本文關(guān)鍵詞： 電子齒輪箱 數(shù)控齒輪加工 滾齒 插齒 展成運(yùn)動(dòng) 多軸聯(lián)動(dòng) 非圓齒輪 柔性　出處：《合肥工業(yè)大學(xué)》2014年博士論文　論文類(lèi)型：學(xué)位論文

【摘要】：電子齒輪箱是一種特殊的多軸同步運(yùn)動(dòng)控制技術(shù),可以實(shí)現(xiàn)復(fù)雜的多軸耦合聯(lián)動(dòng)關(guān)系,具有傳動(dòng)比范圍寬、傳動(dòng)精度高、調(diào)整方便等特點(diǎn)。電子齒輪箱的基本功能是代替機(jī)械傳動(dòng)鏈,實(shí)現(xiàn)兩個(gè)或多個(gè)運(yùn)動(dòng)的定速比或變速比控制,保證各軸運(yùn)動(dòng)之間嚴(yán)格的同步關(guān)系。在數(shù)控齒輪加工機(jī)床中,采用電子齒輪箱控制模塊,可以實(shí)現(xiàn)多坐標(biāo)軸按照給定的約束關(guān)系進(jìn)行同步運(yùn)動(dòng)。采用軟件式電子齒輪箱控制策略,不僅可以實(shí)現(xiàn)滾齒機(jī)和插齒機(jī)等齒輪機(jī)床加工常規(guī)圓柱齒輪對(duì)多軸聯(lián)動(dòng)的要求,還能實(shí)現(xiàn)非圓齒輪加工的變比傳動(dòng)要求。在齒輪的展成加工過(guò)程中,齒輪形狀的產(chǎn)生依賴(lài)于刀具與工件的耦合運(yùn)動(dòng)及進(jìn)給附加運(yùn)動(dòng)的多軸聯(lián)動(dòng)關(guān)系,該運(yùn)動(dòng)關(guān)系由電子齒輪箱控制實(shí)現(xiàn),其精度控制不僅包含刀具路徑軌跡本身的輪廓精度,還包含從運(yùn)動(dòng)軸與主運(yùn)動(dòng)軸之間的同步精度。 本文設(shè)計(jì)了適用于齒輪數(shù)控展成加工的柔性電子齒輪箱結(jié)構(gòu),使其在自主研發(fā)的齒輪加工數(shù)控系統(tǒng)中實(shí)現(xiàn),并深入研究了電子齒輪箱的精度控制方法。論文的主要研究?jī)?nèi)容如下： 1.通過(guò)對(duì)滾齒、插齒及非圓齒輪加工原理的分析和研究,推導(dǎo)出滾齒加工數(shù)學(xué)模型、插齒加工數(shù)學(xué)模型及非圓齒輪加工數(shù)學(xué)模型,構(gòu)建了一種主從式復(fù)合結(jié)構(gòu)的柔性電子齒輪箱,通過(guò)電子齒輪箱控制系數(shù)和數(shù)控軸定義的改變,形成滾齒加工電子齒輪箱、插齒加工電子齒輪箱(電子螺旋導(dǎo)軌)及非圓齒輪加工電子齒輪箱,提出柔性電子齒輪箱的概念,充分展現(xiàn)了軟件式電子齒輪箱具有易改變、可重構(gòu)的柔性特征。 2.提出將柔性電子齒輪箱與插補(bǔ)模塊相結(jié)合,形成柔性電子齒輪箱插補(bǔ)模塊,在嵌入式多CPU數(shù)控系統(tǒng)硬件平臺(tái)上,采用模塊化可重構(gòu)思想,設(shè)計(jì)了數(shù)控系統(tǒng)總體架構(gòu),詳細(xì)剖析了數(shù)控系統(tǒng)軟件內(nèi)部的信息流向,將柔性電子齒輪箱無(wú)縫地嵌入在齒輪加工數(shù)控系統(tǒng)中。在自行開(kāi)發(fā)的嵌入式齒輪加工數(shù)控系統(tǒng)中實(shí)現(xiàn)了柔性電子齒輪箱的NC控制,通過(guò)程序運(yùn)行實(shí)驗(yàn)數(shù)據(jù)與理論計(jì)算數(shù)據(jù)的對(duì)比分析,說(shuō)明了柔性電子齒輪箱軟件執(zhí)行的正確性。 3.詳細(xì)研究了數(shù)控系統(tǒng)常用輪廓精度和跟蹤精度的基本控制策略,分析其控制結(jié)構(gòu)和試用條件,建立了柔性電子齒輪箱的基本控制模型。根據(jù)柔性電子齒輪箱的結(jié)構(gòu)特點(diǎn),選擇合適的增益匹配方式,推導(dǎo)出增益匹配數(shù)學(xué)模型,并在閉環(huán)數(shù)控實(shí)驗(yàn)平臺(tái)上驗(yàn)證了增益匹配模型的有效性。考慮到增益匹配在一定程度上會(huì)帶來(lái)跟蹤精度的降低,結(jié)合柔性電子齒輪箱運(yùn)動(dòng)過(guò)程中刀具軌跡的特點(diǎn),將交叉耦合控制模型應(yīng)用在有多軸聯(lián)動(dòng)要求的進(jìn)給軸之間,建立其交叉耦合補(bǔ)償模型,并在閉環(huán)數(shù)控實(shí)驗(yàn)平臺(tái)上驗(yàn)證了交叉耦合控制模型的有效性。