CN111857042A - PMAC-based five-axis high-precision positioning control system and working method - Google Patents
PMAC-based five-axis high-precision positioning control system and working method Download PDFInfo
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- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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Abstract
The invention discloses a PMAC-based five-axis high-precision positioning control system and a working method, wherein the system comprises a motion control module, a driving module, a five-axis motion module, a data acquisition and processing module and a human-computer interaction module; the motion control module includes a PMAC multi-axis motion controller. The invention is based on the PMAC control technology, innovatively adopts a five-axis ultra-precise positioning mode, realizes the ultra-precise positioning of the surface points of the curved surface of the workpiece, and has high precision and good stability. When the PMAC multi-axis motion controller is used for realizing positioning control, the DPRAM chip is added in the motion control module and can automatically return and communicate with an upper computer, so that the automatic operation of the laser etching of the curved surface of the workpiece is realized. The invention uses the dynamic focusing unit controlled by the RTC5 board as the Z axis, can adjust the distance within the range of 10mm, and greatly improves the precision of the positioning system.
Description
Technical Field
The invention relates to the technical field of etching positioning control, in particular to a PMAC-based five-axis high-precision positioning control system and a working method.
Background
In recent years, with the development of modern manufacturing and multidisciplinary cross fusion of machinery, materials, mechanics, electronics, communication, optics and the like, secondary precision machining is often required on the surface of curved parts. Before the curved surface etching, based on the requirement on the etching precision, the positioning operation needs to be carried out firstly, so that the positioning precision directly influences the etching precision. At present, a PMAC (multi-axis motion controller) is applied to control systems of numerical control machines, antenna scanning frames, missile rotary table tests and the like in all aspects, and has the advantages of high cost performance, good shielding performance, strong anti-interference capability, compatibility with various motor drivers and high compatibility. However, at present, the PMAC-based control technology is mostly biaxial, triaxial or quadcoptric, which cannot meet the requirement of high-precision positioning on the three-dimensional surface, and requires high-precision positioning and ensures that the normal distance is equal to the laser focal length when laser processing is performed on the three-dimensional surface.
Disclosure of Invention
In order to solve the problems in the prior art, the invention aims to design a PMAC-based five-axis high-precision positioning control system and a working method, which can greatly improve the positioning precision of a three-dimensional surface.
In order to achieve the purpose, the technical scheme of the invention is as follows: a PMAC-based five-axis high-precision positioning control system comprises a motion control module, a driving module, a five-axis motion module, a data acquisition and processing module and a human-computer interaction module;
the motion control module comprises a PMAC multi-axis motion controller, the driving module comprises three drivers, the three drivers are respectively a Naflange DC servo driver, an Anchuan servo driver and an Aerotech driver, the five-axis motion module comprises a horizontal axis, a vertical axis, a horizontal turntable, a pitching turntable and a Z-axis dynamic focusing unit, the data acquisition and processing module comprises a grating ruler, a displacement sensor, an A/D signal converter, a data sending unit and a data processing unit, the man-machine interaction module comprises an upper computer, and a five-axis high-precision positioning control program is installed in the upper computer;
the human-computer interaction module is respectively connected with the motion control module, the Z-axis dynamic focusing unit, the displacement sensor, the horizontal grating ruler and the vertical grating ruler through data lines; the motion control module is respectively connected with the horizontal shaft, the vertical shaft, the horizontal turntable and the pitching turntable through the driving module;
the horizontal shaft is arranged on the front side of the base, the horizontal turntable is arranged on the horizontal shaft through a sliding block, and a workpiece is arranged on the horizontal turntable; the vertical shaft is arranged at the rear side of the base, the pitching rotary table is arranged on the vertical shaft through a sliding block, and the scanning assembly is arranged on the pitching rotary table;
a horizontal grating scale is arranged on the horizontal shaft, a vertical grating scale is arranged on the vertical shaft, the Z-axis dynamic focusing unit is arranged on the pitching turntable, and the displacement sensor is arranged on the Z-axis dynamic focusing unit;
the motion control module is composed of an instruction receiving unit, a DPRAM (dual port RAM) communication unit and a signal sending unit, and is connected with the human-computer interaction module through a network cable; the human-computer interaction module sends a special motion instruction and workpiece curved surface contour data to the motion control module, the special motion instruction is received by the instruction receiving unit, the workpiece curved surface contour data is received and stored by the DPRAM communication unit, the motion control module converts the special motion instruction and the workpiece curved surface contour data into a CLK + DIR (pulse + direction) signal, and the CLK + DIR signal is sent to the driving module through the signal sending unit.
The three drivers in the driving module are respectively composed of a signal receiving unit, a PID debugging unit and a signal sending unit; the driving module is physically connected with the motion control module through an RS232 interface, the signal receiving unit receives CLC + DIR signals sent by the motion control module and then sends the CLC + DIR signals to the driving module through the signal sending unit, and the driving module respectively sends the CLC + DIR signals to the horizontal axis motor, the vertical axis motor, the horizontal turntable motor and the pitching turntable motor to perform corresponding motion; the PID debugging unit adjusts the gain parameter from small to large in a mode of adjusting the position loop gain parameter until the overshoot stable value of vibration does not appear, and the gain parameter is set as an optimal value, so that the signal output by the driving module is more stable.
