三杆少自由度混联机床精度分析及相关问题的研究
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摘要
混联机床是从上个世纪末开始出现的一种新型制造装备,它可以实现多坐标联动数控加工、装配和测量等功能,也可以满足复杂零件加工的需要。由于具有刚度重量比大、响应速度快、易十实现模块化设计、环境适应能力强等特点,混联机床已经成为新一代机床发展的一个方向,而少自由度混联机床因其自身的优点已成为此类机床发展的趋势。
世界上许多国家已经对混联机床的研究投入了大量的人力物力,也取得了许多的研究成果,但目前对混联机床的研究总体上还是处于研发、试制和试用阶段。与国外相比,我国关于混联机床的研究也取得了一些阶段性成果,但在整体水平上还存在一定差距。在限制混联机床发展的众多因素中,加工精度是一个比较突出的问题,目前混联机床的加工精度还无法与传统高精度的数控机床相比拟。在实现混联机床产业化的发展道路上,还有许多内容值得我们去研究。
本论文以东北大学研制的3-TPT型混联机床和3-TPS型混联机床为研究对象,主要对两种混联机床进行了精度分析,并对误差补偿理论进行了探讨,主要研究内容如下：
(1)结合两种混联机床的结构特点,对它们的运动位置及工作空间进行了分析,建立了运动学方程,并以雅可比矩阵的可操作度和条件数为衡量指标,分析了两种机床在工作空间内的奇异性和操作灵巧性,借此来说明两种混联机床的运动性能及误差敏感性。
(2)根据误差独立作用原理对两种混联机床的位置误差进行了分析。分析内容包括驱动杆长度误差、铰链点位置误差、运动平台姿态误差等因素对机床位置误差的影响,针对各误差影响因素建立了误差模型,并获得了相应的误差传递函数。
(3)对处于稳态切削条件下两种混联机床的位置误差进行了分析。建立了稳态切削条件下机床位置误差模型并分析了在工作空间内机床位置误差的变化情况。然后,基于虚拟样机技术对稳态切削条件下机床的位置误差进行了仿真分析,将仿真结果与理论分析结果相比较以说明理论分析结论的准确性。
(4)以热误差和动态切削力变形误差为对象对混联机床的动态误差进行了初步研究。内容涉及热误差来源、热误差建模方法及动态切削力建模方法等。另外,还基于虚拟样机技术,在ADAMS软件环境中对两种混联机床的动态误差进行了初步仿真。
(5)根据位置误差理论,对3-TPT型混联机床的试验样机进行了结构参数误差测量,进而求得了机床位置误差受结构参数误差影响的结果。另外,还对机床样机的直线度、平行度和重复位置精度进行了初步评定。
(6)针对两种混联机床建立了误差标定模型,并基于遗传算法阐述了辨识标定模型参数的理论方法。另外,对混联机床的误差补偿策略进行了研究,根据两种混联机床的特点提出了相应的补偿方式。
本论文对两种混联机床的精度分析结果,对于研究此类结构混联机床的误差变化特点、实现机床位置误差的补偿都具有重要意义,并为进一步的精度综合奠定了基础。但是,由于混联机床精度问题的复杂性和时变性,为了提高混联机床的加工精度,还需要在误差控制及实时补偿等方面做许多的研究工作。
Since the end of the last century, the Hybrid Machine Tools (HMT) has emerged as a new type of manufacturing equipment. By using HMT, it is easy to satisfy the requirements of multi-axis NC machining, assemble and measurement, so the HMT can be utilized to fabricate the parts with complex surface. Due to the merits of great ratio of stiffness to mass, fast response, module design and environment adaptability, developing excellent HMT has been to the one of the research trends in the machine tool domain. Furthermore, the lower-mobility HMT is the most attractable one.
Although many people in the worldwide range have resorted to develop the HMT, and even to achieve a little progress, the current focuses of the HMT research are still on its design, try and error stages. In the P.R. China, although domestic scholars and designers have gotten some research fruits, there is still a great gap compare to the level of the developed countries. Through the study on the HMT, the error problem or the issue about the accuracy has been found to be one of the greatest difficulties. Nowadays, the accuracy of the HMT is still lower than the traditional precision NC machine tool, so there is still a long way to go.
