光栅刻划机虚拟样机技术及应用研究
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摘要
光栅制造技术是当今最为精密的技术之一，而制作光栅的设备——光栅刻划机则被誉为“精密机械之王”，它通常需要在毛坯上实现每毫米数千道刻槽的刻划，并且要求刻划偶然误差小于1/10光栅常数、周期误差小于1/100光栅常数、同时使用干涉方法检验波面差必须小于1/3条纹。这些性能指标决定了光栅刻划机具有极高的精度要求，包括机械精度以及控制精度。光栅刻划机的超精密性使得零部件加工困难、制造周期长且造价昂贵，因而要求一次制造成功。传统的基于物理样机的开发流程在得到最终的物理样机之前，中间存在着反复的试制与修改过程，需要多次制造物理样机，因而不适用于光栅刻划机的研发。基于此种情况，本文中采用基于虚拟样机技术来进行光栅刻划机的开发，它能够减少物理模拟，降低了开发成本，并且这种方式缩短了开发周期，有效提高了产品的开发速度及设计质量，更重要的是由此避免了基于物理样机开发所存在的缺点，不需要重复制造物理样机即可实现光栅刻划机的开发。
本文首先建立了光栅刻划机的虚拟样机模型，它主要是由分度系统及刻划系统两部分组成。分度系统实现了光栅毛坯的超精密定位，刻划系统则用于执行刻划操作，两者协同工作，共同完成光栅的刻划。在光栅刻划机的工作过程中，传动机构对光栅的刻划质量有着至关重要的影响，因而需要对其进行分析与优化，以获得最优的传动机构设计方案。在分度系统传动装置中，分析了机构转动惯量对传动效果的影响，从系统响应的快速性、平稳性等角度确定了转动惯量的优化目标。基于参数化的虚拟样机模型，采用灵敏度分析的方法获取结构参数与转动惯量之间的关系，并以机构的最大变形位移作为约束条件以确定各结构参数的取值从而使得所设计的传动机构既实现了转动惯量的优化目标，同时又能够满足机构的刚度与强度要求。在刻划系统中，为了保证光栅的刻划质量，要求刻刀始终保持匀速运动，因此对刻划传动链中的等速传动机构提出了较为严格的要求。本文基于虚拟样机技术进行运动学仿真，得到了传动机构的位移、速度及加速度曲线，分析得到初始传动机构设计中所存在的不足之处：加速度在往复运动的始末位置处存在跳变，因而对传动机构的凸轮结构采用了摆线运动规律对其进行修正，得到了较好的设计效果，保证了运动特性的连续性。
光栅刻划机作为机电一体化的重大装备，其设计与分析需要一个综合的开发及性能评价平台。本文提出了机械、控制一体化联合仿真开发技术，利用虚拟样机技术所提供的集成开发环境，在制造物理样机之前，联合控制系统设计软件，将复杂的控制系统添加到机械结构虚拟样机模型中，对机械系统与控制系统进行联合仿真分析，模拟实际产品中各个模块的工作特性，为复杂机械产品的开发提供了一种全新的设计方法。本文利用专业的机械分析及控制设计软件，对光栅刻划机中实现超精密刻划的最关键部分——分度系统精定位机构进行了仿真分析，首先建立经过适当简化的工作台运动学仿真模型，并构建相应的控制系统，进行联合仿真开发研究。在联合仿真平台中，通过对多组控制参数及采样时间的研究，验证了控制算法的有效性并确定了较佳的控制参数及相应的采样时间。
在光栅刻划机的系统设计中，控制软件是其中的重要组成部分。传统的软件开发一般需要等到硬件加工完成后再进行软件的调试，这就延长了软件的开发周期，无法适应于当前日益激烈的市场竞争环境。为了实现系统软件的并行开发，提出了基于虚拟硬件在环的软件仿真开发方法。利用计算机模拟实际控制单元的硬件运行情况，与被控对象的仿真模型相连进行软件的开发与调试，构建了应用软件运行所需要的虚拟硬件环境。本文以光栅刻划机控制软件为研究对象，详细介绍了基于虚拟硬件在环的软件仿真开发流程，并将开发完成的软件系统应用到光栅刻划机上，协调控制光栅刻划机的各个子系统共同实现了光栅的刻划。
Grating manufacturing technology is one of the most sophisticated technologies,and the grating ruling engine, which is used to manufacture grating, is known as the"King of precision machinery". It usually scores thousands of grooves per mm on theglass pressing blank, and requires accidental error less than1/10of grating constant,periodic error less than1/100grating constant and wavefront difference also less than1/3stripes. All of these performances determine that the grating ruling engine has ahigh precision, not only mechanism but also control system. Because ofultra-precision, parts are difficult to be manufactured, the development cycle is long,and the cost is also expensive. The traditional development process based on thephysical prototype does not apply to develop the grating ruling engine because itneeds repeated trial and modification and multiple physical prototypes aremanufactured before the final product. In this paper, the development process basedon virtual prototyping technology, which can reduce the physical experiments anddevelopment cost, shorten the development cycle, and improve the design quality, ispresented to develop the grating ruling engine. More importantly, this method doesnot repeat to manufacture the physical prototyp, so it avoids the traditional method’sdefect.
