超大构件分区自适应定位加工及其可移动机床的研制
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摘要
重大科技装备中,高品质超大构件的应用越来越多,对质量和性能的要求也越来越高,但通常这类装备中的超大构件尺寸大、重量大、生产批量小、更新快、难以移动,其加工制造是很大的难题。目前,针对超大构件加工的研究开展的较少,缺少对加工方法及加工误差理论方面的系统分析。因此,开展超大构件加工方法、加工误差等关键技术的研究,对于提高超大构件加工精度、加工效率、降低制造成本具有很重要的现实意义。
本文根据重大科技工程中超大构件的特点,提出了可移动小机床分区自适应加工超大构件的方法,给出了该方法的方案原理、系统结构,并根据该方法给出了可移动机床的可重构设计方案,机床采用轮式移动结构,可以沿工件加工面移动,将超大构件分为若干个小区域进行加工时,利用大空间测量技术实现机床精确定位,采用并联加工头实现自适应加工。该机床具有可移动性、可重构性与加工灵活性,可以提高超大构件加工柔性和加工效率,同时也能降低加工成本。
要实现超大构件的精确加工,首先要解决的问题是工件和机床间相对位置的精确定位。文中结合刚体运动矩阵及李代数等原理方法,系统地研究了超大构件自适应定位的相关理论。通过对超大构件加工过程中涉及的多坐标系间关系的分析,建立了超大构件自适应定位一般模型。为了保证自适应定位矩阵的唯一性,提出了基于工件完全约束的测量定位方法,建立了求解自适应定位矩阵的非线性优化目标函数,给出了基于欧氏群切向量法的超大构件自适应定位优化模型的求解方法,仿真分析了算法的精度、收敛速度与收敛条件,并通过仿真实例验证了自适应定位方法的正确性与可靠性。
文中根据超大构件分区自适应加工原理,给出了超大构件加工区域分割方法与分割规则,根据被加工几何特征的分类,提出了加工特征分割原则,建立了分割树状模型;并给出了超大构件规则几何特征的区域分割方法与基于机床工作空间的区域分割优化法。阐述了面向区域分割加工的刀具路径规划方法,并以最短加工路径为优化目标提出了基于遗传算法的刀具路径加工次序的优化方法,并仿真验证了其正确性,最后根据分割后的理论刀具路径及自适应定位模型,阐述了实际加工路径及数控程序的生成方法。
为了保证超大构件加工的可靠性,文中给出分区自适应定位加工的精度评价与控制方法,从理论上分析了超大构件加工误差因素的影响,并结合螺旋理论建立了超大构件自适应定位加工中总体位姿误差模型、平面度误差预测模型、空间直线度误差预测模型和平面内圆度误差预测模型,分别从自适应定位误差、机床几何误差、机床刚度三个角度详细分析了误差的影响。给出了基于统计分析的工件定位误差预测方法,并仿真验证了工件定位误差预测模型的正确性;分析了可移动小机床几何误差的影响,建立了机床误差模型,并结合多元线性插值与卡尔曼滤波离线标定法,预测不可校准误差,并给出补偿方法。最后结合蒙特卡罗法将上述几种误差整合,给出超大构件加工误差的预测方法,并完成了其仿真验证。
在以上理论分析的基础上,研制出一种加工超大法兰的可移动小机床,并进行了超大构件的加工实验。实验结果表明采用可移动小机床实现分区自适应定位加工超大构件的方法是可行的,同时也验证了超大构件分区自适应定位加工误差预测方法的正确性。
Super-large components are required increasingly in major science and technology projects for better performance and higher quality. However, it is difficult to machine super-large components because of their huge volume, large weight, poor mobility and small-batch production. Currently, super-large components machining method and machining error theory are lacked. Therefore, the research in machining super-large components and analyzing machining errors has practical significance for improving machining accuracy, efficiency and cost-effectiveness.
According to the characteristics of large components, a method using small movable machine tool to machine super-large components by adaptive subdivision was proposed in this thesis. The principle of the method, system architecture and reconfigurable scheme were provided. Wheeled movable structure was designed for roughly localization in large space, and large-space measuring technology was utilized for precisely localization. Parallel machining head implemented adaptive machining. The machine tool enhanced the machining flexibility and efficiency as well as reduced production costs because of its mobility, flexibility, reconfigurability.
To achieve accurate machining of super-large components, the precise location of the workpiece should be obtained firstly. Studying adaptive localization theories of super-large component combined with rigid body motion Matrix and Lie algebra theory, a self-adaptive localization model was established by analyzing the relationship among multi-coordinate systems during super-large components machining. In this thesis, a complete localization method based on workpiece machining features was proposed. The objective function solving adaptive positioning model was derived, and a general solution method, tangent plane algorithm based on Euler angle methods was applied to solve the super-large components adaptive localization. The accuracy, convergence rate and convergence condition of the method were evaluated by simulation for verifying the correctness and reliability of adaptive localization method.