In this work, the error analysis has been conducted on two HMTs developed by Northeastern University with 3-TPT and 3-TPS type respectively, and the corresponding error compensation algorithms are discussed too. The main contents of this work are listed as following:
(1) Based on the specialties of the 3-TPT and 3-TPS HMTs, the trajectories and workspace of them are analyzed. Their kinematics equations are derived, and their singularity and the dexterity are evaluated based on the operational degree and condition number of their Jacobin matrices. Hence, their kinematics performances and the error sensitivities are clarified.
(2) Based on the independent principle of the error source, the error models and error transfer functions of the 3-TPT and 3-TPS HMTs have been developed. The influences of the error sources from the driving bar length, joint position, position and pose of the moveable platform are discussed.
(3) The positional errors of the 3-TPT and 3-TPS HMTs are analyzed under the static machining condition. Their positional error models are developed. The variations of their positional error in the workspace have been found by the models and simulated based on the Virtual Prototype. Two agreements show good agreement, which can be used to verify the correctness of the model analysis.
(4) The first period dynamic error analysis is performed on the 3-TPT and 3-TPS HMTs in order to discuss the effects of the thermal error and deformation caused by the dynamic cutting force. The research topics include the sources and modeling of the thermal and dynamic cutting force errors. The dynamic error analysis of the 3-TPT and 3-TPS HMTs are conducted in ADAMS.
(5) The errors of the structural parameters are measured on the 3-TPT HMT prototype based on the positional error theory, and their effects to the position are obtained. Furthermore, the straightness, parallelism and repeatability are evaluated.
(6) The error calibration models are built for the 3-TPT and 3-TPS HMTs. The parameter identification method is deduced based on the gene algorithm. The strategies of error compensation are studied, and the corresponding compensation approaches are proposed to the 3-TPT and 3-TPS HMTs respectively.
The error analysis results on the 3-TPT and 3-TPS HMTs are meaningful to do the error compensation for them. The deeper research on the error variation and accuracy synthesis of the HMTs in the similar configuration can be conducted based on this work. However, due to the complexity and time variability of the HMT, there is still a long way to go in order to improve the machining accuracy of the HMT. The urgent and most important research focuses should be concentrated on the error control and real-time compensation.
世界上许多国家已经对混联机床的研究投入了大量的人力物力,也取得了许多的研究成果,但目前对混联机床的研究总体上还是处于研发、试制和试用阶段。与国外相比,我国关于混联机床的研究也取得了一些阶段性成果,但在整体水平上还存在一定差距。在限制混联机床发展的众多因素中,加工精度是一个比较突出的问题,目前混联机床的加工精度还无法与传统高精度的数控机床相比拟。在实现混联机床产业化的发展道路上,还有许多内容值得我们去研究。
本论文以东北大学研制的3-TPT型混联机床和3-TPS型混联机床为研究对象,主要对两种混联机床进行了精度分析,并对误差补偿理论进行了探讨,主要研究内容如下：
(1)结合两种混联机床的结构特点,对它们的运动位置及工作空间进行了分析,建立了运动学方程,并以雅可比矩阵的可操作度和条件数为衡量指标,分析了两种机床在工作空间内的奇异性和操作灵巧性,借此来说明两种混联机床的运动性能及误差敏感性。
(2)根据误差独立作用原理对两种混联机床的位置误差进行了分析。分析内容包括驱动杆长度误差、铰链点位置误差、运动平台姿态误差等因素对机床位置误差的影响,针对各误差影响因素建立了误差模型,并获得了相应的误差传递函数。
(3)对处于稳态切削条件下两种混联机床的位置误差进行了分析。建立了稳态切削条件下机床位置误差模型并分析了在工作空间内机床位置误差的变化情况。然后,基于虚拟样机技术对稳态切削条件下机床的位置误差进行了仿真分析,将仿真结果与理论分析结果相比较以说明理论分析结论的准确性。
(4)以热误差和动态切削力变形误差为对象对混联机床的动态误差进行了初步研究。内容涉及热误差来源、热误差建模方法及动态切削力建模方法等。另外,还基于虚拟样机技术,在ADAMS软件环境中对两种混联机床的动态误差进行了初步仿真。
(5)根据位置误差理论,对3-TPT型混联机床的试验样机进行了结构参数误差测量,进而求得了机床位置误差受结构参数误差影响的结果。另外,还对机床样机的直线度、平行度和重复位置精度进行了初步评定。
(6)针对两种混联机床建立了误差标定模型,并基于遗传算法阐述了辨识标定模型参数的理论方法。另外,对混联机床的误差补偿策略进行了研究,根据两种混联机床的特点提出了相应的补偿方式。
本论文对两种混联机床的精度分析结果,对于研究此类结构混联机床的误差变化特点、实现机床位置误差的补偿都具有重要意义,并为进一步的精度综合奠定了基础。但是,由于混联机床精度问题的复杂性和时变性,为了提高混联机床的加工精度,还需要在误差控制及实时补偿等方面做许多的研究工作。
