微细电火花加工伺服运动预测与控制方法研究
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摘要
精微制造技术已成为当今制造业中十分重要的生产加工技术,其中微细电火花加工凭借加工过程无宏观的作用力、对加工系统的刚性无过高要求等优势,在微尺度加工领域得到了广泛的应用,并表现出了强大的技术潜能,受到了国内外工业界以及学术界的重视与关注。然而,微细电火花加工本身的脉冲电源频率高、放电能量十分微弱、加工环境复杂以及稳定的火花放电状态难以获得等特点,导致其加工过程中存在大量的不确定性与显著的随机性。确保微细电火花加工过程控制的稳定性以及有效性已成为提高加工系统性能、加工效率以及加工精度的关键。
目前,微细电火花加工过程的控制已广泛地采用了模糊逻辑理论,并取得了良好的效果。与传统模糊逻辑相比较而言,二型模糊逻辑对非线性时变系统当中不确定性的处理有着明显的优势。为了进一步增强模糊控制器对加工过程中不确定性的处理能力,改善微细电火花加工系统的性能,本论文引入区间二型模糊逻辑理论,在传统一型模糊控制器的基础上设计并实现了基于区间二型模糊逻辑的两阶伺服运动控制器,增强了加工控制系统对各个输入量与控制量中不确定信息的描述能力；同时,分析了检测控制方法的滞后性对微细电火花加工过程稳定性的影响,并结合区间二型模糊控制方法,以伺服进给速度为预测研究对象,提出了基于灾变灰色预测的伺服运动预测控制方法,旨在克服单纯依靠检测控制方法所导致的控制滞后性问题,提高加工过程控制的稳定性,从而获得更优的加工效率。
本文依托自主研发的微细电火花加工机床,以微小孔加工作为实验研究对象,针对所提出的区间二型模糊控制方法与基于灾变灰色预测的加工过程预测控制方法,分别开展加工实验。实验结果表明：区间二型模糊逻辑能够更好地处理微细电火花加工系统中的不确定性,相对于传统一型模糊控制方法而言,区间二型模糊控制方法能够显著提高加工过程的效率,适用于微细电火花加工控制；相对于常规检测控制方法而言,所提出的伺服运动预测控制方法能够有效地提高加工效率,同时显著地减少了加工过程中伺服回退(抬刀)出现的次数。因此,本文提出的基于灾变灰色预测的伺服运动预测控制方法能够有效地克服传统控制方法的滞后性,从而获得稳定的加工过程。
本文开展的微细电火花加工伺服运动预测与控制方法研究,对保证加工过程稳定性、提高加工效率以及促进微细电火花加工控制技术的发展提供了一定的借鉴及参考。
Micro precision machining technology becomes one of the most important production technologies in manufacturing industry field, and particularly with several advantages, such as no macro-forces in machining process and no excessive requirement for machining system etc., micro-EDM has been widely applied in micro-scale machining field, showing tremendous technology potential, and receives attention and concern from both industry and academia all over the world. However, due to the natural characteristics of micro-EDM, such as high pulse power supply frequency, extremely weak discharge energy, complex machining environment and unstable spark discharge states etc., the machining process tend to have lots of uncertainties and randomness. To ensure the stability and effectiveness of machining process control becomes the key to promote the performance of the machining system and the efficiency and precision of the machining process.
At present, fuzzy logic theory has been widely adopted in the machining process control of micro-EDM, which achieves good results. In comparison with traditional fuzzy logic, type-2fuzzy logic has better capability of handling the uncertainties in the nonlinear time-varying systems. In order to further enhance the fuzzy controller's capability of handling the uncertainties of the machining process and improve the performance of micro-EDM system, on the foundation of the type-1fuzzy controller, a two-stage servo motion controller is designed based on the interval type-2fuzzy logic theory which is introduced in this paper, which enhance the machining system's capability of describing the uncertainties of each variable; meanwhile, through the analysis of the affect caused to the stability of the machining process by the lagging of the regular detection-based control, coupled with the interval type-2fuzzy control method, a servo motion predictive control method is presented, which is based on calamities grey prediction and takes the servo feed speed as the prediction object, aiming at overcoming the affect caused by the lagging of the regular detection-based control method and improving the stability of the machining process, so that better machining efficiency can be obtained.
Relying on the independently developed micro-EDM machine tool and taking micro-holes as the machining targets, the experiment researches are carried out to verify the feasibility of the interval type-2fuzzy control method and the calamities grey prediction based predictive control method, which are introduced in this paper. The experiment results show that, interval type-2fuzzy logic can handle the uncertainties of the micro-EDM system, in comparison with the type-1fuzzy control method, interval type-2fuzzy control method can obviously promote the machining efficiency, which confirms that interval type-2fuzzy logic is applicable in the machining control of micro-EDM; comparing with the machining process relying on the regular detection-based control, the predictive control method introduced in this paper can promote the machining efficiency to some extent and effectively minimize the frequency of the servo rollback (tool lifting). So, the calamities grey prediction based servo motion predictive control method can effectively overcome the affect caused by the lagging of the regular detection-based control method, which results in the stable machining process.
