复合进给电解加工机床控制系统设计与测试
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摘要
为解决航空制造领域复杂零件的加工难题,针对研制的复合进给电解加工机床,开发了基于PC(personal computer,个人计算机)和PMAC(programmable multi-axles controller,可编程多轴控制器)运动控制卡的开放式数控系统。基于虚拟仪器技术及其开发环境LabVIEW平台,遵循模块化设计思路,采用ActiveX自动化技术和CLF(call library function,调用库函数)节点设计了复合进给电解加工机床控制系统的人机交互界面,通过调用PMAC运动控制卡中的服务程序PmacServer,实现上位机与PMAC运动控制卡之间的功能交互。为了验证该控制系统的可靠性和运行稳定性,使用激光干涉仪进行了实验测试。实验结果显示,该控制系统响应迅速,运行稳定,人机交互界面易于操作;机床运动误差控制在-5～5μm内,重复定位误差小于2.3μm,能够满足航空发动机叶片的电解加工精度要求。研究结果在电解加工领域具有重要工程应用价值,可以为新一代高性能电解加工机床的设计提供参考。
To solve the problem of complex parts machining in aviation manufacturing field,an open CNC(computerized numerical control) system based on PC(personal computer) and PMAC(programmable multi-axles controller) motion control card was built for the compound feed electrochemical machine tool.Based on the virtual instrument technology and its development environment LabVIEW platform,following the modular design idea,the human-computer interaction interface of the control system for compound feed electrochemical machining machine tool was designed by using ActiveX automation technology and CLF(call library function) node.The function interaction between host computer and PMAC motion control card was realized by calling the service program PmacServer in the software.The experiments were carried out to verify the reliability and stability of the control system by using a laser interferometer.The results showed that the control system responded quickly and stably,the human-machine interface was easy to operate,the motion error of the machine tool was controlled within-5 to 5 μm,and the repetitive positioning accuracy was less than 2.3μm,which met the accuracy requirements of high precision electrochemical machining.The research results have important engineering application value in the field of electrochemical machining,which can provide a useful reference for the design of a new generation of high performance electrochemical machine tool.
To solve the problem of complex parts machining in aviation manufacturing field,an open CNC(computerized numerical control) system based on PC(personal computer) and PMAC(programmable multi-axles controller) motion control card was built for the compound feed electrochemical machine tool.Based on the virtual instrument technology and its development environment LabVIEW platform,following the modular design idea,the human-computer interaction interface of the control system for compound feed electrochemical machining machine tool was designed by using ActiveX automation technology and CLF(call library function) node.The function interaction between host computer and PMAC motion control card was realized by calling the service program PmacServer in the software.The experiments were carried out to verify the reliability and stability of the control system by using a laser interferometer.The results showed that the control system responded quickly and stably,the human-machine interface was easy to operate,the motion error of the machine tool was controlled within-5 to 5 μm,and the repetitive positioning accuracy was less than 2.3μm,which met the accuracy requirements of high precision electrochemical machining.The research results have important engineering application value in the field of electrochemical machining,which can provide a useful reference for the design of a new generation of high performance electrochemical machine tool.
引文
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[9]张明歧,傅军英.高温合金整体叶盘精密振动电解加工方法的应用分析[J].航空制造技术,2009,22(4):26-29.doi:10.3969/j.issn.1671-833X.2009.22.001ZHANG Ming-qi,FU Jun-ying.Application analysis of precise vibrating electrochemical machining in high-tem‐perature alloy disk[J].Aeronautical Manufacturing Tech‐nology,2009,22(4):26-29.
[10]MARTIN B,KRAUS-PETER R,ERWIN B.New manufacturing techniques for new engine component designs[C]//Proceedings of 20th International Symposium on Air Breathing Engines,Gothenburg,Sep.12-16,2011.
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[13]徐正扬,朱荻,史先传.基于LabVIEW/Flexmotion电解加工机床控制系统软件的设计[J].计算机与应用化学,2007,24(4):539-542.doi:10.3969/j.issn.1001-4160.2007.04.028XU Zheng-yang,ZHU Di,SHI Xian-chuan.Design of ECM machine tool control system software based on Lab‐VIEW/Flexmotion[J].Computers and Applied Chemis‐try,2007,24(4):539-542.
[14]高端,苗长云,王中伟.基于LabVIEW的多轴运动控制系统的设计与开发[J].天津工业大学学报,2008,27(6):58-61.doi:10.3969/j.issn.1671-024X.2008.06.017GAO Duan,MIAO Chang-yun,WANG Zhong-wei.De‐sign and exploitation on multi-axes motion control sys‐tem based on LabVIEW[J].Journal of Tianjin Polytech‐nic University,2008,27(6):58-61.
