嵌入式可重构CNC系统研究与实现
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摘要
可重构制造系统是未来制造系统发展的新趋势，而可重构数控系统是实现可重构制造系统的关键技术。可重构技术可以增强CNC（计算机数控）系统的柔性，快速响应加工需求的变化，并能合理配置系统资源，节约生产制造成本。另外，随着微电子技术和现场可编程逻辑器件的发展，嵌入式数控系统将是今后一个重要的发展方向。从宏观的角度来说，研究嵌入式可重构CNC系统，既顺应国家政策，也符合加工市场的需要。
目前国内基于嵌入式体系结构的CNC系统研究不多，且结构设计上较少考虑系统的可重构性，逻辑扩展能力不强，系统通用性较差；另外，尽管NURBS插补算法研究的人很多，但几乎没有考虑短样条曲线的插补情况，以致算法的通用性有所欠缺。基于以上原因，本文首先提出一种嵌入式可重构的CNC系统体系结构，然后在此基础上研究了NURBS插补算法和可重构伺服算法。最后，开发和搭建了嵌入式可重构CNC系统，并通过实验和项目应用证实了系统平台的性能。主要研究工作和创新之处体现在：
1.通过分析基于PC机的数控系统及目前嵌入式数控系统结构存在的局限性，结合开放式数控系统的功能需求，提出了一种模块化、可重构的嵌入式CNC系统体系结构。该系统改进了传统的基于ARM+DSP+FPGA的嵌入式系统设计结构，并扩展了工业以太网功能模块。在此基础上，从软、硬件方面分析了系统的可重构性及网络功能。
2.在研究和分析伺服工作模式和相应的控制方法的基础上，结合当前市场上出现的商用运动控制器的优缺点，提出了可重构伺服算法模型。同时，基于此模型分析了算法的可重构性，并以数字PID控制器和陷波滤波器作为重点介绍了算法的实现。
3.提出了一种新颖的、精确的实时NURBS插补算法，克服了现有NURBS曲线插补算法的不足。该算法采用S曲线加减速方法，优化了前瞻过程。同时，算法通过引入环形缓冲区和预插补（非离线），提高了加工效率，并通过合理地安排插补任务增强了系统的实时性。
4.依据提出的嵌入式可重构CNC系统的体系结构，设计并实现了一个具有工业以太网功能的模块化嵌入式可重构CNC系统，给出了系统关键硬件模块的组成及接口电路的设计，同时介绍了系统应用层和硬件驱动层软件的实现。
5.基于本文设计的可重构嵌入式CNC硬件平台及提出的相关算法，搭建了一个可重构的嵌入式CNC系统控制平台，并通过实验和项目应用验证了系统的性能。
The reconfigurable manufacturing system (RMS) is a new trend of the futuremanufacturing system, and the reconfigurable computer numerical control (CNC) system is akey technology in the reconfigurable manufacturing systems. The reconfigurable technologycan improve the flexibility of the CNC system, respond quickly to the machining processrequirement, configure reasonably system resources and save the cost of manufacturing.Additionally, with the development of microelectronics and the field-programmable logicdevices, embedded numerical control system will be an important direction of developmentin the future. From a macro perspective, the research of embedded reconfigurable CNCsystem, not only keep with the national policy, but also meet with the needs of the machiningmarket.
At present, there are few researches of CNC system based on the embedded architecture.In structural design, system reconfigurability is often ignored. Moreover, the logicalextension is not strong, and the system is less universal. In addition, there have been manyresearchers working on NURBS interpolation algorithm, but most of them did not considershort spline curve interpolation, which resulted in the algorithms lacking versatility. Forthese reasons, this paper proposed the architecture of an embedded reconfigurable CNCsystem, then on the base of which, NURBS interpolation algorithm and reconfigurable servoalgorithm have been studied. Finally, an embedded reconfigurable CNC system, whoseperformance was confirmed by experiment and project applications, was developed and built.The major research works and contributions of the thesis are introduced as follows:
1. By analyzing the limitations of the PC-based CNC system and the present embeddedCNC system, a modular, reconfigurable embedded CNC system architecture was proposed,which combined the functional requirements of the opening numerical control system. Thesystem was improved from the traditional embedded system architecture which was based onthe ARM+DSP+FPGA architecture, and expanded the industrial Ethernet function module. Then, the reconfigurability and network capabilities of the system were analyzed from theperspective of hardware and software.
2. Based on the research and analysis of the servo operating mode and thecorresponding control method, and combined with the advantages and disadvantages of thepresent commercial motion controller on the market, a reconfigurable servo controlalgorithm model was proposed. Meanwhile, the reconfigurability was analyzed based on theproposed algorithm, and the implementation of the proposed algorithm was introduced byfocusing on the implementation of digital PID controller and notch filters.
3. A novel and accurate real-time NURBS interpolation algorithm was proposed, whichovercame the deficiencies of the existing NURBS curve interpolation algorithm. An S-curveacceleration/deceleration (Acc/Dec) control was adopted, and the look-ahead process wasoptimized. Meanwhile, it improved machining efficiency by adding the circular buffer andpre-interpolation (non-off-line) and enhanced the real-time performance by reasonablearrangement of the interpolation tasks.
4. According to the proposed embedded reconfigurable CNC system architecture, amodular, reconfigurable embedded CNC system with industrial Ethernet function wasdesigned and implemented. Then the composition of system key hardware module andinterface circuit design was presented. Finally, the software implementation of theapplication layer and the hardware driver layer was given.
