基于LabVIEW高速滚珠丝杠综合性能动态测试系统设计与分析
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摘要
高速滚珠丝杠综合性能动态测试系统为典型的机电测控系统。该系统综合床身结构设计技术、传感器测试技术、电机位置闭环控制技术和数据采集、分析技术。对高速滚珠丝杠在不同工况下温度、加速度、噪声、温位移和定位精度等进行数据采集分析,评价影响高速滚珠性能的主要因素,为高速丝杠结构设计优化、加工制造工艺改进、材料选型等提供有效的试验数据支持。因此该系统的研制具有很好的工程应用价值。
论文研究内容包括:(1)系统总体方案设计。设计了系统总体框架、硬件构成及软件功能;(2)机械平台设计。包括床身设计,直线导轨、丝杠螺母副和支撑单元设计选型;(3)测量和控制硬件平台设计。包括传感器、数据采集卡、计数卡、电机控制卡和驱动器单元的设计选型和布线;(4)软件平台设计。基于LabVIEW软件系统完成了系统参数模块、综合性能测试模块、电机控制模块、数据分析模块等设计和功能集成,可以实现高速滚珠丝杠综合性能曲线测量、分析和打印;(5)联调与运行。综合各种工况进行软硬件联调并进行实际运行考核。完成了高速滚珠丝杠性能影响因素分析,对改进方法进行了研究和探讨。从系统机械结构、弹性形变和测量误差等方面寻找丝杠性能影响因素并提出解决措施。
目前该系统已在汉江机床有限公司现场运行达6个月,运行平稳可靠,达到了设计要求,为进一步开发高速滚珠丝杠打下了坚实基础。
The comprehensive measure system for dynamic performance of high-speed ball screw is a typical electromechanical system. The system combines lathe bed structures design technology, sensor testing technology,closed-loop control technology of motor position and data collection and analysis technology. With the data acquisition and analysis of high-speed ball screw in different set of parameters for the temperature, acceleration, noise, thermal deformation and positioning accuracy, we can evaluate the main factors affecting the performance of high-speed ball screw .The system can provide test data for optimization of the structural design of high-speed screw, manufacturing process improvements and material selection. Therefore the system development has a good value to engineering application.
The paper research contents include:(1)design of overall scheme. The design includes general framework of system,hardwore constitution and software function.(2)design of mechanical platform. The design includes lathe bed design and type selection of linear guide,screw-nut pairs and supporting units.(3)design of platform for measurement and control. The design include type selection and wiring of sensors,data acquisition card,counter card,motor control card and driver units.(4)design of software platform. The software system based on LabVIEW completes the design and integration of system parameter module,comprehensive testing module of lead screw performance,motor control module and data analysis module etc. And the platform can realize curves testing,analysis and printing for high-speed ball screw comprehensive measure system.(5)joint debugging and run. The joint debugging of software and hardware is executed under all kinds of conditions and to check the system performance through practical running. The paper completes analysis to affecting factors of high-speed ball screw and studies on improved method. Find influencing factors and solving measures from system mechanical structure,elastic deformation and measurement errors etc.
The current system has a steady running for six monthes in Shanxi Hanjiang Tools Company and has reached design requirements. And this is a solid foundation to further development of high-speed ball screws.