[15]吴成东,孙秋野,盛科.LabVIEW虚拟仪器程序设计及应用[M].北京:人民邮电出版社,2015:1-20.WU Cheng-dong,SUN Qiu-ye,SHENG Ke.The pro‐gram design and application of LabVIEW[M].Beijing:Posts&Telecom Press,2015:1-20.
[16]韦宏利,史媛,温军会.基于PMAC与LabVIEW的多轴运动控制系统的开发[J].西安工业大学学报,2012,32(2):112-118.doi:10.3969/j.issn.1673-9965.2012.02.006WEI Hong-li,SHI Yuan,WEN Jun-hui.Development of multi-axes motion control system based on PMAC and LabVIEW[J].Journal of Xi'an Technological Universi‐ty,2012,32(2):112-118.
[17]林延昌,鱼洋,沈跃.基于PMAC控制卡的机器人控制软件设计[J].计算机测量与控制,2005,13(8):854-857.doi:10.3969/j.issn.1671-4598.2005.08.037LIN Yan-chang,YU Yang,SHEN Yue.Robot control system based on PMAC card[J].Computer Measure‐ment&Control,2005,13(8):854-857.
[18]傅秀清,康敏,杨勇.基于PMAC5轴数控电解加工机床设计[J].电加工与模具,2009(2):62-65.doi:10.3969/j.issn.1009-279X.2009.02.018FU Xiu-qing,KANG Min,YANG Yong.Design of fiveaxis NC electrochemical manufacturing machine tool based on PMAC5[J].Electromachining&Mould,2009,(2):62-65.
[19]付立冬,康敏,杨勇.基于PMAC的数控电解加工机床控制系统设计[J].机床与液压,2010,38(15):50-52.doi:10.3969/j.issn.1001-3881.2010.15.016FU Li-dong,KANG Min,YANG Yong.Control system design of NC electrochemical manufacturing machine tool based on PMAC[J].Machine Tool&Hydraulics,2010,38(15):50-52.
[2]ZHU D,RAJURKARK P.Modeling and verification of interelectrode gap in electrochemical machining with passivating electrolyte[J].American Society of Mechanical Engineers Manufacturing Engineering Division,1999(10):589-596.
[3]孙伦业,徐正扬,朱荻.基于叶栅通道可加工性分析的整体叶盘径向电解加工阴极设计及实验[J].中国机械工程,2013,24(9):1137-1141.doi:10.3969/j.issn.1004-132X.2013.09.001SUN Lun-ye,XU Zheng-yang,ZHU Di.Cathode design and experiments on radial feeding in ECM of blisk based on cascade channel machinability analysis[J].China Me‐chanical Engineering,2013,24(9):1137-1141.
[4]刘嘉,方忠东,邓守成,等.整体叶盘电解加工阴极修正方法与试验[J].南京航空航天大学学报,2014,46(5):744-749.doi:10.3969/j.issn.1005-2615.2014.05.013LIU Jia,FANG Zhong-dong,DENG Shou-cheng,et al.Experimental study on cathode modification for electro‐chemical machining of blisk[J].Journal of Nanjing Uni‐versity of Aeronautics&Astronautics,2014,46(5):744-749.
[5]RAJURKARK P,SUNDARAM M M,MALSHE A P.Review of electrochemical and electrodischarge machining[J].Procedia CIRP,2013,6(1):13-26.doi:10.1016/j.procir.2013.03.002
[6]朱栋,朱荻,徐正扬.航空发动机叶片电解加工阴极数字化修正模型及其试验研究[J].机械工程学报,2011,47(7):191-197.doi:10.3901/JME.2011.07.191ZHU Dong,ZHU Di,XU Zheng-yang.Experimental study on the cathode digital modification of turbine blade in electrochemical machining[J].Journal of Mechanical Engineering,2011,47(7):191-197.
[7]刘嘉,徐正扬,万龙凯,等.整体叶盘叶型电解加工流场设计及实验[J].航空学报,2014,35(1):259-267.doi:10.7527/S1000-6893.2013.0380LIU Jia,XU Zheng-yang,WAN Long-kai,et al.Design and experiment of electrolyte flow mode in electrochemi‐cal machining of blisk[J].Acta Aeronautica et Astronauti‐ca Sinica,2014,35(1):259-267.