The research on the prediction and control method of servo motion of micro-EDM in this paper provides conducive reference to ensuring the stability of machining process and promoting machining efficiency as well as facilitating the development of micro-EDM control method.
目前,微细电火花加工过程的控制已广泛地采用了模糊逻辑理论,并取得了良好的效果。与传统模糊逻辑相比较而言,二型模糊逻辑对非线性时变系统当中不确定性的处理有着明显的优势。为了进一步增强模糊控制器对加工过程中不确定性的处理能力,改善微细电火花加工系统的性能,本论文引入区间二型模糊逻辑理论,在传统一型模糊控制器的基础上设计并实现了基于区间二型模糊逻辑的两阶伺服运动控制器,增强了加工控制系统对各个输入量与控制量中不确定信息的描述能力；同时,分析了检测控制方法的滞后性对微细电火花加工过程稳定性的影响,并结合区间二型模糊控制方法,以伺服进给速度为预测研究对象,提出了基于灾变灰色预测的伺服运动预测控制方法,旨在克服单纯依靠检测控制方法所导致的控制滞后性问题,提高加工过程控制的稳定性,从而获得更优的加工效率。
本文依托自主研发的微细电火花加工机床,以微小孔加工作为实验研究对象,针对所提出的区间二型模糊控制方法与基于灾变灰色预测的加工过程预测控制方法,分别开展加工实验。实验结果表明：区间二型模糊逻辑能够更好地处理微细电火花加工系统中的不确定性,相对于传统一型模糊控制方法而言,区间二型模糊控制方法能够显著提高加工过程的效率,适用于微细电火花加工控制；相对于常规检测控制方法而言,所提出的伺服运动预测控制方法能够有效地提高加工效率,同时显著地减少了加工过程中伺服回退(抬刀)出现的次数。因此,本文提出的基于灾变灰色预测的伺服运动预测控制方法能够有效地克服传统控制方法的滞后性,从而获得稳定的加工过程。
本文开展的微细电火花加工伺服运动预测与控制方法研究,对保证加工过程稳定性、提高加工效率以及促进微细电火花加工控制技术的发展提供了一定的借鉴及参考。
Micro precision machining technology becomes one of the most important production technologies in manufacturing industry field, and particularly with several advantages, such as no macro-forces in machining process and no excessive requirement for machining system etc., micro-EDM has been widely applied in micro-scale machining field, showing tremendous technology potential, and receives attention and concern from both industry and academia all over the world. However, due to the natural characteristics of micro-EDM, such as high pulse power supply frequency, extremely weak discharge energy, complex machining environment and unstable spark discharge states etc., the machining process tend to have lots of uncertainties and randomness. To ensure the stability and effectiveness of machining process control becomes the key to promote the performance of the machining system and the efficiency and precision of the machining process.
At present, fuzzy logic theory has been widely adopted in the machining process control of micro-EDM, which achieves good results. In comparison with traditional fuzzy logic, type-2fuzzy logic has better capability of handling the uncertainties in the nonlinear time-varying systems. In order to further enhance the fuzzy controller's capability of handling the uncertainties of the machining process and improve the performance of micro-EDM system, on the foundation of the type-1fuzzy controller, a two-stage servo motion controller is designed based on the interval type-2fuzzy logic theory which is introduced in this paper, which enhance the machining system's capability of describing the uncertainties of each variable; meanwhile, through the analysis of the affect caused to the stability of the machining process by the lagging of the regular detection-based control, coupled with the interval type-2fuzzy control method, a servo motion predictive control method is presented, which is based on calamities grey prediction and takes the servo feed speed as the prediction object, aiming at overcoming the affect caused by the lagging of the regular detection-based control method and improving the stability of the machining process, so that better machining efficiency can be obtained.
Relying on the independently developed micro-EDM machine tool and taking micro-holes as the machining targets, the experiment researches are carried out to verify the feasibility of the interval type-2fuzzy control method and the calamities grey prediction based predictive control method, which are introduced in this paper. The experiment results show that, interval type-2fuzzy logic can handle the uncertainties of the micro-EDM system, in comparison with the type-1fuzzy control method, interval type-2fuzzy control method can obviously promote the machining efficiency, which confirms that interval type-2fuzzy logic is applicable in the machining control of micro-EDM; comparing with the machining process relying on the regular detection-based control, the predictive control method introduced in this paper can promote the machining efficiency to some extent and effectively minimize the frequency of the servo rollback (tool lifting). So, the calamities grey prediction based servo motion predictive control method can effectively overcome the affect caused by the lagging of the regular detection-based control method, which results in the stable machining process.
The research on the prediction and control method of servo motion of micro-EDM in this paper provides conducive reference to ensuring the stability of machining process and promoting machining efficiency as well as facilitating the development of micro-EDM control method.
引文
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