5. Based on designed reconfigurable embedded CNC hardware platform and theproposed algorithms, an embedded reconfigurable CNC system controller, whoseperformance was confirmed by experiment and project applications, was developed andbuilt.
目前国内基于嵌入式体系结构的CNC系统研究不多，且结构设计上较少考虑系统的可重构性，逻辑扩展能力不强，系统通用性较差；另外，尽管NURBS插补算法研究的人很多，但几乎没有考虑短样条曲线的插补情况，以致算法的通用性有所欠缺。基于以上原因，本文首先提出一种嵌入式可重构的CNC系统体系结构，然后在此基础上研究了NURBS插补算法和可重构伺服算法。最后，开发和搭建了嵌入式可重构CNC系统，并通过实验和项目应用证实了系统平台的性能。主要研究工作和创新之处体现在：
1.通过分析基于PC机的数控系统及目前嵌入式数控系统结构存在的局限性，结合开放式数控系统的功能需求，提出了一种模块化、可重构的嵌入式CNC系统体系结构。该系统改进了传统的基于ARM+DSP+FPGA的嵌入式系统设计结构，并扩展了工业以太网功能模块。在此基础上，从软、硬件方面分析了系统的可重构性及网络功能。
2.在研究和分析伺服工作模式和相应的控制方法的基础上，结合当前市场上出现的商用运动控制器的优缺点，提出了可重构伺服算法模型。同时，基于此模型分析了算法的可重构性，并以数字PID控制器和陷波滤波器作为重点介绍了算法的实现。
3.提出了一种新颖的、精确的实时NURBS插补算法，克服了现有NURBS曲线插补算法的不足。该算法采用S曲线加减速方法，优化了前瞻过程。同时，算法通过引入环形缓冲区和预插补（非离线），提高了加工效率，并通过合理地安排插补任务增强了系统的实时性。
4.依据提出的嵌入式可重构CNC系统的体系结构，设计并实现了一个具有工业以太网功能的模块化嵌入式可重构CNC系统，给出了系统关键硬件模块的组成及接口电路的设计，同时介绍了系统应用层和硬件驱动层软件的实现。
5.基于本文设计的可重构嵌入式CNC硬件平台及提出的相关算法，搭建了一个可重构的嵌入式CNC系统控制平台，并通过实验和项目应用验证了系统的性能。
The reconfigurable manufacturing system (RMS) is a new trend of the futuremanufacturing system, and the reconfigurable computer numerical control (CNC) system is akey technology in the reconfigurable manufacturing systems. The reconfigurable technologycan improve the flexibility of the CNC system, respond quickly to the machining processrequirement, configure reasonably system resources and save the cost of manufacturing.Additionally, with the development of microelectronics and the field-programmable logicdevices, embedded numerical control system will be an important direction of developmentin the future. From a macro perspective, the research of embedded reconfigurable CNCsystem, not only keep with the national policy, but also meet with the needs of the machiningmarket.
At present, there are few researches of CNC system based on the embedded architecture.In structural design, system reconfigurability is often ignored. Moreover, the logicalextension is not strong, and the system is less universal. In addition, there have been manyresearchers working on NURBS interpolation algorithm, but most of them did not considershort spline curve interpolation, which resulted in the algorithms lacking versatility. Forthese reasons, this paper proposed the architecture of an embedded reconfigurable CNCsystem, then on the base of which, NURBS interpolation algorithm and reconfigurable servoalgorithm have been studied. Finally, an embedded reconfigurable CNC system, whoseperformance was confirmed by experiment and project applications, was developed and built.The major research works and contributions of the thesis are introduced as follows:
1. By analyzing the limitations of the PC-based CNC system and the present embeddedCNC system, a modular, reconfigurable embedded CNC system architecture was proposed,which combined the functional requirements of the opening numerical control system. Thesystem was improved from the traditional embedded system architecture which was based onthe ARM+DSP+FPGA architecture, and expanded the industrial Ethernet function module. Then, the reconfigurability and network capabilities of the system were analyzed from theperspective of hardware and software.
2. Based on the research and analysis of the servo operating mode and thecorresponding control method, and combined with the advantages and disadvantages of thepresent commercial motion controller on the market, a reconfigurable servo controlalgorithm model was proposed. Meanwhile, the reconfigurability was analyzed based on theproposed algorithm, and the implementation of the proposed algorithm was introduced byfocusing on the implementation of digital PID controller and notch filters.
3. A novel and accurate real-time NURBS interpolation algorithm was proposed, whichovercame the deficiencies of the existing NURBS curve interpolation algorithm. An S-curveacceleration/deceleration (Acc/Dec) control was adopted, and the look-ahead process wasoptimized. Meanwhile, it improved machining efficiency by adding the circular buffer andpre-interpolation (non-off-line) and enhanced the real-time performance by reasonablearrangement of the interpolation tasks.
4. According to the proposed embedded reconfigurable CNC system architecture, amodular, reconfigurable embedded CNC system with industrial Ethernet function wasdesigned and implemented. Then the composition of system key hardware module andinterface circuit design was presented. Finally, the software implementation of theapplication layer and the hardware driver layer was given.
5. Based on designed reconfigurable embedded CNC hardware platform and theproposed algorithms, an embedded reconfigurable CNC system controller, whoseperformance was confirmed by experiment and project applications, was developed andbuilt.
引文
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