由于本文所提出的電子齒輪箱控制模型對(duì)工作臺(tái)回轉(zhuǎn)軸的跟蹤精度有較高要求,故研究了零相前饋控制方法,可以在精確建立系統(tǒng)模型并且系統(tǒng)超前信號(hào)已知的情況下實(shí)現(xiàn)單軸的高精度跟蹤控制。 4.研究了由前饋控制器和交叉耦合控制器構(gòu)成的復(fù)合式交叉耦合控制器的實(shí)現(xiàn)原理,并詳細(xì)分析了該控制結(jié)構(gòu)的設(shè)計(jì)步驟及系統(tǒng)穩(wěn)定性,證明該控制器可以同時(shí)提高系統(tǒng)的輪廓精度和跟蹤精度。以圓柱斜齒輪的軸向滾切為例,從加工工藝和幾何的角度分析了電子齒輪箱控制誤差的產(chǎn)生原因,并對(duì)相關(guān)誤差的計(jì)算公式進(jìn)行推導(dǎo),結(jié)合主從式電子齒輪箱的結(jié)構(gòu)特點(diǎn)與復(fù)合式交叉耦合控制器的設(shè)計(jì)原理,構(gòu)建了復(fù)合式交叉耦合柔性電子齒輪箱結(jié)構(gòu)模型,采用Matlab仿真的形式驗(yàn)證了復(fù)合式交叉耦合柔性電子齒輪箱具有較好的控制效果。.研究了模糊控制原理和生物免疫調(diào)節(jié)機(jī)理,將兩者與PID控制相結(jié)合,構(gòu)成模糊免疫PID控制器,并將這種智能控制算法應(yīng)用在復(fù)合式交叉耦合電子齒輪箱的位置控制環(huán)節(jié),仿真結(jié)果表明該控制方法可以進(jìn)一步提高電子齒輪箱的控制精度。 5.將復(fù)合式交叉耦合柔性電子齒輪箱模型與主從式電子齒輪箱模型分別嵌入齒輪加工數(shù)控系統(tǒng)中,采用軸向滾切法進(jìn)行實(shí)驗(yàn),實(shí)驗(yàn)結(jié)果表明復(fù)合式交叉耦合柔性電子齒輪箱具有較好的控制精度,并在此基礎(chǔ)上做了對(duì)角滾切實(shí)驗(yàn)及電子齒輪箱控制精度分析,驗(yàn)證了圓柱齒輪滾切加工電子齒輪箱軟件具有精確的控制功能；采用電子螺旋導(dǎo)軌實(shí)現(xiàn)圓柱斜齒輪插齒加工運(yùn)動(dòng)控制實(shí)驗(yàn),并對(duì)運(yùn)動(dòng)過(guò)程中各軸的位置軌跡及各軸的跟蹤誤差進(jìn)行采集和分析,結(jié)果表明電子螺旋導(dǎo)軌可以精確實(shí)現(xiàn)圓柱斜齒輪的插齒加工運(yùn)動(dòng)控制；采用非圓滾齒加工電子齒輪箱實(shí)現(xiàn)一階橢圓齒輪的加工運(yùn)動(dòng)控制,采用非圓插齒電子齒輪箱實(shí)現(xiàn)三階橢圓齒輪的加工運(yùn)動(dòng)控制,并分別對(duì)運(yùn)動(dòng)過(guò)程數(shù)據(jù)進(jìn)行了采樣分析,實(shí)驗(yàn)結(jié)果表明柔性電子齒輪箱可以精確實(shí)現(xiàn)非圓齒輪加工所要求的多軸聯(lián)動(dòng)運(yùn)動(dòng)控制關(guān)系。 6.最后本文將電子齒輪箱控制軟件成功的應(yīng)用于自主研發(fā)的齒輪加工數(shù)控系統(tǒng)中,并將該數(shù)控系統(tǒng)與重慶機(jī)床廠生產(chǎn)的YS3118CNC5滾齒機(jī)床及天津第一機(jī)床總廠生產(chǎn)的YK5132B插齒機(jī)床配套。在自主研發(fā)的滾齒數(shù)控系統(tǒng)的控制下,完成了標(biāo)準(zhǔn)測(cè)試齒輪的加工,其中滾齒機(jī)床所加工的標(biāo)準(zhǔn)直齒輪精度可達(dá)5級(jí),標(biāo)準(zhǔn)斜齒輪精度可達(dá)7級(jí),插齒機(jī)床所加工的標(biāo)準(zhǔn)直齒輪精度可達(dá)6級(jí)。充分證明了本文所提出的柔性電子齒輪箱在實(shí)際加工應(yīng)用中的高精度、可靠性和實(shí)用性。
