数控系统的算法仿真及其硬件设计
摘要
随着现代制造业的飞速发展,数控系统被广泛应用于现代加工业。数控系统是一种控制系统。它自动输入载体上预先给定的数字量,并将其译码,再进行必要的信息处理和运算后,控制机床动作和加工零件。
本文首先在PC(Personal Computer)机上,采用Turbo C软件完成了对数控系统基本功能的模拟。包括对数控语言的翻译、界面的开发、点插补、直线插补、圆弧顺时针插补、圆弧逆时针插补、坐标的跟踪、主轴正转与反转、车刀进给速度的控制以及最终程序的退出等等。整个系统通过PC机显示,控制并口输出高低电平。
然后,在PC机上仿真并设计了一款以DSP(Digital Signal Processor)为主控单元的数控系统。将在PC机上完成的仿真算法移植到DSP芯片当中,在芯片中完成界面实现的相关算法。首先,设计了数控系统的硬件电路,其中包括DSP的最小系统电路、电源模块、串口通信模块、外围电路。其中外围电路包括：电机接口电路、译码电路、中断电路、编码器脉冲差分接收电路、时钟电路。其次,为提高硬件集成度和可靠性,运用CPLD(Complex Programmable Device)进行了系统集成性开发,并作为主控芯片外围电路的核心部件。系统主要运用CPLD进行原理图设计的方法来完成编码器四倍频鉴向电路和30位的计数电路的功能,并在QuartusⅡ中进行了仿真。
结合前面设计的系统以及PC机界面仿真,针对刀具中心控制存在的刀具半径补偿问题,本文采用matlab软件对刀具半径补偿算法进行系统的研究。基于刀具半径补偿原理,在matlab中仿真并实现了一种新型的刀具半径补偿算法,该算法能有效剔除在缩短型刀具半径补偿情况下产生的冗余刀位点。
With the rapid development of modern manufacturing, Numerical control system has been widely used in modern processing industry. NC (numerical control) system is a control system; it inputs the digital automatically which has been assigned in advance and decoded. After processing and computing necessary information, it controls machine to process parts.
Firstly, this paper achieves the basic functions of numerical control system simulation using Turbo C software based on PC, including NC languages translation, interface development, point interpolation, linear interpolation, circular interpolation clockwise, counterclockwise circular interpolation, tracking coordinates, principal axis rotate and reversal, speed control, exiting from the final program and so on. The system displayed by PC, and puts out signal from parallel port.
In view of the simulation base on PC, design numerical control system whose control unit is based on DSP, transplant algorithm into DSP Firstly, the hardware of the NC system is designed, including the minimum system DSP circuits, power modules, serial communication module and peripheral circuits which include electromotor interface circuit, coding circuit, interrupt circuit, currency I/O interface circuit, and encoder impulse difference incept circuit and lock circuit. Secondly, in order to improve the integration and reliability of the hardware, CPLD is used to develop the system as a cential part of peripheral circuit. Use CPLD to design the schematic diagram to finish the coder's four times frequency circuit and 30 bits count circuit. At last, the system is simulated by Quartus II.
Combined with the former designed system and simulation on PC, according to the problem of tool radius compensation, the algorithm is researched though matlab. Based on the theory of tool radius compensation, an improved algorithm is simulated and realized in matlab, which can remove redundant points in the case of shortening tool radius compensation.