In this thesis, machining area subdivision rules for were introduced referring adaptive machining principle of super-large component. According to geometrical features, machining features subdivision rules were introduced and the tree model of subdivision was constructed. Simultaneously, regular geometrical features subdivision method for super-large component and machining area subdivision method based on machine tool workspace were proposed. Theoretical tool path generation method based on subdivision region was presented. Aiming at to obtain the shortest machining path, a tool path optimization method based on genetic algorithms was also discussed and validated by simulation. Finally, actual tool path and NC program were generated on the basis of theoretical tool path and adaptive localization model.
To ensure the reliability of super-large component machining, the influence of error factors to super-large component machining was theoretically analyzed in the thesis. Combined with spiral theory, a series of error models in super-large component adaptive localization were established, including global position and orientation error model, flatness error prediction model, spatial straightness error prediction model and roundness error prediction model in machining plane. The influence of errors were further analyzed from the aspects of adaptive localization error, machine tool geometric error and machine stiffness error. A workpiece automatic positioning error prediction method based on statistical analysis was presented, and the prediction model of the workpiece automatic orientation errors was validated by simulation. Analyzed the influences of geometric errors in the movable small machine tools, the error model of parallel mechanism was described. Referring multi-linear interpolation and Kalman filter off-line calibration theory, un-calibrated errors were predicted and a compensation method was provided. Finally, an integrated error prediction based on Monte Carlo method for super-large component machining was presented and it was verified by simulation.
A movable machine tool for machining super-large flange was developed on the basis of theoretical analysis, and machining experiment was conducted. The experiment results demonstrate that the method of subdivision by adaptive localization for machining super-large component using movable machine tool is feasible, and its error predication methods are correct.
本文根据重大科技工程中超大构件的特点,提出了可移动小机床分区自适应加工超大构件的方法,给出了该方法的方案原理、系统结构,并根据该方法给出了可移动机床的可重构设计方案,机床采用轮式移动结构,可以沿工件加工面移动,将超大构件分为若干个小区域进行加工时,利用大空间测量技术实现机床精确定位,采用并联加工头实现自适应加工。该机床具有可移动性、可重构性与加工灵活性,可以提高超大构件加工柔性和加工效率,同时也能降低加工成本。
要实现超大构件的精确加工,首先要解决的问题是工件和机床间相对位置的精确定位。文中结合刚体运动矩阵及李代数等原理方法,系统地研究了超大构件自适应定位的相关理论。通过对超大构件加工过程中涉及的多坐标系间关系的分析,建立了超大构件自适应定位一般模型。为了保证自适应定位矩阵的唯一性,提出了基于工件完全约束的测量定位方法,建立了求解自适应定位矩阵的非线性优化目标函数,给出了基于欧氏群切向量法的超大构件自适应定位优化模型的求解方法,仿真分析了算法的精度、收敛速度与收敛条件,并通过仿真实例验证了自适应定位方法的正确性与可靠性。
文中根据超大构件分区自适应加工原理,给出了超大构件加工区域分割方法与分割规则,根据被加工几何特征的分类,提出了加工特征分割原则,建立了分割树状模型;并给出了超大构件规则几何特征的区域分割方法与基于机床工作空间的区域分割优化法。阐述了面向区域分割加工的刀具路径规划方法,并以最短加工路径为优化目标提出了基于遗传算法的刀具路径加工次序的优化方法,并仿真验证了其正确性,最后根据分割后的理论刀具路径及自适应定位模型,阐述了实际加工路径及数控程序的生成方法。
为了保证超大构件加工的可靠性,文中给出分区自适应定位加工的精度评价与控制方法,从理论上分析了超大构件加工误差因素的影响,并结合螺旋理论建立了超大构件自适应定位加工中总体位姿误差模型、平面度误差预测模型、空间直线度误差预测模型和平面内圆度误差预测模型,分别从自适应定位误差、机床几何误差、机床刚度三个角度详细分析了误差的影响。给出了基于统计分析的工件定位误差预测方法,并仿真验证了工件定位误差预测模型的正确性;分析了可移动小机床几何误差的影响,建立了机床误差模型,并结合多元线性插值与卡尔曼滤波离线标定法,预测不可校准误差,并给出补偿方法。最后结合蒙特卡罗法将上述几种误差整合,给出超大构件加工误差的预测方法,并完成了其仿真验证。
在以上理论分析的基础上,研制出一种加工超大法兰的可移动小机床,并进行了超大构件的加工实验。实验结果表明采用可移动小机床实现分区自适应定位加工超大构件的方法是可行的,同时也验证了超大构件分区自适应定位加工误差预测方法的正确性。
Super-large components are required increasingly in major science and technology projects for better performance and higher quality. However, it is difficult to machine super-large components because of their huge volume, large weight, poor mobility and small-batch production. Currently, super-large components machining method and machining error theory are lacked. Therefore, the research in machining super-large components and analyzing machining errors has practical significance for improving machining accuracy, efficiency and cost-effectiveness.
