齿轮加工综合误差在线估测与智能补偿方法

The comprehensive error and compensation of machine tools is an important and hot topic to improve the performance of CNC machining. There are some achievements of the existing research, which were mainly conducted from the aspects of machine tool geometric error, thermal deformation error, force deformation error and motion control error, etc. The compensation of gear machining comprehensive error has its own characteristics. This project focus on the dynamic mechanism and the inherent reason of the gear machining error, which caused by the relative posture error of the tool and the workpiece in the machining process, and this research work is conducted from the perspective of the combination of the gear CNC machine tools’ structure, the multi-axis linkage control structure model and the gear processing technology. The mechanism of gear machining error is explained from the perspective of the geometry and the kinematics of the gear machining process. The mapping relationship of the gear machine tool parameters, the gear machining process parameters and the gear precision index is founded, and the online estimation mathematic model of the gear precision index are also established. The gear machining error is decoupled and mapped to each axis, which according to the estimation model of gear machining error and the relative motion of the tool and the workpiece during the gear machining process. The real-time gear machining error compensation model is built and implemented at the bottom of the CNC using the iterative learning structure, which is combined with the characteristics of the electronic gearbox control structure and the thought of cross-coupling compensation method. The high speed and high precision of gear machining would be realized through this research.

机床加工综合误差建模与补偿是提高机床加工性能的重要热点问题，已有研究主要从机床几何误差、热变形误差、力变形误差和运动控制误差等方面开展，取得一定成效。齿轮加工有其自身特点，本项目提出的齿轮加工综合误差在线估测和实时补偿方法，从机床结构、多轴耦合联动控制结构模型及齿轮加工工艺相结合的角度，研究齿轮加工过程中刀具与工件的相对位姿误差对齿轮各项精度指标的动态作用机理和内在规律，从几何和运动学角度解释齿轮加工误差的产生机理；建立齿轮机床参数、加工工艺参数与齿轮关键精度指标之间的映射关系，构建齿轮加工关键精度指标在线估测数学模型；根据齿轮加工综合误差的估测模型及加工过程中刀具与工件的相对运动关系，将齿轮加工综合误差解耦辨识并映射到各运动轴上，结合电子齿轮箱控制结构的特点及交叉耦合补偿的思想，构建实时的齿轮加工误差补偿模型，在数控系统底层以迭代学习的方式进行在线实时补偿，从而实现齿轮的高速高精度加工。

机床加工误差建模与补偿是提高机床加工性能的重要热点问题，多年来受到业界的广泛重视。齿轮的展成法数控加工是刀具切削刃在三维空间中的非自由切削，其成型原理是在电子齿轮箱的控制下，机床刀具与齿轮毛坯按照齿轮的啮合原理做展成运动，由分布在基本蜗杆面上的若干切削刃包络形成齿轮齿廓，同时由同步轴向进给运动加工出全齿宽，其成型过程具有其自身的特点和复杂性。.项目采用一套新的技术路线，从几何和运动学角度解释齿轮数控展成法加工误差的产生机理，研究齿轮加工过程中各种因素对刀具与工件的相对位姿误差产生的影响，以及对齿轮各项误差的动态作用机理和内在规律，构建齿轮加工关键精度指标在线估测数学模型，实现数控系统在线显示所加工齿轮的关键精度指标示值与等级，将齿轮加工综合误差解耦并映射到参与机床多轴联动的各坐标轴上，采用实时的多轴耦合补偿模型，实现齿轮加工误差的实时补偿，避免了传统繁琐的误差辨识过程及离线补偿效率低的缺点。项目研究发现滚齿、插齿等加工过程中断续的切削过程会引起加工振动，刀齿与工件因振动偏离理想位置后造成齿轮加工误差，根据齿轮加工原理及齿形几何特征，建立了基于齿轮加工机床工件轴振动的齿形偏差、齿距偏差及螺旋线偏差数学模型，并提出了基于振动信号分析的齿轮加工过程振动抑制方法，通过机床模态分析及齿轮加工正交试验完成了实验验证。.项目研究发现随着新能源汽车等运输装备对齿轮传动系统的噪声和振动特性要求越来越高，高速低噪声传动齿轮对复杂齿面拓扑修形理论及精密制造技术提出了新挑战，对传动齿轮加工的几何精度、齿面修形质量和表面纹理结构等提出了更高要求。因此，项目针对齿轮高速低噪声传动的具体要求，进一步研究连续展成磨齿过程齿面扭曲误差的产生机理，提出并实现基于电子齿轮箱的齿轮齿面扭曲计算及补偿，再此基础上提出了一种基于齿面法相偏差敏感度矩阵的数控蜗杆砂轮磨齿齿面无扭曲高阶修形方法，并完成了相关的仿真和实验验证。