At first, the virtual prototype model of the grating ruling engine is established,including indexing subsystem and ruling subsystem. The indexing subsystem achievesthe ultra-precision positioning, and the ruling subsystem performs the ruling operation.These two subsystems work together to rule grating. In the working process, thetransmission performance affects the quality of grating, so it is necessary to beanalyzed and optimized to obtain the optimal design. In the transmission of theindexing system, influence of inertia on the control is analyzed and the inertiaoptimization objective is determined with the fast and stable respond. The sensitivityanalysis method is used to obtain the relationship between structural parameters andinertia, and then parameters are calculated to meet the requirements of inertia andstiffness. In order to ensure the quality of grating, the nickingtool need to maintainuniform motion, so the equal-speed transmission mechanism of the ruling subsystemis very important. In this paper, the displacement, velocity and acceleration of theinitial transmission mechanism design is calculated by using kinematics simulation based on virtal prototype technology. From the analysis, the inadequacies that jump ofacceleration occur at transition location is presented, so cycloidal motion law isadopted to amend this phenomenon to get better design and ensure the continuity ofmotion.
Grating ruling engine is one of the major mechanical and electrical equipment,whose design and analysis require a comprehensive platform for development andperformance evaluation. This paper presents a new methodology which combinesmechanism and control to simulation. In the integrated development environmentprovided by virtual prototype technology, complex control system is jointed tomechanism system to simulate the product performance. In this paper, the micro stagewhich is most important for positioning accuracy is analyzed. An appropriatesimplified stage’s simulation mode is established and control system is also built toachieve co-simulation. The effectiveness of control algorithms is verified and controlparameters are obtained by using co-simulation platform.
In the grating ruling engine system design, control software is an important part.In the traditional software development approach, the software is usually developedand debugged after the completion of the hardware processing which extendsdevelopment cycle and is unable to adapt to the fierce market competition. In order toachieve the parallel software development, software simulation developmentmethodology based on the virtual hardware in the loop is proposed. Computer is usedto simulate the actual control unit for software development and debugging with thecontrolled object’s model. This paper uses grating ruling engine’s control software asresearch subjects to describe the software simulation development. The developedapplication is ported to control the real grating ruling engine
本文首先建立了光栅刻划机的虚拟样机模型，它主要是由分度系统及刻划系统两部分组成。分度系统实现了光栅毛坯的超精密定位，刻划系统则用于执行刻划操作，两者协同工作，共同完成光栅的刻划。在光栅刻划机的工作过程中，传动机构对光栅的刻划质量有着至关重要的影响，因而需要对其进行分析与优化，以获得最优的传动机构设计方案。在分度系统传动装置中，分析了机构转动惯量对传动效果的影响，从系统响应的快速性、平稳性等角度确定了转动惯量的优化目标。基于参数化的虚拟样机模型，采用灵敏度分析的方法获取结构参数与转动惯量之间的关系，并以机构的最大变形位移作为约束条件以确定各结构参数的取值从而使得所设计的传动机构既实现了转动惯量的优化目标，同时又能够满足机构的刚度与强度要求。在刻划系统中，为了保证光栅的刻划质量，要求刻刀始终保持匀速运动，因此对刻划传动链中的等速传动机构提出了较为严格的要求。本文基于虚拟样机技术进行运动学仿真，得到了传动机构的位移、速度及加速度曲线，分析得到初始传动机构设计中所存在的不足之处：加速度在往复运动的始末位置处存在跳变，因而对传动机构的凸轮结构采用了摆线运动规律对其进行修正，得到了较好的设计效果，保证了运动特性的连续性。
光栅刻划机作为机电一体化的重大装备，其设计与分析需要一个综合的开发及性能评价平台。本文提出了机械、控制一体化联合仿真开发技术，利用虚拟样机技术所提供的集成开发环境，在制造物理样机之前，联合控制系统设计软件，将复杂的控制系统添加到机械结构虚拟样机模型中，对机械系统与控制系统进行联合仿真分析，模拟实际产品中各个模块的工作特性，为复杂机械产品的开发提供了一种全新的设计方法。本文利用专业的机械分析及控制设计软件，对光栅刻划机中实现超精密刻划的最关键部分——分度系统精定位机构进行了仿真分析，首先建立经过适当简化的工作台运动学仿真模型，并构建相应的控制系统，进行联合仿真开发研究。在联合仿真平台中，通过对多组控制参数及采样时间的研究，验证了控制算法的有效性并确定了较佳的控制参数及相应的采样时间。
在光栅刻划机的系统设计中，控制软件是其中的重要组成部分。传统的软件开发一般需要等到硬件加工完成后再进行软件的调试，这就延长了软件的开发周期，无法适应于当前日益激烈的市场竞争环境。为了实现系统软件的并行开发，提出了基于虚拟硬件在环的软件仿真开发方法。利用计算机模拟实际控制单元的硬件运行情况，与被控对象的仿真模型相连进行软件的开发与调试，构建了应用软件运行所需要的虚拟硬件环境。本文以光栅刻划机控制软件为研究对象，详细介绍了基于虚拟硬件在环的软件仿真开发流程，并将开发完成的软件系统应用到光栅刻划机上，协调控制光栅刻划机的各个子系统共同实现了光栅的刻划。