本文首先在PC(Personal Computer)机上,采用Turbo C软件完成了对数控系统基本功能的模拟。包括对数控语言的翻译、界面的开发、点插补、直线插补、圆弧顺时针插补、圆弧逆时针插补、坐标的跟踪、主轴正转与反转、车刀进给速度的控制以及最终程序的退出等等。整个系统通过PC机显示,控制并口输出高低电平。
然后,在PC机上仿真并设计了一款以DSP(Digital Signal Processor)为主控单元的数控系统。将在PC机上完成的仿真算法移植到DSP芯片当中,在芯片中完成界面实现的相关算法。首先,设计了数控系统的硬件电路,其中包括DSP的最小系统电路、电源模块、串口通信模块、外围电路。其中外围电路包括：电机接口电路、译码电路、中断电路、编码器脉冲差分接收电路、时钟电路。其次,为提高硬件集成度和可靠性,运用CPLD(Complex Programmable Device)进行了系统集成性开发,并作为主控芯片外围电路的核心部件。系统主要运用CPLD进行原理图设计的方法来完成编码器四倍频鉴向电路和30位的计数电路的功能,并在QuartusⅡ中进行了仿真。
结合前面设计的系统以及PC机界面仿真,针对刀具中心控制存在的刀具半径补偿问题,本文采用matlab软件对刀具半径补偿算法进行系统的研究。基于刀具半径补偿原理,在matlab中仿真并实现了一种新型的刀具半径补偿算法,该算法能有效剔除在缩短型刀具半径补偿情况下产生的冗余刀位点。
With the rapid development of modern manufacturing, Numerical control system has been widely used in modern processing industry. NC (numerical control) system is a control system; it inputs the digital automatically which has been assigned in advance and decoded. After processing and computing necessary information, it controls machine to process parts.
Firstly, this paper achieves the basic functions of numerical control system simulation using Turbo C software based on PC, including NC languages translation, interface development, point interpolation, linear interpolation, circular interpolation clockwise, counterclockwise circular interpolation, tracking coordinates, principal axis rotate and reversal, speed control, exiting from the final program and so on. The system displayed by PC, and puts out signal from parallel port.
In view of the simulation base on PC, design numerical control system whose control unit is based on DSP, transplant algorithm into DSP Firstly, the hardware of the NC system is designed, including the minimum system DSP circuits, power modules, serial communication module and peripheral circuits which include electromotor interface circuit, coding circuit, interrupt circuit, currency I/O interface circuit, and encoder impulse difference incept circuit and lock circuit. Secondly, in order to improve the integration and reliability of the hardware, CPLD is used to develop the system as a cential part of peripheral circuit. Use CPLD to design the schematic diagram to finish the coder's four times frequency circuit and 30 bits count circuit. At last, the system is simulated by Quartus II.
Combined with the former designed system and simulation on PC, according to the problem of tool radius compensation, the algorithm is researched though matlab. Based on the theory of tool radius compensation, an improved algorithm is simulated and realized in matlab, which can remove redundant points in the case of shortening tool radius compensation.
引文
1.靳希才,姜桂平.数控机床的发展趋势[J],天津职业院校联合学报,2007,9(2)：27-31.
2. 徐宁,杨秀云.数控系统的现状及发展趋势[J],机械设计与制造,2006,10(4)：132-134.
3.汤季安.机床数控系统的现状及其发展趋势[J],电世界,2008,8(2)：57-60.
4.孙斌,杨汝清.基于PC的数控系统的研究现状和发展趋势[J],机床与液压,2001,7(4)：3-5.
5.吴宏,蒋仕龙等.运动控制器的现状与发展[J],制造技术与机床,2004,1(8)：24-27.
6. Hongen Wu, Chengrui Zhang, Guili Li, and Baoren Wang. Window XP Embedded based Open Architecture Computer Numerical Control System [J], Mechtronic and Embedded Systerms and Applications,2006,10(8):1-6.
7. 刘春艳.面向开放式数控运动控制器的研究[D],福州.福州大学,2003.
8. Warren Sweames. Computer Numerical Control [M], Deimar Publishing Inc.1986, 52-60.
9. Ferrolho A., Crisostomo. Flexible manufacturing cell:development, coordination, integration and control [J], Control and Automation,2005,6(2):1050-1055.
10. Yunfei Li, Xuemei Zhu. Fuzzy Control Implementation of Cold Rolling Workpieces CNC Machine [J], Sensing and Control,2006, (8):528-531.
11. Fiona Zhao, Xun Xu, Shane Xie. STEP-NC enabled on-line inspection in support of cldsed-loop machining [J], Robotics and Computer-Integrated Manufacturing,2008, 24(2):200-216.
12.周凯.PC数控原理[M],系统及应用.北京：机械工业出版社,2006,16-22.
13.苏奎峰,吕强,耿庆峰,陈圣俭TMS320F2812原理与开发[M],北京：电子工业出版社,2005,23-24.