论文研究内容包括:(1)系统总体方案设计。设计了系统总体框架、硬件构成及软件功能;(2)机械平台设计。包括床身设计,直线导轨、丝杠螺母副和支撑单元设计选型;(3)测量和控制硬件平台设计。包括传感器、数据采集卡、计数卡、电机控制卡和驱动器单元的设计选型和布线;(4)软件平台设计。基于LabVIEW软件系统完成了系统参数模块、综合性能测试模块、电机控制模块、数据分析模块等设计和功能集成,可以实现高速滚珠丝杠综合性能曲线测量、分析和打印;(5)联调与运行。综合各种工况进行软硬件联调并进行实际运行考核。完成了高速滚珠丝杠性能影响因素分析,对改进方法进行了研究和探讨。从系统机械结构、弹性形变和测量误差等方面寻找丝杠性能影响因素并提出解决措施。
目前该系统已在汉江机床有限公司现场运行达6个月,运行平稳可靠,达到了设计要求,为进一步开发高速滚珠丝杠打下了坚实基础。
The comprehensive measure system for dynamic performance of high-speed ball screw is a typical electromechanical system. The system combines lathe bed structures design technology, sensor testing technology,closed-loop control technology of motor position and data collection and analysis technology. With the data acquisition and analysis of high-speed ball screw in different set of parameters for the temperature, acceleration, noise, thermal deformation and positioning accuracy, we can evaluate the main factors affecting the performance of high-speed ball screw .The system can provide test data for optimization of the structural design of high-speed screw, manufacturing process improvements and material selection. Therefore the system development has a good value to engineering application.
The paper research contents include:(1)design of overall scheme. The design includes general framework of system,hardwore constitution and software function.(2)design of mechanical platform. The design includes lathe bed design and type selection of linear guide,screw-nut pairs and supporting units.(3)design of platform for measurement and control. The design include type selection and wiring of sensors,data acquisition card,counter card,motor control card and driver units.(4)design of software platform. The software system based on LabVIEW completes the design and integration of system parameter module,comprehensive testing module of lead screw performance,motor control module and data analysis module etc. And the platform can realize curves testing,analysis and printing for high-speed ball screw comprehensive measure system.(5)joint debugging and run. The joint debugging of software and hardware is executed under all kinds of conditions and to check the system performance through practical running. The paper completes analysis to affecting factors of high-speed ball screw and studies on improved method. Find influencing factors and solving measures from system mechanical structure,elastic deformation and measurement errors etc.
The current system has a steady running for six monthes in Shanxi Hanjiang Tools Company and has reached design requirements. And this is a solid foundation to further development of high-speed ball screws.
引文
[1]喻忠志.我国滚动功能部件产业现状分析.制造技术与机床.2004(4):92-94