Since the end of the last century, the Hybrid Machine Tools (HMT) has emerged as a new type of manufacturing equipment. By using HMT, it is easy to satisfy the requirements of multi-axis NC machining, assemble and measurement, so the HMT can be utilized to fabricate the parts with complex surface. Due to the merits of great ratio of stiffness to mass, fast response, module design and environment adaptability, developing excellent HMT has been to the one of the research trends in the machine tool domain. Furthermore, the lower-mobility HMT is the most attractable one.
Although many people in the worldwide range have resorted to develop the HMT, and even to achieve a little progress, the current focuses of the HMT research are still on its design, try and error stages. In the P.R. China, although domestic scholars and designers have gotten some research fruits, there is still a great gap compare to the level of the developed countries. Through the study on the HMT, the error problem or the issue about the accuracy has been found to be one of the greatest difficulties. Nowadays, the accuracy of the HMT is still lower than the traditional precision NC machine tool, so there is still a long way to go.
In this work, the error analysis has been conducted on two HMTs developed by Northeastern University with 3-TPT and 3-TPS type respectively, and the corresponding error compensation algorithms are discussed too. The main contents of this work are listed as following:
(1) Based on the specialties of the 3-TPT and 3-TPS HMTs, the trajectories and workspace of them are analyzed. Their kinematics equations are derived, and their singularity and the dexterity are evaluated based on the operational degree and condition number of their Jacobin matrices. Hence, their kinematics performances and the error sensitivities are clarified.
(2) Based on the independent principle of the error source, the error models and error transfer functions of the 3-TPT and 3-TPS HMTs have been developed. The influences of the error sources from the driving bar length, joint position, position and pose of the moveable platform are discussed.
(3) The positional errors of the 3-TPT and 3-TPS HMTs are analyzed under the static machining condition. Their positional error models are developed. The variations of their positional error in the workspace have been found by the models and simulated based on the Virtual Prototype. Two agreements show good agreement, which can be used to verify the correctness of the model analysis.
(4) The first period dynamic error analysis is performed on the 3-TPT and 3-TPS HMTs in order to discuss the effects of the thermal error and deformation caused by the dynamic cutting force. The research topics include the sources and modeling of the thermal and dynamic cutting force errors. The dynamic error analysis of the 3-TPT and 3-TPS HMTs are conducted in ADAMS.
(5) The errors of the structural parameters are measured on the 3-TPT HMT prototype based on the positional error theory, and their effects to the position are obtained. Furthermore, the straightness, parallelism and repeatability are evaluated.
(6) The error calibration models are built for the 3-TPT and 3-TPS HMTs. The parameter identification method is deduced based on the gene algorithm. The strategies of error compensation are studied, and the corresponding compensation approaches are proposed to the 3-TPT and 3-TPS HMTs respectively.
The error analysis results on the 3-TPT and 3-TPS HMTs are meaningful to do the error compensation for them. The deeper research on the error variation and accuracy synthesis of the HMTs in the similar configuration can be conducted based on this work. However, due to the complexity and time variability of the HMT, there is still a long way to go in order to improve the machining accuracy of the HMT. The urgent and most important research focuses should be concentrated on the error control and real-time compensation.
引文
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