14.辛萌萌.RS-485通信接口芯片IC设计与实现[D],大连,大连理工大学硕士学位论文,2008.
15.张卫宁TMS320C28x系列DSP的CPU与外设[M],北京：清华大学出版社,2004,1-5.
16.刘宝琴ALTERA可编程逻辑器件及其应用[M],北京：机械工业出版社,2005,79-91.
17. Lin B-R.Hou Y-L. High-power-factor single-phase capacitor clamped rectifier [J], IEE Proc. Electr Power Appl,2001,48(2):214-224.
18.阎石.数字电子技术基础[M],北京：高等教育出版社,2002,56-71.
19.陈定明.机与控制[M],北京：高等教育出版社,2004,69-85.
20.王晓明.电动机的单片机控制[M],北京：北京航空航天大学,2002,43-46.
21.潘松.EDA技术使用教程[M],北京：科学出版社,2004,14-21.
22.姜雪松.可编程逻辑器件和EDA设计技术[M],北京：机械工业出版社,2006,14-15.
23.王润孝,秦现生.机床数控原理与系统[M],西安：西北工业大学出版社,2002,75-77.
24.龚运新.单片机C语言开发技术[M],北京：清华大学出版社,2006,33-37.
25.唐学飞,贺炜,周建来,王新安.C刀补对圆弧与圆弧缩短型转接的不当处理[J],组合机床与自动化加工技术,2008,7(11)：30-31.
26.冯清华.伺服电机运动控制器的研制[D],西安：西安理工大学,2004.
27. 阚宏林.基于单片机的交流伺服电机运动控制系统的研究与开发[D],西安：西安理工大学,2005.
28. Jeon J W. A generalized approach for the acceleration and deceleration of CNC maehine tools [J], In:Proceeding of the 1996 IEEE 22nd Intemational Conference on Industrial Electronies, Control, and Insturment(IECON), Taiwan,1996:1283-1258.
29.任玉田,焦振学,王宏甫.机床计算机数控技术[M],北京：北京理工大学出版社,2002.
30. Habetler, space vector-based rectifier regulator for AC/DC/AC, convertersm [J], IEEE Trans Power Electronics,1993,8(1):30-36.
31.李国洪.可编程器件EDA技术与实践[M],北京：机械工业出版社,2004,22-33.
32. James Carvajal, Haluk Ogmen. Fuzzy PID controller [M], Information Scinces,2006, 109-111.
33. Ridgely, J. D. Design, performance evaluation, and stability analysis [J], Information Scinces,123,12(2000)249-270.
34. Benjamin C. kuo, Farid Golnaraghi. Automatic Control Systems [M], Advanced education publication,2000,95-102.
35. Data, Aniruddha. Structure and synthesis of PID controllers [M], New York,2000, 65-69.
36. Xia Li, Wangyong Zhang, Jiaxin Zheng, et. Research on key technology and implementation of an open soft CNC system [J], Modular Machine Tool & Automation Manufacturing Technique,2003,5(10):6-8.
37. 薛定宇.反馈控制系统设计与分析-MATLAB语言应用[M],北京：清华大学出版社,2000,121-168.
38. 徐启发,黄健,江福杰.C机能平面刀补算法研究.研究与开发[M],2003,93-96.
39.李峰.C功能刀具半径补偿算法与实现[J],机床与液压,2008,8(8)：40-41.
40.王凌云,和延立,姚伟.数控系统的刀具半径补偿技术研究[J],浙江工业大学学报,2005,33(2)：219-223.
41. Yongzhang Wang, Liangji Chen. A Real-time NURBS Surface Interpolator for 5-axis Surface Machinin [J], Chinese Journal of Aeronautics,2005,18(3):263-272.
42. D. N. Moreton, R. Durnford. Fast Three-Dimensional Tool Compensation for a Three-Axis Turning Centre [J], Advanced Manufacturing Technology,1999,15(9): 649-645.
43. Tsehaw Yong, Ranga Narayanaswami. A parametric interpolator with confined chord errors [J], acceleration and deceleration for NC machining.2003,35(13):1249-1259.