[2]王兆坦.高速精密滚珠丝杠副综合性能测试仪.功能部件.2007(5):122-125
[3]黄祖尧.精密滚珠丝杠副实现高速化的前景.制造技术与机床.2001(3):5-7
[4]宋现春.高速滚珠丝杠副综合性能实验台的研制开发.工具技术.2005(3):21-25
[5]焦洁.滚珠丝杠副综合测试技术.传动与控制.2004(6):38-40
[6]程丹.HJY-012五米激光滚珠丝杠(副)动态测量系统设计.南京理工大学硕士学位论文.2005
[7]孙健利.关于滚动直线导轨摩擦力与预紧力关系的研究.华中理工大学学报.1997(3):36-40
[8]喻步贤.滚珠丝杠导程误差计算机辅助动态测量系统的研制.机械制造.2004(2):32-35
[9]刘春山.动态测量光栅测长仪的位置误差.工业计量.2005(5):25-27
[10]谢少锋.测量系统分析与动态不确定度及其应用研究.合肥工业大学博士论文.2004
[11]任玲.温度传感器动态性能改进的软测量方法.自动化仪表.2007(4):32-35
[12]胡晓明.加速度计偏置及敏感度测量方法的研究.压电与声光.2006(6):49-52
[13]刘清.考虑测量噪声的传感器动态测量误差补偿.江苏大学学报.2006(2):27-30
[14]姜荣.一种基于运动控制卡的伺服电机控制系统.机电产品开发与创新.2006(3):15-18
[15]孟令东.基于DSP交流伺服电机控制的制动系统的设计.微计算机信息.2006(14):33-35
[16]鲜浩.某位置伺服系统中运动控制方法的研究.机械工程与自动化.2006(3):26-28
[17]胡晓明.加速度计偏置及敏感度测量方法的研究.压电与声光.2006(6):49-52
[18]张小苗.基于DSP的多路同步数据采集系统.中国科技信息.2006(12):25-27
[19]朱墨.基于LabView同步控制的数据采集监控仿真平台.计算机仿真.2006(2):22-24
[20]万志远.基于LabVIEW同步控制技术的数据采集平台设计.工业控制计算机.2007(4):12-15
[21]雷振山.LabVIEW 7 Express实用技术教程.第1版.北京:中国铁道出版 社,2004
[22]侯国屏.LabVIEW7.1编程与虚拟仪器设计.第1版.北京:清华大学出版社,2005
[23]肖正义,焦洁.高速滚珠丝杠副的研发和测试技术.功能部件.2004(4):95-97
[24]李亚芹.高速加工中滚珠丝杠进给系统性能分析.机电工程技术.2006(10):13-14
[25]于复生.滚珠丝杠误差检测的速度自适应系统.制造技术与机床.2004(4):85-87
[26]龙泽明.机床工作台滚珠丝杠高速驱动系统精密定位机械特性研究.设计与研究.2006(12):28-30
[27]杨凯,杨庆东.高速机床进给系统动态特性研究.2005年中国机械工程学会年会论文集.2005(3):69-72
[28]阮毅,陈维钧.运动控制系统.第1版.北京:清华大学出版社,2006
[29]罗立辉.机床热误差温度测点优化和补偿建模研究现状.机床与液压.2006(9):52-54
[30]谢春,刘春时.数控机床热误差模型的研究进展.组合机床与自动化加工技术.2007(10):5-8
[31]吴宁.变频器电磁干扰问题原因分析与对策.湖北电力.2005(3):36-37
[32]吴南星,胡如夫,孙庆鸿.数控机床丝杠进给系统刚度对定位精度的影响.中国工程科学.2004(9):46-49
[33]李恒熙.机床导轨误差对机械加工品质的影响.机械制造与研究.2005:34-40
[34]施维.高速数控机床的结构特点.现代制造工程.2006,3:135-138
[35]高中汉.数控机床光栅测量系统及其维护.机床电器.2001,6:14-16
[36]雷贤卿.机床导轨对主轴回转轴线平行度的精密测量.工艺与检测.2006,5:68-74
[37]曹建国.实现高速丝杠螺母副高速化的技术措施.机床与液压.2005,5:54-56
[38]周志红.滚珠丝杠安装方式的研究.功能部件.2007,8:140-142
[39]张春梅.保持机床导轨持久精度的技术探讨.润滑与密封.2004,9:91-96
[40]汤文成.加工中心床身结构分析.机械强度.1998,3:11-18
[41]沈金华.数控机床热补偿中温度变量的选择与建模.上海交通大学学报.2006,2:181-184
[42]Shyh-chour Huang.Analysis of a model to forecast thermal deformation of ball screw feed drive systems.Machine Tools,1994,8:1099-1104
[43]Her-Terng Yau,Jun-Juh Yan.Adaptive sliding mode control of a high precision ball-screw-driven stage.Nonlinear Analysis,2008,1:2-17
[44]Dominic S.Guevarra.Design and experimental study of a automatic lapping machine with in-process torque monitoring system.Precision Engineering,2002,26:389-395
[45]Xuesong Mei,Masaomi Tsutsumi.Study on the load distribution of ball screws with errors.Mechanism and Mechine Theory,2003,38:1257-1269
[46]Mohammed A.Alfares.Effects of exial preloading of angular contact ball bearings on the dynamics of a grinding machine spindle system.Materials Processing Technology,2003,136:48-59
[47]Lin,Kai.Multichannel system for vibration measurement andanalysis based on LabVIEW.Journal of Tsinghua University,May,2003:659-661