[Abstract]:The electronic gear box is a kind of special multi axis synchronous motion control technology, multi axis coupling relationship can realize complex, with a wide range of transmission ratio, high transmission precision, easy adjustment and so on. The basic functions of electronic gear box is used instead of mechanical transmission chain, to achieve two or more fixed ratio or a variable motion than the control, ensure strict synchronous relation between each axis. In NC gear machine, electronic gear box control module, can realize multi axis according to the constraints of the given synchronous movement. By using the software of electronic gear box control strategy can not only achieve the requirements of gear hobbing machine and gear slotting machine etc. conventional machining of cylindrical gear of multi axis linkage, can realize the transmission ratio of noncircular gear machining requirements. In gear machining process, which depends on the shape of gear cutter and workpiece The multi axis linkage relationship between coupling motion and feed additional motion is realized by electronic gearbox control. The accuracy control includes not only the contour accuracy of tool path itself, but also the synchronization accuracy between the motion axis and the main motion axis.
In this paper, a flexible electronic gearbox structure suitable for gear NC generating process is designed, which is implemented in a self-developed gear manufacturing CNC system, and the accuracy control method of electronic gearbox is further studied.
1. through the hobbing, inserted and non analysis and Research on circular gear hobbing machining principle, mathematical model, mathematical model and slotting machining of noncircular gear machining model, builds a flexible electronic gear box a master-slave type composite structure, control coefficient and NC axis defined by electronic gear box change, the formation of hobbing electronic gear box, gear shaping electronic gear box (electronic spiral rail) and noncircular gear machining electronic gear box, put forward the concept of flexible electronic gear box, full software type electronic gear box is easy to change, flexible features can be reconstructed.
