载转矩观测器,并根据观测器估计结果对速度环控制器进行再设计,实现了速度环参数在线优化。通过仿真和台架试验证明,系统速度的跟踪性能和转矩响应能力得到了有效提高,改善了伺服系统的动态性能,增强了交流伺服控制系统的鲁棒性。(4)提出了低成本EtherCAT从站小型化、模块化、快速化设计方法。根据工业机械臂伺服控制系统对通讯实时性和可靠性的要求,采用基于FPGA IP核实现的EtherCAT总线通讯技术,使数据链路层和应用层在FPGA内高度集成,从而实现了单片FPGA代替EtherCAT从站控制芯片(ESC)和从站微处理器芯片(从站协议栈)的功能,完成了 EtherCAT模块化、易移植性、小型化的设计。并对通讯过程中的传输延时进行了理论分析计算,结合板级对基于FPGA设计的EtherCAT总线接口进行了同步性和实时性验证试验,结果表明此设计方案有效,满足工业机械臂交流伺服系统对总线通讯功能的要求。(5)研制了基于EtherCAT总线通信的高性能全数字化工业机械臂双轴交流伺服控制系统。完成了工业机械臂交流伺服控制系统的数字化设计;搭建了主电路、检测保护电路等数字化交流伺服系统硬件平台,开发了交流伺服系统软件,研制了基于DSP+FPGA架构为控制器的交流伺服电机矢量控制系统。(6)试验和仿真。对研制的工业机械臂交流伺服系统进行了仿真及试验测试,结果表明:该系统支持三相380V±15%,电流环、速度环、位置环控制周期为62.5us;工业机械臂末端速度为0.2m/s时,其位置稳定时间为0.026ms,位置超调量为0.111mm;1m/s时,其位置稳定时间为0.09ms,位置超调量为0.123mm,符合工业机械臂对伺服控制系统的要求,具有较好的鲁棒性与实用性。
[Abstract]:AC servo control system control field has no place in the modern industrial automation, industrial applications including robot, high-precision CNC machine tools and other high precision motion control machine. Especially in the field of robotics, AC servo system has been widely used, is a collection of industrial robot has more degrees of freedom robot arm. Each joint movement requires at least a set of AC servo system, the robot applications of real-time and synchronization of communication of servo system, system reliability and accuracy of the proposed higher requirements, as well as for AC servo system of robot in China started late, less experience, most of the market of industrial manipulator of AC servo system occupied by foreign brands. This paper deeply researches the key technology for industrial manipulator of AC servo system, based on the industry Analysis of application characteristics of special manipulator servo control system in AC servo system, torque observer, parameter variables, the theoretical analysis and experimental study of a large number of communication bus and digital servo system design, and developed a EtherCAT bus communication of high performance digital industrial manipulator double servo control system based on the main contents of this paper include: (1) proposed SVPWM vector control algorithm in field programmable gate array (Field-Programmable Gate Array, FPGA). The implementation method of AC permanent magnet synchronous motor (PMSM) analysis based on the mathematical model, and the basic thought of AC servo motor coordinate transform principle in detail, and the application of AC servo system in the voltage space vector PWM (Space Vector Puls wide E Width Modulation, SVPWM) principle is discussed, the research and Realization of SVPWM vector control algorithms based on FPGA. (2) designed three closed-loop mathematical model of AC servo control system. Based on the modern control theory of AC servo control of each part of the system transfer function, as the load torque observer and self realization the setting provides a theoretical basis for the parameter identification results based on, and established the AC servo control system mathematical model of current loop, speed loop and position loop on the loop level three closed-loop control structure, discusses the current, speed and position control of the regulator design method, and verify the correctness of the controller design through simulation test for the research to further improve the performance of the system provides the basis. (3) proposed Li Yapu Ivanov Lyapunov load torque observer is designed based on the principle of Design method and optimization method based on the load torque identification of speed loop parameters online. Due to the industrial manipulator in different applications in different load torque, will affect the control performance of AC servo system, in order to improve the reliability of the system, the dynamic motor mechanical motion equation using permanent magnet synchronous electric machine stator shaft construction current and speed equation the design of Lyapunov, a load torque observer based on observer and according to the estimation results of speed loop controller design, realization of the on-line optimization loop parameters speed. Through the simulation and experiment results show that the tracking performance of torque and speed of the system response ability is effectively improved, and improve the dynamic performance of servo system, robustness AC servo control system. (4) proposed a low cost EtherCAT from the station miniaturization, modularization, fast design method according to the work. The requirements of real-time and reliability of communications industry manipulator servo control system using EtherCAT bus communication technology FPGA IP core implementation based on the data link layer and application layer in FPGA highly integrated, so as to realize the monolithic FPGA instead of EtherCAT from the station control chip (ESC) and slave microprocessor chip (slave protocol stack) function, complete the EtherCAT modular, easy portability and miniaturization design. And the transmission delay in the process of communication is analyzed and calculated in theory, combined with the board level of synchronization and real-time test of EtherCAT bus interface based on FPGA, the results show that this design scheme is effective, meet the requirements the bus communication function of industrial manipulator servo system. (5) developed EtherCAT bus communication of high performance digital industrial manipulator double servo control system based on the finished industrial machine. Digital design of mechanical arm of AC servo control system; build the main circuit, the hardware platform of detection and protection circuit of the digital AC servo system, AC servo system is developed based on DSP+FPGA software development framework for AC servo motor vector control system. The controller (6) test and simulation. For the developed industrial manipulator servo system the simulation and test results show that the system supports three 380V + 15%, current loop, speed loop, position loop control cycle is 62.5us; industrial manipulator speed is 0.2m/s, the position of stable time is 0.026ms, the position overshoot is 0.111mm; 1m/s, the position of stable time is 0.09ms. The position of the overshoot is 0.123mm, to meet the requirements of the servo control system of industrial manipulator, robust and practical.

【学位授予单位】：中国农业机械化科学研究院
【学位级别】：博士
【学位授予年份】：2017
【分类号】：TP273

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