[48]Liu,Yanzheng.Development of a data-acquistion program for an integrated temperature measurement system.Proceedings of SPIE,2005,2:1-8
[49]Li,Guomin.Concurrent relay-PID control for motor position servo systems.International Journal of Control,Automation and Systems,June,2007:234-242
[50]Xi,Youbao.Real time self-calibration of digital measurement system.2005International Conference on Communications,Circuits and Systems,2003:1362-1365
[51]Min-Seok Kim.Integrated design methodology of ball-screw driven servomechanisms with discrete controllers.Mechatronics,January,2006:491-502
[52]C.L.Chen,M.J.Jang,K.C.Lin.Modeling and high-presion control of a ball-screw-driven stage.Precision Engineering,2003,28:483-495
[53]Jui-Pin Hung.Impact failure analysis of re-circulating mechanism in ball screw.Engineering Failure Analysis,2004,2:561-573
[54]S.K.Kim.Real-time estimation of temperature distribution in a ball-screw system.Machine Tools Manufact,1997,4:451-464
[55]Xin-Cheng Tian.Self-learning error compensation in CNC grinding.Proceedings of the First International Conference on Machine Learning and Cybernetics,November,2002:1044-1047
[56]H.H.F.Castro.Calibration system based on a laser interferometer for kinematic accuracy assessment on machine tools.Machine Tools&Manufacture,2006,46:89-07
[2]王兆坦.高速精密滚珠丝杠副综合性能测试仪.功能部件.2007(5):122-125
[3]黄祖尧.精密滚珠丝杠副实现高速化的前景.制造技术与机床.2001(3):5-7
[4]宋现春.高速滚珠丝杠副综合性能实验台的研制开发.工具技术.2005(3):21-25
[5]焦洁.滚珠丝杠副综合测试技术.传动与控制.2004(6):38-40
[6]程丹.HJY-012五米激光滚珠丝杠(副)动态测量系统设计.南京理工大学硕士学位论文.2005
[7]孙健利.关于滚动直线导轨摩擦力与预紧力关系的研究.华中理工大学学报.1997(3):36-40
[8]喻步贤.滚珠丝杠导程误差计算机辅助动态测量系统的研制.机械制造.2004(2):32-35
[9]刘春山.动态测量光栅测长仪的位置误差.工业计量.2005(5):25-27
[10]谢少锋.测量系统分析与动态不确定度及其应用研究.合肥工业大学博士论文.2004
[11]任玲.温度传感器动态性能改进的软测量方法.自动化仪表.2007(4):32-35
[12]胡晓明.加速度计偏置及敏感度测量方法的研究.压电与声光.2006(6):49-52
[13]刘清.考虑测量噪声的传感器动态测量误差补偿.江苏大学学报.2006(2):27-30
[14]姜荣.一种基于运动控制卡的伺服电机控制系统.机电产品开发与创新.2006(3):15-18
[15]孟令东.基于DSP交流伺服电机控制的制动系统的设计.微计算机信息.2006(14):33-35
[16]鲜浩.某位置伺服系统中运动控制方法的研究.机械工程与自动化.2006(3):26-28
[17]胡晓明.加速度计偏置及敏感度测量方法的研究.压电与声光.2006(6):49-52
[18]张小苗.基于DSP的多路同步数据采集系统.中国科技信息.2006(12):25-27
[19]朱墨.基于LabView同步控制的数据采集监控仿真平台.计算机仿真.2006(2):22-24
[20]万志远.基于LabVIEW同步控制技术的数据采集平台设计.工业控制计算机.2007(4):12-15
[21]雷振山.LabVIEW 7 Express实用技术教程.第1版.北京:中国铁道出版 社,2004
[22]侯国屏.LabVIEW7.1编程与虚拟仪器设计.第1版.北京:清华大学出版社,2005
[23]肖正义,焦洁.高速滚珠丝杠副的研发和测试技术.功能部件.2004(4):95-97
[24]李亚芹.高速加工中滚珠丝杠进给系统性能分析.机电工程技术.2006(10):13-14
[25]于复生.滚珠丝杠误差检测的速度自适应系统.制造技术与机床.2004(4):85-87
[26]龙泽明.机床工作台滚珠丝杠高速驱动系统精密定位机械特性研究.设计与研究.2006(12):28-30
[27]杨凯,杨庆东.高速机床进给系统动态特性研究.2005年中国机械工程学会年会论文集.2005(3):69-72
[28]阮毅,陈维钧.运动控制系统.第1版.北京:清华大学出版社,2006
[29]罗立辉.机床热误差温度测点优化和补偿建模研究现状.机床与液压.2006(9):52-54
[30]谢春,刘春时.数控机床热误差模型的研究进展.组合机床与自动化加工技术.2007(10):5-8