[8]黄春峰.现代航空发动机整体叶盘及其制造技术[J].航空制造技术,2006(4):94-100.doi:10.3969/j.issn.1671-833X.2006.04.021HUANG Chun-feng.Modern aeroengine integral blisk and its manufacturing technology[J].Aeronautical Manufac‐turing Technology,2006(4):94-100.
[9]张明歧,傅军英.高温合金整体叶盘精密振动电解加工方法的应用分析[J].航空制造技术,2009,22(4):26-29.doi:10.3969/j.issn.1671-833X.2009.22.001ZHANG Ming-qi,FU Jun-ying.Application analysis of precise vibrating electrochemical machining in high-tem‐perature alloy disk[J].Aeronautical Manufacturing Tech‐nology,2009,22(4):26-29.
[10]MARTIN B,KRAUS-PETER R,ERWIN B.New manufacturing techniques for new engine component designs[C]//Proceedings of 20th International Symposium on Air Breathing Engines,Gothenburg,Sep.12-16,2011.
[11]KLOCKE F,ZEIS M,KLINK A.Technological and economical capabilities of manufacturing titanium and nickel-based alloys via electrochemical machining(ECM)[J].Key Engineering Materials,2012,504-506(2):1237-1242.doi:10.4028/www.scientific.net/kem.504-506.1237
[12]史先传,丁端瑞,刘嘉,等.电解加工中振动与放电控制系统设计[J].机床与液压,2012,40(15):74-76.doi:10.3969/j.issn.1001-3881.2012.15.021SHI Xian-chuan,DING Duan-rui,LIU Jia,et al.De‐sign of vibration and discharge control system in ECM[J].Machine Tool&Hydraulics,2012,40(15):74-76.
[13]徐正扬,朱荻,史先传.基于LabVIEW/Flexmotion电解加工机床控制系统软件的设计[J].计算机与应用化学,2007,24(4):539-542.doi:10.3969/j.issn.1001-4160.2007.04.028XU Zheng-yang,ZHU Di,SHI Xian-chuan.Design of ECM machine tool control system software based on Lab‐VIEW/Flexmotion[J].Computers and Applied Chemis‐try,2007,24(4):539-542.
[14]高端,苗长云,王中伟.基于LabVIEW的多轴运动控制系统的设计与开发[J].天津工业大学学报,2008,27(6):58-61.doi:10.3969/j.issn.1671-024X.2008.06.017GAO Duan,MIAO Chang-yun,WANG Zhong-wei.De‐sign and exploitation on multi-axes motion control sys‐tem based on LabVIEW[J].Journal of Tianjin Polytech‐nic University,2008,27(6):58-61.
[15]吴成东,孙秋野,盛科.LabVIEW虚拟仪器程序设计及应用[M].北京:人民邮电出版社,2015:1-20.WU Cheng-dong,SUN Qiu-ye,SHENG Ke.The pro‐gram design and application of LabVIEW[M].Beijing:Posts&Telecom Press,2015:1-20.
[16]韦宏利,史媛,温军会.基于PMAC与LabVIEW的多轴运动控制系统的开发[J].西安工业大学学报,2012,32(2):112-118.doi:10.3969/j.issn.1673-9965.2012.02.006WEI Hong-li,SHI Yuan,WEN Jun-hui.Development of multi-axes motion control system based on PMAC and LabVIEW[J].Journal of Xi'an Technological Universi‐ty,2012,32(2):112-118.
[17]林延昌,鱼洋,沈跃.基于PMAC控制卡的机器人控制软件设计[J].计算机测量与控制,2005,13(8):854-857.doi:10.3969/j.issn.1671-4598.2005.08.037LIN Yan-chang,YU Yang,SHEN Yue.Robot control system based on PMAC card[J].Computer Measure‐ment&Control,2005,13(8):854-857.
[18]傅秀清,康敏,杨勇.基于PMAC5轴数控电解加工机床设计[J].电加工与模具,2009(2):62-65.doi:10.3969/j.issn.1009-279X.2009.02.018FU Xiu-qing,KANG Min,YANG Yong.Design of fiveaxis NC electrochemical manufacturing machine tool based on PMAC5[J].Electromachining&Mould,2009,(2):62-65.
[19]付立冬,康敏,杨勇.基于PMAC的数控电解加工机床控制系统设计[J].机床与液压,2010,38(15):50-52.doi:10.3969/j.issn.1001-3881.2010.15.016FU Li-dong,KANG Min,YANG Yong.Control system design of NC electrochemical manufacturing machine tool based on PMAC[J].Machine Tool&Hydraulics,2010,38(15):50-52.