高速嵌入式数控系统速度前瞻控制算法的研究

为了实现嵌入式数控系统对微小轨迹的高速加工,避免数控设备频繁加减速产生的冲击,提出了一种高速数控加工中根据小线段标志判别前瞻分界点,自动调整前瞻段数的加减速控制前瞻算法,有效简化了连接点衔接速度的计算方法。首先分析了相邻轨迹加工路径衔接速度限制条件,提出了小线段判别条件和自适应前瞻段数的确定方法,然后通过对样条曲线加工代码的30个轨迹点进行仿真实验,结果表明该算法显著缩短了加工时间,速度变化平稳。     

一种小线段的非对称S曲线速度规划与前瞻算法

针对基于小线段高速、高精度数控加工路径,提出并实现了一种具有速度前瞻功能的非对称S曲线加减速规划策略.首先对已知线段总长的加工路径实现非对称S曲线加减速算法进行了阐述,然后基于小线段间的转折角提出了适用于小线段加工的实用前瞻模型.利用模型通过计算小线段间的转折角来对转折处加工速度进行预规划,在实现轨迹精度的前提下使加工速度达到最高,从而实现小线段数控加工时在高速度和高精度之间达到协调.实验结果证明了该算法的有效性和实用性.     

引入路径夹角的粒子群-禁忌搜索寻优的速度前瞻算法研究

对于数控系统中路径为连续微线段的情况,本文提出一种采用路径夹角进行优化的多轨迹速度前瞻算法。首先基于前后路径的约束关系初算衔接速度;其次,利用路径夹角对衔接速度和最大加加速度进行矢量函数映射;最后,将所得的加减速参数带入S加减速模型,得到非对称S型加减速数据。并且采用粒子群-禁忌搜索混合算法对路径夹角的调整系数进行优化,通过熵权法计算适应度函数合成指标的权重,得到全局最优解。结果表明,相较于传统S型加减速,本文采用的算法显著提高了加工效率,具有较高的柔性,极大的提升了加工精度。     

5轴联动数控系统速度控制方法

高速加工过程中,在刀具路径上容易产生过冲,影响加工精度,因此必须提前对加工速度进行优化处理.基于数据采样法,利用当量位移和坐标轴方向系数实现了5轴联动线性插补;利用直线加减速原理进行插补前加减速控制;对速度前瞻控制方法进行了深入探讨,实现了相邻程序段转接处速度优化、连续微小程序段速度计算、减速点提前预测及前瞻程序段数动态选择等.仿真结果表明,速度平滑连续,有效地解决了5轴联动线性插补中的速度控制问题,提高了加工精度和加工效率.     

小线段高速加工的速度模型研究和实现

针对数控插补中离散化进给速度控制的特点，导出了在直线加减速情况下的小线段长度和轨迹形状误差对进给速度的约束条件；完善了小线段高速加工速度衔接数学模型，形成了能实际应用的工程化方法，该方法以给定的最大预处理段数为条件，根据小线段路径的具体形状和长短、速度变化的平滑性和位置误差精度的要求，求解出离散化的进给速度值。同时提出了在指令进给速度实时变化的情况下进给速度的求解方法。仿真结果表明，此数学模型及离散速度的求解方法能实现进给速度的高速衔接，从而大大提高加工效率。     

一种优化轨迹段间衔接速度的自适应前瞻控制

为实现数控系统中轨迹段的高速高精加工,提出一种优化轨迹段间衔接速度的自适应前瞻控制算法。在传统轨迹段间速度衔接模型的基础上,该前瞻算法增加了非对称S曲线加减速控制的轨迹长度约束,并根据相邻两段轨迹的长度变化,自适应规划出轨迹段间的最优衔接速度。通过自主开发的x-y数控系统平台进行验证,综合加工性能试验的加工精度可以达到?0.6 mm,加工效率提高9.8%。结果表明所提出的自适应前瞻算法可避免回溯计算转接点速度时计算量显著增加这一问题,并在加工过程中减少大量微小轨迹段的进给轴频繁启停,从而使相邻轨迹段间衔接速度平滑性、加工效率和加工精度方面相对于传统前瞻算法都有明显提高。     

参数曲线的自适应实时前瞻插补算法

为实现数控加工中进给速度的平滑过渡,减少速度急剧变化时对机床的冲击,提出了一种参数曲线的实时前瞻插补算法。该算法根据加工弓高误差要求自适应地调整进给速度,同时找出速度敏感点。通过把前瞻距离分成两部分的方法,分析速度敏感点,找出最佳的加减速控制点,避免相邻速度敏感点间加减速过程的互相干涉,提早进行加减速控制,防止速度的急剧变化,从而在满足加工精度的同时也满足了机床的加减速性能。通过RT-Linux软数控下的实例,表明该算法能够适应曲线的各种变化,验证了其可行性。     