According to the characteristics of large components, a method using small movable machine tool to machine super-large components by adaptive subdivision was proposed in this thesis. The principle of the method, system architecture and reconfigurable scheme were provided. Wheeled movable structure was designed for roughly localization in large space, and large-space measuring technology was utilized for precisely localization. Parallel machining head implemented adaptive machining. The machine tool enhanced the machining flexibility and efficiency as well as reduced production costs because of its mobility, flexibility, reconfigurability.
To achieve accurate machining of super-large components, the precise location of the workpiece should be obtained firstly. Studying adaptive localization theories of super-large component combined with rigid body motion Matrix and Lie algebra theory, a self-adaptive localization model was established by analyzing the relationship among multi-coordinate systems during super-large components machining. In this thesis, a complete localization method based on workpiece machining features was proposed. The objective function solving adaptive positioning model was derived, and a general solution method, tangent plane algorithm based on Euler angle methods was applied to solve the super-large components adaptive localization. The accuracy, convergence rate and convergence condition of the method were evaluated by simulation for verifying the correctness and reliability of adaptive localization method.
In this thesis, machining area subdivision rules for were introduced referring adaptive machining principle of super-large component. According to geometrical features, machining features subdivision rules were introduced and the tree model of subdivision was constructed. Simultaneously, regular geometrical features subdivision method for super-large component and machining area subdivision method based on machine tool workspace were proposed. Theoretical tool path generation method based on subdivision region was presented. Aiming at to obtain the shortest machining path, a tool path optimization method based on genetic algorithms was also discussed and validated by simulation. Finally, actual tool path and NC program were generated on the basis of theoretical tool path and adaptive localization model.
To ensure the reliability of super-large component machining, the influence of error factors to super-large component machining was theoretically analyzed in the thesis. Combined with spiral theory, a series of error models in super-large component adaptive localization were established, including global position and orientation error model, flatness error prediction model, spatial straightness error prediction model and roundness error prediction model in machining plane. The influence of errors were further analyzed from the aspects of adaptive localization error, machine tool geometric error and machine stiffness error. A workpiece automatic positioning error prediction method based on statistical analysis was presented, and the prediction model of the workpiece automatic orientation errors was validated by simulation. Analyzed the influences of geometric errors in the movable small machine tools, the error model of parallel mechanism was described. Referring multi-linear interpolation and Kalman filter off-line calibration theory, un-calibrated errors were predicted and a compensation method was provided. Finally, an integrated error prediction based on Monte Carlo method for super-large component machining was presented and it was verified by simulation.
A movable machine tool for machining super-large flange was developed on the basis of theoretical analysis, and machining experiment was conducted. The experiment results demonstrate that the method of subdivision by adaptive localization for machining super-large component using movable machine tool is feasible, and its error predication methods are correct.
引文
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69 Ko K H, Maekawa T, Patrikalakis N M et al. Shape intrinsic properties for free-form object matching. Journal of computing and information science in engineering, 2003, 3 (4):325~333
70 Ko K H, Maekawa T, Patrikalakis N M. An algorithm for optimal free-form object matching. Computer-aided design, 2003, 35(10):913~923
71 Ko K H, Maekawa T, Patrikalakis N M. Algorithms for optimal partial matching of free-form objects with scaling effects.Graphical models, 2005, 67(2):120~148
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74武殿梁,黄海量,丁玉成,赵万华.基于遗传算法和最小二乘法的曲面匹配.航空学报, 2002,23(3): 285~288
