专用数控铣床的研究设计

专用数控铣床的研究设计重庆大学硕士学位论文（学术学位）学生姓名：XXX指导教师：王秋晓副教授专业：机械制造及其自动化学科门类：工学重庆大学机械工程学院二O一三年四月ResearchandDesignoftheSpecialCNCMillingMachineAThesisSubmittedtoChongqingUniversityinPartialFulfillmentoftheRequirementfortheMaster’sDegreeofEngineeringByZhangXiaohuiSupervisedbyA.Prof.WangQiuxiaoSpecialty：MechanicalManufactureandAutomationCollegeofMechanicalEngineeringofChongqingUniversity,Chongqing,ChinaApril,2013中文摘要I摘要普通立式铣床铣削一定角度的圆弧时效率低下，操作困难且互换性常常达不到要求，易造成废品，不能满足工厂大批量生产的需求。本文设计了并研制出了一种专用数控铣床，在保证一定加工精度的同时，实现了半自动化控制和双主轴加工，极大地提高了生产效率。本文首先介绍了专用数控铣床的加工工艺、坐标系和刀具补偿算法。根据飞轮加工的要求，明确了加工过程及精度，设定了机床坐标系，包括机床原点、程序原点、工件坐标系等。由于铣削的特点，在主轴加工时考虑到刀具半径，即刀补问题，专门设计了刀具补偿算法，尽量减小主动误差。其次，对专用数控铣床的整体结构、主轴系统、传动系统分别进行了设计，建立了三维模型。考虑到加工的效率，系统采用了双主轴、双工位的特殊设计，本质上区别于普通数控铣床。另外运用ANSYS有限元仿真软件对主轴箱进行了模态分析，得到了主轴箱的固有频率值和振型，验证了结构设计的可行性。再次，设计了一种基于ARM7微处理器和μC/OS-Ⅱ操作系统的控制方案，即由微处理器向机床电机系统提供控制信息，控制铣刀的旋转、工作台的进给以及回转工作台的进给。检测电路中采用接近开关传感器和限位开关实时检测各坐标运动情况并反馈到微处理器。另外，对专用数控铣床的控制系统软件的流程进行了设计。然后，为了保证系统的稳定性和可靠性，对设备的部分强电电路和电磁兼容性进行了设计。最后，完成了专用数控铣床的样机制造，包括嵌入式硬件平台、软件平台、强电系统、主轴系统、传动系统、辅助系统等的建立和安装。并对整个铣床进行了现场调试，验证了机床控制系统和结构设计的正确性和可行性。专用数控铣床是一个高难度的机电一体化产品，涉及到众多学科领域，包括机械设计技术，电工电子技术，传感器技术，信息处理技术，自动控制原理等。本课题研制的专用数控铣床，可以极大地提高一定角度圆弧的加工效率和精度，对于节省生产资源具有重要的意义。关键词：双工位，刀具补偿，ARM7，电磁兼容重庆大学硕士学位论文IIABSTRACTMillingacertainAngleofthearcwiththeordinaryverticalmillingmachineislowefficiency,difficulttooperateandtheinterchangeabilityoftencannotmeettherequirementsandtheneedsofmassproduction.Inaddition,it’seasytocausewaste.Tosolvetheseproblems,akindofspecialmillingmachinetoolisdesignedanddeveloped.Thismachineachievesasemi-automatedcontrolanddual-spindlemachining,whichwillgreatlyimprovetheproductionefficiencywhenthemachiningaccuracyisguaranteed.Thispaperfirstlyintroducestheprocess,coordinatesystemandtoolcompensationalgorithmoftheCNCspecialmillingmachine.Accordingtotheflywheelprocessingrequirements,aclearprocessandthemachinecoordinatesystemthatincludesmachinetoolsorigin,theoriginoftheprogram,thework-piececoordinatesystemisset.Duetothecharacteristicsofthemilling,thetoolcompensationalgorithmisdesignedtominimizetheactiveerror.Secondly,theoverallstructure,spindlesystemandthetransmissionsystemaredesigned.Takingintoaccounttheefficiencyoftheprocessing,aspecialdouble-spindleanddouble-positionstructureisdesigned,essentiallydifferentfromtheordinaryCNCmillingmachine.Inadditionto,thenaturalfrequencyofthespindleboxisobtainedaccordingtomodalanalysisbyusingANSYS,whichverifiesthefeasibilityofthedesignofthestructure.Thirdly,acontrolplanbasedonARM7microprocessorandμCOS-IIoperatingsystemisdeveloped.Thecontrolinformationissentbythemicroprocessortothemachinetoolmotorsystemtoaccomplishthecutterrotation,tablefeedandrotaryfeed.Switchsensorsandlimitswitchesareusedtodetectthemovementofeachcoordinateandthenfedbacktothemicroprocessor.Furthermore,theprocessofthesoftwareisalsodesigned.Then,highvoltagecircuitandelectromagneticcompatibilityisdesignedinordertoensuresystemstabilityandreliabilityofthemachinetool.Finally,theprototypeofspecialCNCmillingmachinetoolismanufactured,whichincludesembeddedhardwareplatform,softwareplatform,highvoltagesystem,thespindlesystem,transmissionsystemandauxiliarysystems.Entiremillingsitecommissioning,verifythecorrectnessandfeasibilityofthemachinecontrolsystemand英文摘要IIIstructuraldesign.CNCmillingmachineisaverydifficultmechatronicproducts,involvingmanydisciplines,includingmechanicaldesigntechnology,electricalandelectronictechnology,sensortechnology,informationprocessingtechnology,automaticcontroltheory.Thespecialmillingmachinetoolthispaperdesignedcangreatlyimprovetheefficiencyandaccuracymillingacertainanglearcandisofgreatsignificanceinsavingproductionresources.Keywords:dual-spindle,toolcompensation,ARM7,electromagneticcompatibility重庆大学硕士学位论文IV目录中文摘要.........................................................................................................................................I英文摘要........................................................................................................................................II1绪论......................................................................................................................................11.1组合机床概述........................................................................................................................11.2国内外发展现状....................................................................................................................11.3课题研究背景及意义............................................................................................................31.4本篇论文的研究内容............................................................................................................32专用数控铣床的工作原理...........................................................................................52.1飞轮外圆圆弧加工工艺分析................................................................................................52.2圆弧成形算法分析................................................................................................................62.2.1直角坐标系中的圆弧成形...................