基于自适应前瞻和预测校正的实时柔性加减速控制算法

为了提高离散小线段的加工效率和质量,提出一种实时柔性加减速控制算法。该算法由三部分组成：前瞻处理部分利用加减速可行性判断条件,保证加减速可达和实时前瞻;速度规划部分在保证速度和加速度连续变化的条件下,实时计算下一插补周期的进给速度;动态修调部分对当前速度规划结果进行调整,及时响应加工中机床参数的改变。实验结果表明,该算法能够实现数控系统的实时柔性加减速控制,支持动态修调,满足实际加工的要求。     

参数曲线柔性加减速前瞻控制算法

针对参数曲线插补的特点,使用S形加减速和三角函数加减速相结合的柔性加减速方法对参数曲线的插补路径进行前瞻控制。在规划前瞻速度过程中,首先根据加工曲线的曲率变化自适应地将前瞻距离分为曲率上升段和曲率下降段。在对前瞻路径进行S形加减速规划时,遇到路径上曲率频繁变化段,为了减小计算量,采用三角函数加减速的方法对速度进行重新规划。这样,在满足机床加减速要求的同时降低了系统计算负荷。仿真结果和实例表明,该算法能够适应复杂曲线的变化,满足高速高精度插补的要求。     

三次多项式型微段高速自适应前瞻插补方法

为实现微段的高速加工,提出一种三次多项式型高速自适应前瞻插补方法,该方法的实现包括前瞻插补预处理和实时参数化插补两部分。插补预处理时,按轨迹转接点最高速度确定、减速点位置自适应前瞻确定和整体跨段转接点速度校核三个步骤建立连续微段的高速自适应前瞻控制策略。实时插补时,基于三次多项式加减速控制模型为被前瞻插补多微段建立整体跨段参数化插补算法。结果表明,提出的方法能实现连续微段间进给速度的高速衔接与高速加工时减速点位置的前瞻确定,从而大大缩短加工时间并提高加工效率。该方法已成功应用于多坐标数控高速微细加工系统中。     

An optimal feedrate model and solution algorithm for a high-speed machine of small line blocks with look-ahead

In complex high-speed machining of consecutive small line blocks, the tool path segments can be so short that a machining center moving at a high feedrate cannot accelerate or decelerate fast enough to make direction changes accurately. Aiming at adjusting the feedrate automatically to achieve maximum productivity, this paper present a novel mathematical model considering the key and representative factors, and then based on it, propose an algorithm to seek the approximate optimal feedrate by evaluating the toolpath ahead. Simulation results demonstrate the machine using the proposed model and algorithm can go fast where possible and to slow down just enough where needed and the productivity can be improved dramatically .     

CNC参数曲线实时插补进给速度控制方法

通过分析数控加工中参数曲线的实时插补原理和进给速度控制原理,指出了Taylor展开算法和“参数－弧长”分段拟合算法用于参数曲线的实时插补具有理论上的局限性,并对CNC实时插补进给速度控制问题给出了本质描述,提出了基于牛顿迭代法的解决方案,给出了算法流程。仿真对比实验表明,该算法具有稳定性好、收敛快、运算量小、精度高等特点,满足实时运算要求,能够将进给速度波动率控制在理想水平。     

Adaptive parametric interpolation scheme with limited acceleration and jerk values for NC machining

Parametric interpolation has many advantages over the traditional linear or circular interpolation in computer numerical control (CNC) machining. The existing work in this regard is reported to have achieved constant feedrate, confined chord error and limited acceleration/deceleration in one interpolator. However, the excessive jerk still exists due to abrupt change in acceleration profile, which will cause shock to the machine as well as deteriorate the surface accuracy. In this paper, an adaptive interpolation scheme incorporating machine’s dynamics capability consideration is proposed and illustrated in details. In the proposed algorithm, the commanded feedrate is maintained at most of the time and adaptively reduced in large curvature areas to meet the demand of the machining accuracy requirement, while at the same time, the acceleration and jerk values are limited within the machine’s capabilities during the whole interpolation process. It ensures a high machining accuracy, eliminates the phenomenon of overshoot/undershoot and reduces mechanical shock to the machine tools. The real-time performance of this interpolator is also measured to demonstrate its practical application. Two non-uniform rational B-spline (NURBS) curve interpolation experiments are provided to verify the feasibility and advantages of the proposed scheme.     

