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id="print"> <p><span style="font-size: 18px;">近年来，我国航空航天事业发展迅猛，<a href='https://www.yujiangcnc.com/' target='_blank'>五轴加工中心</a>以其独具的结构特性，大加工范围、高加工效率、高动态特性等优点，成为广泛应用于高精尖航空航天大型结构件加工的行业重器。为保证五轴加工中心的高动态响应特性，本文以GMC2040u为研究对象，通过对五轴的插补路径速度变化曲线的实时跟踪以及现场实际情况的反馈，采用自动控制技术，对大型五轴加工中心的速度路径的优化提出了解决方案。</span></p><p><span style="font-size: 18px;">1.结构描述</span></p><p><span style="font-size: 18px;">如图1所示。横梁在床身上水平移动为X轴，X轴由四个电机驱动，横梁的左右两侧各有两个电机拖动，X轴为齿轮齿条结构，横梁两侧的两个伺服电机为主从控制方式，起到分摊力矩和消除齿轮齿条传动间隙的作用，X轴左右两侧的主动电机采用龙门驱动控制方式，这种控制方式不但使X轴运行平稳，还可增加机床的跨距，X轴两侧各配置一根光栅尺，形成全闭环控制系统，提高机床的定位精度。滑板在横梁上沿水平方向左右移动为Y轴，滑枕沿滑板上下移动为Z轴。铣头为叉式结构，绕X轴摆动为A轴、绕Z轴转动为C轴，实现X、Y、Z、A、C五轴联动的机械结构。</span></p><p><img src="/bethel/upload/images/202608/17875483948236.png" title="17875483948236.png" alt="image.png"/></p><p><span style="font-size: 18px;">2.优化</span></p><p><span style="font-size: 18px;">(1)现场速度数据采集</span></p><p><span style="font-size: 18px;">观测零件程序运行过程，开启RTCP后，机床各轴的插补速度在直线运动转换到圆弧运动时和圆弧运动转换到直线运动时，降速特别明显且不稳定。为具体了解降速的程度，分别在进给速度为2000mm/min和3000mm/min时各采集了10组速度数值，如表1所示。</span></p><p><img src="/bethel/upload/images/202608/17875484255744.png" title="17875484255744.png" alt="image.png"/></p><p><span style="font-size: 18px;">(2)仿真速度曲线采集<br/></span></p><p><span style="font-size: 18px;">通过SINUTRAIN软件，采集各轴的速度路径曲线，图2为速度路径变量，图3为仿真得出的速度路径曲线。</span></p><p><img src="/bethel/upload/images/202608/17875484629833.png" title="17875484629833.png" alt="image.png"/></p><p><span style="font-size: 18px;">(3)加加速度的优化</span></p><p><span style="font-size: 18px;">从图3-2可以看出，在开启RTCP后，参与插补的轴的速度为使各轴达到插补速度，数控系统会自动调节各轴的运行速度，从而插补速度有了明显的降低，因此需要检查插补轴的原有路径最大加加速度、轴加加速度、以及最大限制值等参数的设置，如:MD20600，MD20602，MD20606，MD32431，MD32432等的设定值，原始参数设定值如下:</span></p><p><img src="/bethel/upload/images/202608/17875484805415.png" title="17875484805415.png" alt="image.png"/></p><p><span style="font-size: 18px;">提升加加速度的设定值，将所有插补轴的加加速度设置为30，SINUTRAIN仿真如图4所示。</span></p><p><img src="/bethel/upload/images/202608/17875484967955.png" title="17875484967955.png" alt="image.png"/></p><p><span style="font-size: 18px;">(4)工艺程序上的优化</span></p><p><span style="font-size: 18px;">在已经更改上述参数的基础上，增加精优曲面工艺循环(CYCLE832)指令，并选择精加工，轴允差设置成后置处理允差的5倍，如图5所示。</span></p><p><img src="/bethel/upload/images/202608/17875485104883.png" title="17875485104883.png" alt="image.png"/></p><p><span style="font-size: 18px;">编程位置值精确到小数点五位，增加FGROUP(X,Y,Z,A,C)工艺语句，SINUTRAIN仿真图形如图6所示。