[31]吴宁.变频器电磁干扰问题原因分析与对策.湖北电力.2005(3):36-37
[32]吴南星,胡如夫,孙庆鸿.数控机床丝杠进给系统刚度对定位精度的影响.中国工程科学.2004(9):46-49
[33]李恒熙.机床导轨误差对机械加工品质的影响.机械制造与研究.2005:34-40
[34]施维.高速数控机床的结构特点.现代制造工程.2006,3:135-138
[35]高中汉.数控机床光栅测量系统及其维护.机床电器.2001,6:14-16
[36]雷贤卿.机床导轨对主轴回转轴线平行度的精密测量.工艺与检测.2006,5:68-74
[37]曹建国.实现高速丝杠螺母副高速化的技术措施.机床与液压.2005,5:54-56
[38]周志红.滚珠丝杠安装方式的研究.功能部件.2007,8:140-142
[39]张春梅.保持机床导轨持久精度的技术探讨.润滑与密封.2004,9:91-96
[40]汤文成.加工中心床身结构分析.机械强度.1998,3:11-18
[41]沈金华.数控机床热补偿中温度变量的选择与建模.上海交通大学学报.2006,2:181-184
[42]Shyh-chour Huang.Analysis of a model to forecast thermal deformation of ball screw feed drive systems.Machine Tools,1994,8:1099-1104
[43]Her-Terng Yau,Jun-Juh Yan.Adaptive sliding mode control of a high precision ball-screw-driven stage.Nonlinear Analysis,2008,1:2-17
[44]Dominic S.Guevarra.Design and experimental study of a automatic lapping machine with in-process torque monitoring system.Precision Engineering,2002,26:389-395
[45]Xuesong Mei,Masaomi Tsutsumi.Study on the load distribution of ball screws with errors.Mechanism and Mechine Theory,2003,38:1257-1269
[46]Mohammed A.Alfares.Effects of exial preloading of angular contact ball bearings on the dynamics of a grinding machine spindle system.Materials Processing Technology,2003,136:48-59
[47]Lin,Kai.Multichannel system for vibration measurement andanalysis based on LabVIEW.Journal of Tsinghua University,May,2003:659-661
[48]Liu,Yanzheng.Development of a data-acquistion program for an integrated temperature measurement system.Proceedings of SPIE,2005,2:1-8
[49]Li,Guomin.Concurrent relay-PID control for motor position servo systems.International Journal of Control,Automation and Systems,June,2007:234-242
[50]Xi,Youbao.Real time self-calibration of digital measurement system.2005International Conference on Communications,Circuits and Systems,2003:1362-1365
[51]Min-Seok Kim.Integrated design methodology of ball-screw driven servomechanisms with discrete controllers.Mechatronics,January,2006:491-502
[52]C.L.Chen,M.J.Jang,K.C.Lin.Modeling and high-presion control of a ball-screw-driven stage.Precision Engineering,2003,28:483-495
[53]Jui-Pin Hung.Impact failure analysis of re-circulating mechanism in ball screw.Engineering Failure Analysis,2004,2:561-573
[54]S.K.Kim.Real-time estimation of temperature distribution in a ball-screw system.Machine Tools Manufact,1997,4:451-464
[55]Xin-Cheng Tian.Self-learning error compensation in CNC grinding.Proceedings of the First International Conference on Machine Learning and Cybernetics,November,2002:1044-1047
[56]H.H.F.Castro.Calibration system based on a laser interferometer for kinematic accuracy assessment on machine tools.Machine Tools&Manufacture,2006,46:89-07