The data acquisition and processing module respectively acquires and processes data of the horizontal shaft, the vertical shaft, the horizontal turntable, the pitching turntable and the Z-axis dynamic focusing unit.
The human-computer interaction module is respectively connected with the motion control module and the data acquisition and processing module, and comprises a system initialization unit, a parameter setting unit, a real-time display unit and a data monitoring unit. The system initialization unit and the parameter setting unit initialize the whole electric control system and set various parameters, the data monitoring unit judges whether the data exceeds a specified error range after receiving the data acquired and processed by the data acquisition and processing module, and sends alarm information after the data exceeds the specified error range to remind a worker to send a motion instruction to the motion control module for error compensation; the real-time display unit adopts a three-dimensional graph display mode to display the progress of the curved surface positioning etching in real time.
Furthermore, limiting protection devices are arranged at two ends of the horizontal shaft and the vertical shaft, so that the workpiece is prevented from exceeding the range when moving.
Furthermore, the Z-axis dynamic focusing unit is a light path tube which is adjusted in a rotating mode, and the distance within a range of 10mm is adjusted.
A working method of a PMAC-based five-axis high-precision positioning control system comprises the following steps:
A. parameter entry
Setting various parameters on a human-computer interaction interface on the upper computer;
B. data entry
The displacement sensor is matched with a horizontal shaft, a vertical shaft, a horizontal rotary table and a pitching rotary table to scan the workpiece curved surface contour data of the workpiece to be processed, the workpiece curved surface contour data are subjected to simulation arrangement by using a arraying algorithm to generate a space coordinate data table, and the space coordinate data table is sent to a DPRAM dual-port communication unit in the PMAC multi-shaft motion controller;
C. five-axis motion positioning
The upper computer sends an instruction to the motion control module, the motion control module converts the instruction into a CLK + DIR signal and sends the CLK + DIR signal to the driving module, and the driving module respectively sends the CLK + DIR signal to the horizontal axis motor, the vertical axis motor, the horizontal turntable motor and the pitching turntable motor; when the device works, firstly, the horizontal shaft motor operates to drive a workpiece on the horizontal shaft to make linear motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then the vertical axis motor runs to drive the scanning component on the vertical axis to make linear motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then a horizontal turntable motor operates to drive a workpiece on the horizontal turntable to do circular motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the angle specified by the CLC + DIR signal; finally, the pitching rotary table motor operates to drive the scanning component on the pitching rotary table to do circular motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the angle specified by the CLC + DIR signal; the Z-axis dynamic focusing unit rotationally adjusts the light path tube according to data sent by the upper computer to ensure that the focus of the light spot is on an etching point;
D. data acquisition and processing
D1 data acquisition and processing for horizontal, vertical, horizontal and pitch turntables
The horizontal grating ruler collects the actual moving distance, speed and acceleration of the workpiece on the horizontal axis and then transmits the actual moving distance, speed and acceleration to the A/D signal converter, and the vertical grating ruler collects the actual moving distance, speed and acceleration of the scanning assembly on the vertical axis and then transmits the actual moving distance, speed and acceleration to the A/D signal converter; the A/D signal converter converts signals collected by the horizontal grating ruler and the vertical grating ruler into digital signals, and the digital signals are sent to the man-machine interaction module through the data sending unit. After the difference between the actual moving distance and the appointed moving distance exceeds the set moving error range, the man-machine interaction module sends an instruction to the motion control module to respectively control the horizontal axis and the vertical axis to carry out corresponding compensation, and the compensation method comprises the following steps: when the difference between the actual moving distance and the appointed moving distance exceeds the set moving error range, the difference between the actual moving distance and the appointed moving error is calculated, the difference is sent to a motion control module, the horizontal axis and the vertical axis are controlled to move by the distance determined by the difference, and compensation is completed;
d2, data acquisition and processing of Z-axis dynamic focusing unit
The compensation data of the Z-axis dynamic focusing unit collects the distance from light to the normal direction of an etching point on the surface of the curved surface of the workpiece through the displacement sensor, the compensation data is sent to the Z-axis dynamic focusing unit through the data sending unit, and the Z-axis dynamic focusing unit is controlled to adjust the distance for compensation. The compensation data calculation formula is as follows:
X2＝X-X1
where X2 is the compensation data, X is the focal length, and X1 is the normal direction distance.
The horizontal axis and the vertical axis receive a CLK + DIR signal sent by the driving module and carry out corresponding movement according to the signal; the Z-axis dynamic focusing unit consists of a dynamic focusing unit controlled by an RTC5 board. The Z-axis dynamic focusing unit sends compensation data X2 to dynamically adjust through the received data acquisition and processing module, so that the focal point of the light spot is on the etching point.