44. SUN Bing, Ruqing Yang. The present state and perspectives of numerical control based on PC [J], Machine Tool and Hydraulic Pressure,2001(4):3-4.
45. Xunnian Yang. Efficient circular are interpolation based on active tolerance control [J], Computer-Aided Design,2002,34(13):1037-1046.
46. 王宇晗,肖凌剑,曾水生等.小线段高速加工速度衔接数学模型[J],上海交通大学学报,2004,38(6)：901-904.
47. Hongtzong Yau, Junbin Wang, Wenchie Chen, Development and implementation for real-time lookahead interpolator by using Bezier curve to fit CNC continuous short blocks [J], Proceedings of the 2005 IEEE International Conference on Mechatronics, 2005,78-83.
48. Y. Koren. Realtime curve interpolators [J], Computer-Aided Design,1994,1(18): 832-838.
49. 王爱玲,张吉堂,吴雁.现代数控原理及数控系统[M],北京：国防工业出版社,2004,105-109.
50.赵俊生.数控机床电气控制技术基础[M],北京：电子工业出版社,2005.
51.陈福安.数控原理与系统[M],北京：人民邮电出版,2008,159-162.
2. 徐宁,杨秀云.数控系统的现状及发展趋势[J],机械设计与制造,2006,10(4)：132-134.
3.汤季安.机床数控系统的现状及其发展趋势[J],电世界,2008,8(2)：57-60.
4.孙斌,杨汝清.基于PC的数控系统的研究现状和发展趋势[J],机床与液压,2001,7(4)：3-5.
5.吴宏,蒋仕龙等.运动控制器的现状与发展[J],制造技术与机床,2004,1(8)：24-27.
6. Hongen Wu, Chengrui Zhang, Guili Li, and Baoren Wang. Window XP Embedded based Open Architecture Computer Numerical Control System [J], Mechtronic and Embedded Systerms and Applications,2006,10(8):1-6.
7. 刘春艳.面向开放式数控运动控制器的研究[D],福州.福州大学,2003.
8. Warren Sweames. Computer Numerical Control [M], Deimar Publishing Inc.1986, 52-60.
9. Ferrolho A., Crisostomo. Flexible manufacturing cell:development, coordination, integration and control [J], Control and Automation,2005,6(2):1050-1055.
10. Yunfei Li, Xuemei Zhu. Fuzzy Control Implementation of Cold Rolling Workpieces CNC Machine [J], Sensing and Control,2006, (8):528-531.
11. Fiona Zhao, Xun Xu, Shane Xie. STEP-NC enabled on-line inspection in support of cldsed-loop machining [J], Robotics and Computer-Integrated Manufacturing,2008, 24(2):200-216.
12.周凯.PC数控原理[M],系统及应用.北京：机械工业出版社,2006,16-22.
13.苏奎峰,吕强,耿庆峰,陈圣俭TMS320F2812原理与开发[M],北京：电子工业出版社,2005,23-24.
14.辛萌萌.RS-485通信接口芯片IC设计与实现[D],大连,大连理工大学硕士学位论文,2008.
15.张卫宁TMS320C28x系列DSP的CPU与外设[M],北京：清华大学出版社,2004,1-5.
16.刘宝琴ALTERA可编程逻辑器件及其应用[M],北京：机械工业出版社,2005,79-91.
17. Lin B-R.Hou Y-L. High-power-factor single-phase capacitor clamped rectifier [J], IEE Proc. Electr Power Appl,2001,48(2):214-224.
18.阎石.数字电子技术基础[M],北京：高等教育出版社,2002,56-71.
19.陈定明.机与控制[M],北京：高等教育出版社,2004,69-85.
20.王晓明.电动机的单片机控制[M],北京：北京航空航天大学,2002,43-46.
21.潘松.EDA技术使用教程[M],北京：科学出版社,2004,14-21.
22.姜雪松.可编程逻辑器件和EDA设计技术[M],北京：机械工业出版社,2006,14-15.
23.王润孝,秦现生.机床数控原理与系统[M],西安：西北工业大学出版社,2002,75-77.
