基于驱动系统参数化模型的复合轮廓误差预测机理与预补偿策略

The project proposes to predict and compensate the composite contour error models based on which the parameterization model of the drive system. Through the parameter prediction models about the practical process parameters and the processing state, the parameter variation of the drive system can be predicted so that the composite contour errors can be accurately predicted and compensated, and then the practical problem about contour error compensation could be resolved. After the prediction models of the multi-axis contouring error and cutting force-induced error are built, they can be used to build the composite models combining with the geometric error of machines. In order to make the prediction model of the contouring error more accurate, the project proposes to analyze the practical process parameters, the processing state and other factors that affect the parameters of drive system model, and then the parameterization model of the drive system is built. And the prediction model of cutting force is proposed to built to predict the cutting force-induced error. The predicted composite contour error can be used for compensation combining with the path planning. And because the compensation algorithm don't need any programs of the compensation algorithm written in the CNC system, it provides a new way to compensate the contour error of the complex curve surface and has a significant value for the contour error compensation.

课题提出建立基于驱动系统参数化模型的复合轮廓误差预测机理和补偿策略。通过基于实际加工工艺参数和加工状态的参数预测模型，可以实现驱动系统模型中参数变化的预测，从而实现复合轮廓误差的精确预测和补偿，可以解决数控加工中的实际轮廓误差补偿问题。通过多轴轮廓误差的预测模型预测的多轴轮廓误差，以及切削力引起的轮廓误差都可以在加工前预测出来，从而可以与机床几何误差一起建立复合轮廓误差预测模型。为了使多轴轮廓误差的预测模型更加准确，课题提出对实际加工工艺参数和加工状态等对驱动系统模型参数的影响因素进行分析，建立驱动系统的参数化模型；同时建立基于驱动系统的切削力预测模型，对切削力引起的轮廓误差进行预测。预测的复合轮廓误差可以与轨迹规划结合起来进行预补偿，不需要在数控系统中写入补偿算法的程序，为目前复杂曲面轮廓误差的补偿提供了一个新的解决思路，在轮廓误差补偿方面具有重要的实际意义。

针对传统的驱动系统模型无法适应实际加工过程中参数变化的问题，提出了驱动系统的参数化建模方法，用参数化模型来适应加工过程中参数的变化，解决了驱动系统模型的适应性问题。在驱动系统参数化模型的基础上，结合机床几何误差和切削力引起的加工误差研究了复合轮廓误差的预测和补偿方法，能够准确预测和补偿复合轮廓误差。为了提高轮廓误差的补偿效果，项目基于驱动系统的参数化模型研究了驱动系统的迭代预补偿方法，利用驱动系统的参数化模型获得最优预补偿值，结合参数的在线辨识解决了预补偿方法无法适应加工过程变化的问题。针对数控机床的轨迹规划问题，我们提出了一种C3连续的局部拐角平滑算法，可以有效提高轨迹拐角处的光顺程度。项目研究的轮廓误差预补偿方法在实验室搭建的机床上进行了验证，并可以应用到凸轮磨床的轮廓误差补偿和机器人轨迹控制中。.本项目在驱动系统建模、复合轮廓误差预测与补偿、轨迹规划、迭代学习方法等方面取得了一系列成果，发表了SCI论文11篇，授权发明专利2项，实用新型1项，培养博士生2名，硕士生5名，部分成果在实际的机床上获得应用，达到了预期的目标。