多系统集成电解加工控制策略与故障诊断方法研究

为了提高航空发动机整体叶盘、汽车发动机喷油嘴阀体等零件的电解加工精度、可靠性以及工作效率，创建了一种集合机床运动、电解液系统、加工电源、电极振动等多个系统为一体的电解加工集成控制系统，提出了一种基于多系统集成的控制策略与故障诊断方法。该集成控制系统在硬件组成上采用了分布式架构与模块化组建方法，由一个主控制器和多个二级控制器组成。在控制策略上采用了协同控制方法，每个二级控制器完成对各自子系统的控制，同时主控制器对二级子系统进行协同管理，从而实现对电解加工全过程控制。在电解加工故障诊断中，建立了较完善的加工信息采集系统，通过特征提取、加工模式识别等步骤对电解加工过程进行诊断。试验证明，该系统集成度高、响应快、操作方便、工作效率高，故障诊断效果好，可有效预防加工故障对零件及其加工系统造成的损坏，提高了加工可靠性。

Research on Control Strategy and Fault Diagnosis Method of Multi-system for Electrochemical Machining

In order to improve the electrochemical machining precision, reliability and efficiency of the work pieces such as aero-engine blisk, automobile engine nozzle, etc, a new control system for electrochemical machining(ECM), which integrates machine motion, electrolyte conveying, temperature control, power supply and electrode vibration into one, is set up. A new multi-system control strategy and a fault diagnosis method are proposed. The integrated control system is composed of a main controller and several sub-controllers. The distributed architecture and modularized design are adopted in hardware structure. The collaborative control method based on multi-system is used in control strategy. The subsystems are controlled by the respective controller, and the sub-controllers are managed by the main controller; therefore, the whole system can be effectively controlled. In the failure diagnosis, a prefect machining information acquisition system is created, and the status of electrochemical machining is diagnosed by the procedures of feature extraction, processing and pattern recognition. The experiments prove that the control system has the high integration, fast response, convenient operation and high work efficiency. The multi-system can be used to avoid successfully the damage to work-piece and machining system caused by failures and improve the processing reliability.