【摘要】：隨著復雜精密折彎工藝要求的不斷提高、勞動力成本與勞動者對工作環(huán)境要求的日益提升，在鈑金制造業(yè)中應用具有響應速度快、智能化與網(wǎng)絡化程度高、控制精度優(yōu)良、節(jié)能環(huán)保等特點的全電動折彎機已成為發(fā)展趨勢。某些特殊行業(yè)加工的鈑金件尺寸較大、板材較厚以及精度要求高，，對全電動折彎機的研制提出了更苛刻的要求，不僅須具備強勁的折彎壓力，還須有優(yōu)越的多軸同步性能。而大噸位折彎壓力的輸出一般需多臺電機同步并行驅動來實現(xiàn)，因此研究大噸位高精度全電動折彎機伺服同步控制系統(tǒng)及關鍵技術為發(fā)展新一代具有我國自主知識產(chǎn)權的全電動折彎機產(chǎn)業(yè)打下堅實基礎。 本文通過綜合分析市場發(fā)展需求和國內(nèi)外全電動折彎機研究現(xiàn)狀，提出一種基于LinuxCNC2.5開放式數(shù)控平臺的大功率全電動折彎機伺服同步控制系統(tǒng)總體設計方案。重點對電氣控制系統(tǒng)硬件、數(shù)控系統(tǒng)軟件以及折彎控制工藝作出詳細設計與研究。該方案通過實時EtherCAT總線將工業(yè)PC與伺服驅動器聯(lián)接起來，實現(xiàn)了硬件結構的最優(yōu)精簡。數(shù)控軟件采用LinuxCNC2.5數(shù)控平臺具有良好的穩(wěn)健性、擴展性及控制性能。 本文首先在分析全電動折彎機傳動結構與運行原理的基礎上提出了兩種設計方案，一種是基于DSP和FPGA的嵌入式平臺，形成專用于折彎工藝的特制數(shù)控系統(tǒng)。另一種為基于工業(yè)PC和LinuxCNC2.5的開放式控制系統(tǒng)，借助PC強大的運算能力和實時Linux操作系統(tǒng)以實現(xiàn)功能更強、精度更高的控制。經(jīng)多方面比較，本文選取后者展開設計。其次，針對選定的方案進行詳盡系統(tǒng)硬件選型，包括伺服驅動器和電機、位置檢測傳感器、工業(yè)PC等，并利用各個設備組建起一個完整穩(wěn)定的硬件平臺。再次，進行數(shù)控軟件設計及關鍵技術研究，在分析實時Linux系統(tǒng)和LinuxCNC2.5架構的基礎上實現(xiàn)EtherCAT主站模塊的設計、S型加減速控制算法的改進以及面向折彎機工藝的HAL配置。在深入剖析四軸同步控制難點的基礎上，創(chuàng)造性提出一種基于偏差耦合與動態(tài)力矩控制技術融合的同步驅動策略，樣機測試充分表明該策略有效可行。最后，采用PyQt與OpenGL技術實現(xiàn)功能完備的人機界面與3D圖形化編程，并重點研究了利用數(shù)據(jù)庫技術與最小二乘法原理來設計自學習型折彎進深補償算法。 樣機試驗表明上述設計切實可行，具有滿意的同步性能和加工精度，為大功率全電動折彎機提供了一種合理、可靠、高效的控制方法。
[Abstract]:With the development of complex precision bending process and the increasing demand of labor cost and working environment, the application in sheet metal manufacturing industry has fast response speed, high degree of intelligence and networking, and good control precision. Energy-saving and environmental-friendly all-electric bending machine has become a trend of development. The sheet metal parts processed in some special industries are larger in size, thicker in plate and higher in precision, so the development of all-electric bending machine is required to be more stringent. It must not only have strong bending pressure, but also have superior multi-axis synchronous performance. The output of large tonnage bending pressure usually requires synchronous and parallel drive of multiple motors. Therefore, the research on servo synchronous control system of large-tonnage and high-precision all-electric bending machine and its key technologies lay a solid foundation for the development of a new generation of all-electric bending machine industry with independent intellectual property rights in China. Based on the comprehensive analysis of the market development requirements and the research status of all-electric bending machines at home and abroad, this paper presents an overall design scheme of servo synchronous control system for high-power all-electric bending machines based on LinuxCNC2.5 open CNC platform. Focus on the electrical control system hardware, numerical control system software and bending control technology to make a detailed design and research. This scheme connects industrial PC with servo driver by real-time EtherCAT bus, and realizes the optimal reduction of hardware structure. Numerical control software using LinuxCNC2.5 CNC platform has good robustness, expansibility and control performance. In this paper, based on the analysis of transmission structure and operation principle of all-electric bending machine, two design schemes are put forward. One is embedded platform based on DSP and FPGA to form a special CNC system for bending process. The other is an open control system based on industrial PC and LinuxCNC2.5. With the help of the powerful computing power of PC and the real-time Linux operating system, the control system with stronger function and higher precision can be realized. After many aspects of comparison, this paper selects the latter to expand the design. Secondly, the hardware selection of the selected system is carried out in detail, including servo driver and motor, position detection sensor, industrial PC and so on, and a complete and stable hardware platform is constructed by using each equipment. Thirdly, the numerical control software design and the key technology are studied. Based on the analysis of the real-time Linux system and the LinuxCNC2.5 architecture, the design of the EtherCAT master station module and the improvement of the S-type acceleration and deceleration control algorithm and the HAL configuration oriented to the bending machine process are realized. On the basis of deeply analyzing the difficulties of four-axis synchronous control, a synchronous drive strategy based on the combination of deviation coupling and dynamic torque control is proposed. The prototype test shows that the strategy is effective and feasible. Finally, PyQt and OpenGL are used to realize the fully functional man-machine interface and 3D graphical programming, and the algorithm of self-learning bending depth compensation is designed by using database technology and least square method. The prototype test shows that the design is feasible, has satisfactory synchronous performance and machining precision, and provides a reasonable, reliable and efficient control method for the high-power all-electric bending machine.
【學位授予單位】：華南理工大學
【學位級別】：碩士
【學位授予年份】：2013
【分類號】：TP273

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