75 Shen B, Huang G Q, Mak K L et al. A best-fitting algorithm for optical location of large-scale blanks with free-form surfaces. Journal of materials processing technology, 2003,139(2):210~314
76 Dassanayake M, Tsutsumi. Saito A. A Strategy for Identifying Static Deviations in Universal Spindle Head Type Multi-Axis Machining Centers. International Journal of Machine Tools and Manufacture 2006, 46:1097~1106
77 Bringmann B, Kung A, Knapp W. A Measuring Artifact for True 3D Machine Testing and Calibration. Annals of the CIRP. 2005, 54(1): 471~474
78 Y.Y. Hsu etc.. A new compensation method for geometry errors of five-axis machine tools, International Journal of Machine Tools & Manufacture. 2007, 47: 352~360
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87 H. Chanal, E. Duc, and P. Ray. A study of the impact of machine tool structure on machining processes. International Journal of Machine Tools and Manufacture, 2006, 46(2): 98~106
88 Perreira PH, Hocken RJ. Characterization and Compensation of Dynamic Errors of a Scanning Coordinate Measuring Machine. Precision Engineering 2007, 31(1): 22–32
89 Chunhe Gong, Jingxia Yuan, and Jun Ni. Nongeometric error identification and compensation for robotic system by inverse calibration. International Journal of Machine Tools and Manufacture, 2000, 40(14): 2119~2137
90 Vatchara Lertpiriyasuwat, Martin C. Berg. Adaptive Real-Time Estimation of End-Effector Position and Orientation Using Precise Measurements of End-Effector Position. IEEE / ASME Transactions on Mechatronics, 2006, 11(3): 304~319
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73严思杰,周云飞,彭芳瑜等.大型复杂曲面零件加工余量均布优化问题研究.华中科技大学学报, 2002, 30 (10),35~37
74武殿梁,黄海量,丁玉成,赵万华.基于遗传算法和最小二乘法的曲面匹配.航空学报, 2002,23(3): 285~288
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76 Dassanayake M, Tsutsumi. Saito A. A Strategy for Identifying Static Deviations in Universal Spindle Head Type Multi-Axis Machining Centers. International Journal of Machine Tools and Manufacture 2006, 46:1097~1106
77 Bringmann B, Kung A, Knapp W. A Measuring Artifact for True 3D Machine Testing and Calibration. Annals of the CIRP. 2005, 54(1): 471~474
78 Y.Y. Hsu etc.. A new compensation method for geometry errors of five-axis machine tools, International Journal of Machine Tools & Manufacture. 2007, 47: 352~360
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81 B.A.Woody, S.Smith, J.A..Miller. J. A Technique for Enhancing Machine Tool Accuracy by Transferring the Metrology Reference From the Machine Tool to the Workpiece. Manufuncture. Science and Engneering. 2007, 129: 636~643
82 Schwenke, H; Knapp, W; Haitjema, H (Han), etc..Geometric error measurement and compensation of machines– An update. CIRP Annals, 2008, 57(2): 660~675
83 Schellekens P, Rosielle N, Vermeulen H, Vermeulen M, Wetzels S, Pril W. Design for Precision, Current Status and Trends. Annals of the CIRP. 1993, 47(2): 557~586
84 Spaan HAM. Software Error Compensation of Machine Tools, PhD Thesis, Eindhoven University of Technology, 1995: 11~18
85 Kornel F. Ehmann, Shih-Ming Wang. Error Model and Accuracy Analysis of a Six-DOF Stewart Platform. J. Manuf. Sci. Eng., 2002, 124(2): 286~295
86 J. Chen, and F. Lan. Instantaneous stiffness analysis and simulation for hexapod machines. Simulation Modelling Practice and Theory, 2008, 16(4): 419~428
87 H. Chanal, E. Duc, and P. Ray. A study of the impact of machine tool structure on machining processes. International Journal of Machine Tools and Manufacture, 2006, 46(2): 98~106
88 Perreira PH, Hocken RJ. Characterization and Compensation of Dynamic Errors of a Scanning Coordinate Measuring Machine. Precision Engineering 2007, 31(1): 22–32
89 Chunhe Gong, Jingxia Yuan, and Jun Ni. Nongeometric error identification and compensation for robotic system by inverse calibration. International Journal of Machine Tools and Manufacture, 2000, 40(14): 2119~2137
90 Vatchara Lertpiriyasuwat, Martin C. Berg. Adaptive Real-Time Estimation of End-Effector Position and Orientation Using Precise Measurements of End-Effector Position. IEEE / ASME Transactions on Mechatronics, 2006, 11(3): 304~319
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94 Z.X. Li, J.B. Gou and Y.X. Chu, Geometrical Algorithms for Workpiece Localization. IEEE Trans. on Robotics and Automation 1998,14(6): 864~878
95吴宝海,罗明,张莹,李山,张定华.自由曲面五轴加工刀具轨迹规划技术的研究进展.机械工程学报, 2008, 44(10): 9~18
96 Sartori S, Zhang GX. Geometric error measurement and compensation of machines. Annals of the CIRP, Vol. 1995, 44(2), 599~609
97 Portman, V. T.. Deterministic Metrology of Platform-Type Machine Tools. International Journal of Machine Tools and Manufacture, 2000, 40: 1423~1442
98平面度误差检测(GBT 11337-2004),中华人民共和国国家标准, 2004.
99产品几何量技术规范(GPS)圆度测量术语、定义及参数(GB/T7234—2004).中华人民共和国国家标准, 2004