2. the flexible electronic gear box and the interpolation module combination, form a flexible electronic gear box interpolation module in the hardware platform of embedded multi CPU CNC system, modular reconfigurable idea, designed the overall architecture of the CNC system, a detailed analysis of the CNC system software in the information flow, will be seamlessly embedded flexible electronic gear the box in gear machining CNC system. In embedded gear machining CNC system developed by the realization of flexible electronic gear box NC control, through the program of experimental data and the calculated data comparative analysis, illustrate the correctness of the flexible electronic gearbox software implementation.
3. a detailed study of the basic control strategy commonly used contour accuracy and tracking accuracy of CNC system, analyzes its control structure and operating conditions, establish the basic control model of flexible electronic gear box. According to the structure characteristics of flexible electronic gear box, select the appropriate gain matching, derived gain matching mathematical model, and verify the effectiveness gain matching model in closed loop NC experimental platform. Considering the gain, to a certain extent will reduce the tracking precision, combined with the characteristics of the tool path of flexible electronic gear box in the process of movement, the cross coupling control is applied in Multi Axis axis requirements, establish the cross coupling compensation model, and to verify the effectiveness of the proposed control model of cross coupling in closed loop NC experimental platform. Because the electronic gear box control model proposed in this paper to rotary table The accuracy of axis tracking is high, so the zero phase feedforward control method is studied. It can achieve single axis high precision tracking control under the condition of accurately establishing the system model and the system's leading signal is known.
4. realization of the principle of the composite cross coupling controller consists of feedforward controller and cross coupled controller, and a detailed analysis of the stability of the control system design steps and structure, proved that the controller can improve system accuracy and tracking accuracy. The contour to the axial helical gear hobbing as an example, analysis of the electronic gear the causes of the error control box from the machining process and geometry, and the calculation formula of relative error was derived, the design principle of master-slave structure according to the characteristics of electronic gear box and composite cross coupling controller, constructed a composite cross coupled flexible electronic gear box structure model, using Matlab simulation to verify the composite form cross coupled flexible electronic gear box has a better control effect. On the principle of fuzzy control and immune regulation mechanism, the two Combined with PID control, a fuzzy immune PID controller is constructed, and the intelligent control algorithm is applied to the position control part of the compound cross coupled electronic gearbox. The simulation results show that the control method can further improve the control accuracy of the electronic gearbox.
5. composite cross coupled flexible electronic gear box model and master-slave electronic gear box model are respectively embedded CNC gear machining, the axial hobbing method, the experimental results show that the composite cross coupling flexible electronic gear box has better control accuracy, and on the basis of the diagonal roll cutting experiment and electronic gear box control precision analysis, verify the cylindrical gear hobbing electronic gearbox software has accurate control function; using electronic spiral helical gear tooth movement guide insert process control experiment, and to collect and analyze the trajectory of the movement of the shaft in the process and the axis of the tracking error, the results show that the electronic spiral guide can to achieve precise motion control inserted tooth machining cylindrical helical gear; non circular gear hobbing machining electronic gear box movement order elliptic gear control For non circular gear electronic gear box realization of three order elliptic gear machining motion control, and the movement process of data were collected and analyzed, the experimental results show that the flexible electronic gear box can accurately realize multi axis motion non circular gear machining control system.
6. finally the gear machining CNC system of electronic gear box control application software is successful in the independent research and development, and the CNC system and Chongqing machine tool factory production of YS3118CNC5 rolling factory of machine tool and the Tianjin first machine tool production YK5132B machine. In the control gear hobbing CNC system developed under the complete the processing standard test of gear hobbing machine, the processing precision can reach 5 level standard spur gear, helical gear standard precision can reach 7, slotting machine processing standard spur gear precision can reach 6. Fully demonstrated the high accuracy in the actual processing and application of flexible electronic gear box is proposed in this paper, the reliability and practicability.

【學(xué)位授予單位】：合肥工業(yè)大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2014
【分類(lèi)號(hào)】：TH132.4

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