</span></p><p><img src="/bethel/upload/images/202608/17875485231799.png" title="17875485231799.png" alt="image.png"/></p><p><span style="font-size: 18px;">(5)速度优化</span></p><p><span style="font-size: 18px;">将插补轴的原有路径的最大加加速度、轴加加速度、以及最大限制值等参数的数值提高，如下参数:</span></p><p><span style="font-size: 18px;">MD32300 $MA_MAX_AX_ACCEL[0,AX5]=70</span></p><p><span style="font-size: 18px;">MD32300 $MA_MAX_AX_ACCEL[1,AX5]=70</span></p><p><span style="font-size: 18px;">MD32300 $MA_MAX_AX_ACCEL[2,AX5]=70 //粗加工</span></p><p><span style="font-size: 18px;">MD32300 $MA_MAX_AX_ACCEL[3,AX5]=70 //半精加工</span></p><p><span style="font-size: 18px;">MD32300 $MA_MAX_AX_ACCEL[4,AX5]=70 //精加工</span></p><p><span style="font-size: 18px;">MD32431 $MA_MAX_AX_JERK[0,AX5]=30</span></p><p><span style="font-size: 18px;">MD32431 $MA_MAX_AX_JERK[1,AX5]=30</span></p><p><span style="font-size: 18px;">MD32431 $MA_MAX_AX_JERK[2,AX5]=30 //粗加工</span></p><p><span style="font-size: 18px;">MD32431 $MA_MAX_AX_JERK[3,AX5]=30 //半精加工</span></p><p><span style="font-size: 18px;">MD32431 $MA_MAX_AX_JERK[4,AX5]=30 //精加工</span></p><p><span style="font-size: 18px;">MD32432 $MA_PATH_TRANS_JERK_LIM[0,AX5]=30</span></p><p><span style="font-size: 18px;">MD32432 $MA_PATH_TRANS_JERK_LIM[1,AX5]=30</span></p><p><span style="font-size: 18px;">MD32432 $MA_PATH_TRANS_JERK_LIM[2,AX5]=30 //粗加工</span></p><p><span style="font-size: 18px;">MD32432 $MA_PATH_TRANS_JERK_LIM[3,AX5]=30 //半精加工</span></p><p><span style="font-size: 18px;">MD32432 $MA_PATH_TRANS_JERK_LIM[4,AX5]=30 //精加工</span></p><p><span style="font-size: 18px;">SINUTRAIN仿真图形如图7所示。</span></p><p><img src="/bethel/upload/images/202608/17875485399415.png" title="17875485399415.png" alt="image.png"/></p><p><span style="font-size: 18px;">3.结语</span></p><p><span style="font-size: 18px;">从仿真图7中可以看出，优化后插补速度最低降至1300mm/min，但是据现场实际数据采集反馈得到的速度降到800mm/min，虽然没有达到十分理想的速度，但是确实通过自动控制技术使插补速度得到了明显提升;由优化过程可见，只通过更改参数或只优化工艺语句不能达到想要的提速效果，需要综合电气控制和工艺路径进行优化。此外，经机床集团技术专家及西门子服务工程师确认，针对这台机床，控制参数的设置已经达到最优，在对控制系统的插补优化技术方面已经完成。而开启五轴插补会有降速是正常现象，但是还能否进一步提升相关参数设定值和插补速度，还需要进行机械设计和装配工艺方面的研究，才能解决仿真的插补速度和实际切削的插补速度不一致的问题。</span></p></div> <div class="blank30"></div> <!-- tag --> <div class="blank10"></div> 标签： <a href='/index.php?case=tag&act=show&tag=%E4%BA%94%E8%BD%B4%E5%8A%A0%E5%B7%A5%E4%B8%AD%E5%BF%83' target='_blank'>五轴加工中心</a> <div class="blank30"></div> <!--自动调用自定义字段--> <div class="blank20"></div> <div class="blank30"></div> <!-- 投票 --> <script 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