临界曲率值分割曲线尖角的NURBS曲线插补

为兼顾插补含尖角NURBS曲线的精度与速度,提出尖角分割且速度修正插补算法。由插补弦高误差限、法向加速度及其导数约束,得满足插补精度及机床动力学性能的临界曲率;用大于临界曲率的局部极大曲率及临界曲率分割NURBS曲线为是否包含尖角的若干子段;用S曲线加减速算法规划各子段进给速度,并用段间速度及位移协调关系修正各段加速度及其导数,使各段加减速时间为整数倍插补周期。在相同约束条件下,分别用曲率单调无速度修正、尖角分割无速度修正及尖角分割有速度修正算法,规划一条含大曲率尖角NURBS曲线插补速度,并用一阶泰勒级数展开算法插补该曲线。对比结果表明尖角分割且有速度修正算法可稳定得到较高插补精度,因此该算法可用于含大曲率尖角NURBS曲线高速度高精度加工。     

NURBS曲线S形加减速双向寻优插补算法研究

由于非均匀有理B样条(Non-uniform rational B-splines,NURBS)曲线的弧长与参数之间无精确解析关系,并且进给速度总是受到非线性变化的曲线曲率的约束,因此基于S形加减速进行NURBS曲线插补时,减速点难以准确预测。传统算法通常是沿曲线单方向插补,不仅未考虑曲率对进给速度的持续限制,而且加减速分类与计算公式复杂。为此,提出运动路程未知情况下不依赖于弧长精确计算的正向和反向同步加速的插补新算法,实时动态地求解曲线段内最大进给速度和正反向插补会合点,从而实现处处满足全部速度约束条件的最优插补。该算法无需求解高次方程与繁琐的加减速模式分类,并可保证以确定的速度通过曲率极值点和曲线终点。通过两个插补实例证明算法简明高效,适应性好,能够满足高速高精度数控要求。     

High accurate interpolation of NURBS tool path for CNC machine tools

Feedrate fluctuation caused by approximation errors of interpolation methods has great effects on machining quality in NURBS interpolation, but few methods can efficiently eliminate or reduce it to a satisfying level without sacrificing the computing efficiency at present. In order to solve this problem, a high accurate interpolation method for NURBS tool path is proposed. The proposed method can efficiently reduce the feedrate fluctuation by forming a quartic equation with respect to the curve parameter increment, which can be efficiently solved by analytic methods in real-time. Theoretically, the proposed method can totally eliminate the feedrate fluctuation for any 2nd degree NURBS curves and can interpolate 3rd degree NURBS curves with minimal feedrate fluctuation. Moreover, a smooth feedrate planning algorithm is also proposed to generate smooth tool motion with considering multiple constraints and scheduling errors by an efficient planning strategy. Experiments are conducted to verify the feasibility and applicability of the proposed method. This research presents a novel NURBS interpolation method with not only high accuracy but also satisfying computing efficiency.     

Design of a real-time adaptive interpolator with parameter compensation

The interpolator is the key part of a CNC system, which has strong effect on machining accuracy, tool motion smoothness, and machining efficiency. In this paper, a real-time adaptive interpolator is developed for non-uniform rational B-spline curves (NURBS) interpolation while considering the maximum acceleration/deceleration of the machine tool. In this proposed interpolator, both constant feedrate and high accuracy are achieved while the inconsistency of feedrate is dramatically reduced as well. In order to deal with the acceleration/deceleration around the feedrate-sensitive sharp corners, a look-ahead function is introduced to detect and adjust the feedrate adaptively. Furthermore, a parameter compensation scheme is proposed to eliminate the parametric truncation error which has been analyzed by several researchers but still not incorporated into any real-time interpolator so far. A case study was conducted to evaluate the feasibility of the developed interpolator.     

An improved feedrate scheduling method for NURBS interpolation in five-axis machining

Five-axis machining plays an important role in manufacturing by dint of its high efficiency and accuracy. While two rotation axes benefit the flexibility of machining, it also brings limitations and challenges. In order to further balance machining precision and efficiency, an improved feedrate scheduling method is presented considering geometric error and kinematic constraints for the Non Uniform Rational B-Spline (NURBS) interpolation in five-axis machining. A simplification method is proposed to calculate the geometric error which describes the deviation between the ideal tool path and the real tool path induced by the non-linear movement. A linear relation between geometric error and feedrate is built to limit the feedrate. The constraints determined by single axis kinematic performance and tangential kinematic performance are also considered. Under these constraints, a constrained feedrate profile is determined. Aiming to get more constant feedrate in the difficult-to-machine areas, this work proposes a scheduling method which combines morphological filtering and S-shape acceleration/deceleration (acc/dec) mode. Simulations and experiments are performed to compare the proposed feedrate scheduling method with two previous feedrate scheduling method and the results prove that the proposed feedrate scheduling method is reliable and effective.     

An optimal feedrate model and solution algorithm for a high-speed machine of small line blocks with look-ahead

In complex high-speed machining of consecutive small line blocks, the tool path segments can be so short that a machining center moving at a high feedrate cannot accelerate or decelerate fast enough to make direction changes accurately. Aiming at adjusting the feedrate automatically to achieve maximum productivity, this paper present a novel mathematical model considering the key and representative factors, and then based on it, propose an algorithm to seek the approximate optimal feedrate by evaluating the toolpath ahead. Simulation results demonstrate the machine using the proposed model and algorithm can go fast where possible and to slow down just enough where needed and the productivity can be improved dramatically.