Grating manufacturing technology is one of the most sophisticated technologies,and the grating ruling engine, which is used to manufacture grating, is known as the"King of precision machinery". It usually scores thousands of grooves per mm on theglass pressing blank, and requires accidental error less than1/10of grating constant,periodic error less than1/100grating constant and wavefront difference also less than1/3stripes. All of these performances determine that the grating ruling engine has ahigh precision, not only mechanism but also control system. Because ofultra-precision, parts are difficult to be manufactured, the development cycle is long,and the cost is also expensive. The traditional development process based on thephysical prototype does not apply to develop the grating ruling engine because itneeds repeated trial and modification and multiple physical prototypes aremanufactured before the final product. In this paper, the development process basedon virtual prototyping technology, which can reduce the physical experiments anddevelopment cost, shorten the development cycle, and improve the design quality, ispresented to develop the grating ruling engine. More importantly, this method doesnot repeat to manufacture the physical prototyp, so it avoids the traditional method’sdefect.
At first, the virtual prototype model of the grating ruling engine is established,including indexing subsystem and ruling subsystem. The indexing subsystem achievesthe ultra-precision positioning, and the ruling subsystem performs the ruling operation.These two subsystems work together to rule grating. In the working process, thetransmission performance affects the quality of grating, so it is necessary to beanalyzed and optimized to obtain the optimal design. In the transmission of theindexing system, influence of inertia on the control is analyzed and the inertiaoptimization objective is determined with the fast and stable respond. The sensitivityanalysis method is used to obtain the relationship between structural parameters andinertia, and then parameters are calculated to meet the requirements of inertia andstiffness. In order to ensure the quality of grating, the nickingtool need to maintainuniform motion, so the equal-speed transmission mechanism of the ruling subsystemis very important. In this paper, the displacement, velocity and acceleration of theinitial transmission mechanism design is calculated by using kinematics simulation based on virtal prototype technology. From the analysis, the inadequacies that jump ofacceleration occur at transition location is presented, so cycloidal motion law isadopted to amend this phenomenon to get better design and ensure the continuity ofmotion.
Grating ruling engine is one of the major mechanical and electrical equipment,whose design and analysis require a comprehensive platform for development andperformance evaluation. This paper presents a new methodology which combinesmechanism and control to simulation. In the integrated development environmentprovided by virtual prototype technology, complex control system is jointed tomechanism system to simulate the product performance. In this paper, the micro stagewhich is most important for positioning accuracy is analyzed. An appropriatesimplified stage’s simulation mode is established and control system is also built toachieve co-simulation. The effectiveness of control algorithms is verified and controlparameters are obtained by using co-simulation platform.
In the grating ruling engine system design, control software is an important part.In the traditional software development approach, the software is usually developedand debugged after the completion of the hardware processing which extendsdevelopment cycle and is unable to adapt to the fierce market competition. In order toachieve the parallel software development, software simulation developmentmethodology based on the virtual hardware in the loop is proposed. Computer is usedto simulate the actual control unit for software development and debugging with thecontrolled object’s model. This paper uses grating ruling engine’s control software asresearch subjects to describe the software simulation development. The developedapplication is ported to control the real grating ruling engine
引文
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