24.龚运新.单片机C语言开发技术[M],北京：清华大学出版社,2006,33-37.
25.唐学飞,贺炜,周建来,王新安.C刀补对圆弧与圆弧缩短型转接的不当处理[J],组合机床与自动化加工技术,2008,7(11)：30-31.
26.冯清华.伺服电机运动控制器的研制[D],西安：西安理工大学,2004.
27. 阚宏林.基于单片机的交流伺服电机运动控制系统的研究与开发[D],西安：西安理工大学,2005.
28. Jeon J W. A generalized approach for the acceleration and deceleration of CNC maehine tools [J], In:Proceeding of the 1996 IEEE 22nd Intemational Conference on Industrial Electronies, Control, and Insturment(IECON), Taiwan,1996:1283-1258.
29.任玉田,焦振学,王宏甫.机床计算机数控技术[M],北京：北京理工大学出版社,2002.
30. Habetler, space vector-based rectifier regulator for AC/DC/AC, convertersm [J], IEEE Trans Power Electronics,1993,8(1):30-36.
31.李国洪.可编程器件EDA技术与实践[M],北京：机械工业出版社,2004,22-33.
32. James Carvajal, Haluk Ogmen. Fuzzy PID controller [M], Information Scinces,2006, 109-111.
33. Ridgely, J. D. Design, performance evaluation, and stability analysis [J], Information Scinces,123,12(2000)249-270.
34. Benjamin C. kuo, Farid Golnaraghi. Automatic Control Systems [M], Advanced education publication,2000,95-102.
35. Data, Aniruddha. Structure and synthesis of PID controllers [M], New York,2000, 65-69.
36. Xia Li, Wangyong Zhang, Jiaxin Zheng, et. Research on key technology and implementation of an open soft CNC system [J], Modular Machine Tool & Automation Manufacturing Technique,2003,5(10):6-8.
37. 薛定宇.反馈控制系统设计与分析-MATLAB语言应用[M],北京：清华大学出版社,2000,121-168.
38. 徐启发,黄健,江福杰.C机能平面刀补算法研究.研究与开发[M],2003,93-96.
39.李峰.C功能刀具半径补偿算法与实现[J],机床与液压,2008,8(8)：40-41.
40.王凌云,和延立,姚伟.数控系统的刀具半径补偿技术研究[J],浙江工业大学学报,2005,33(2)：219-223.
41. Yongzhang Wang, Liangji Chen. A Real-time NURBS Surface Interpolator for 5-axis Surface Machinin [J], Chinese Journal of Aeronautics,2005,18(3):263-272.
42. D. N. Moreton, R. Durnford. Fast Three-Dimensional Tool Compensation for a Three-Axis Turning Centre [J], Advanced Manufacturing Technology,1999,15(9): 649-645.
43. Tsehaw Yong, Ranga Narayanaswami. A parametric interpolator with confined chord errors [J], acceleration and deceleration for NC machining.2003,35(13):1249-1259.
44. SUN Bing, Ruqing Yang. The present state and perspectives of numerical control based on PC [J], Machine Tool and Hydraulic Pressure,2001(4):3-4.
45. Xunnian Yang. Efficient circular are interpolation based on active tolerance control [J], Computer-Aided Design,2002,34(13):1037-1046.
46. 王宇晗,肖凌剑,曾水生等.小线段高速加工速度衔接数学模型[J],上海交通大学学报,2004,38(6)：901-904.
47. Hongtzong Yau, Junbin Wang, Wenchie Chen, Development and implementation for real-time lookahead interpolator by using Bezier curve to fit CNC continuous short blocks [J], Proceedings of the 2005 IEEE International Conference on Mechatronics, 2005,78-83.
48. Y. Koren. Realtime curve interpolators [J], Computer-Aided Design,1994,1(18): 832-838.
49. 王爱玲,张吉堂,吴雁.现代数控原理及数控系统[M],北京：国防工业出版社,2004,105-109.
50.赵俊生.数控机床电气控制技术基础[M],北京：电子工业出版社,2005.
51.陈福安.数控原理与系统[M],北京：人民邮电出版,2008,159-162.
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