E. Human-computer interaction interface display
Judging whether the difference between the actual moving distance and the appointed moving distance and the difference between the focal length and the normal direction distance exceed respective specified error ranges, if so, sending alarm information at a man-machine interaction module to remind a worker to send a motion instruction to a motion control module for error compensation; meanwhile, a three-dimensional graph display mode is adopted in the man-machine interaction module, and the progress of curved surface positioning etching is displayed in real time.
F. Judging whether all etching point positioning work is finished or not, and if so, closing the whole system; otherwise, turning to the step C.
Compared with the prior art, the invention has the following advantages:
1. the invention adopts a PMAC-based control technology, innovatively adopts a five-axis ultra-precise positioning mode, realizes ultra-precise positioning of the surface points of the curved surface of the workpiece, and has high precision and good stability.
2. When the PMAC multi-axis motion controller is used for realizing positioning control, the DPRAM chip is added in the motion control module and can automatically return and communicate with an upper computer, so that the automatic operation of the laser etching of the curved surface of the workpiece is realized.
3. The invention uses as the Z-axis a dynamic focusing cell controlled by a RTC5 board, equipped with an aperture of 6mm emitting laser light of 355nm length. And the dynamic focusing unit dynamically adjusts the focal distance according to the data of the displacement sensor and focuses light spots on the etching points. The dynamic focusing unit can adjust the distance within the range of 10mm, and the precision of the positioning system is greatly improved.
4. The invention adopts the limit protection device to prevent the workpiece from exceeding the range during moving, thereby playing a role in protecting equipment.
Drawings
Fig. 1 is a schematic diagram of the hardware architecture of the present invention.
Fig. 2 is a schematic block diagram of the present invention.
Fig. 3 is a program flow diagram of the present invention.
Wherein: the system comprises a host computer 1, a motion control module 2, a driving module 3, a vertical shaft 4, a pitching rotary table 5, a dynamic focusing unit 6-Z shaft 7, a displacement sensor 8, a horizontal rotary table 9, a horizontal shaft 10, a horizontal grating ruler 11 and a vertical grating ruler.
Detailed Description
The invention will be further described with reference to the accompanying drawings in which:
as shown in fig. 1-3, a five-axis high-precision positioning control system based on PMAC comprises a motion control module 2, a driving module 3, a five-axis motion module, a data acquisition and processing module and a human-computer interaction module;
the motion control module 2 comprises a PMAC multi-axis motion controller, the driving module 3 comprises three drivers, the three drivers are respectively a Naflange DC servo driver, an Anchuan servo driver and an Aerotech driver, the five-axis motion module comprises a horizontal axis 9, a vertical axis 4, a horizontal turntable 8, a pitching turntable 5 and a Z-axis dynamic focusing unit 6, the data acquisition and processing module comprises a horizontal grating ruler 10, a vertical grating ruler 11, a displacement sensor 7, an A/D signal converter, a data transmitting unit and a data processing unit, the human-computer interaction module comprises an upper computer 1, and a five-axis high-precision positioning control program is installed in the upper computer 1;
the human-computer interaction module is respectively connected with the motion control module 2, the Z-axis dynamic focusing unit 6, the displacement sensor 7, the horizontal grating ruler 10 and the vertical grating ruler 11 through data lines; the motion control module 2 is respectively connected with a horizontal shaft 9, a vertical shaft 4, a horizontal turntable 8 and a pitching turntable 5 through a driving module 3;
the horizontal shaft 9 is arranged on the front side of the base, the horizontal rotary table 8 is arranged on the horizontal shaft 9 through a sliding block, and a workpiece is arranged on the horizontal rotary table 8; the vertical shaft 4 is arranged at the rear side of the base, the pitching rotary table 5 is arranged on the vertical shaft 4 through a sliding block, and the scanning assembly is arranged on the pitching rotary table 5;
a horizontal grating ruler 10 is installed on the horizontal shaft 9, a vertical grating ruler 11 is installed on the vertical shaft 4, the Z-axis dynamic focusing unit 6 is installed on the pitching turntable 5, and the displacement sensor 7 is installed on the Z-axis dynamic focusing unit 6;
the motion control module 2 consists of an instruction receiving unit, a DPRAM dual-port RAM communication unit and a signal sending unit, and the motion control module 2 is connected with the human-computer interaction module through a network cable; the human-computer interaction module sends a special motion instruction and workpiece curved surface contour data to the motion control module 2, the special motion instruction is received by the instruction receiving unit, the workpiece curved surface contour data is received and stored by the DPRAM communication unit, the motion control module 2 converts the special motion instruction and the workpiece curved surface contour data into CLK + DIR pulse + direction signals, and the CLK + DIR signals are sent to the driving module 3 through the signal sending unit.
The three drivers in the driving module 3 are all composed of a signal receiving unit, a PID debugging unit and a signal sending unit; the driving module 3 is physically connected with the motion control module 2 through an RS232 interface, the signal receiving unit receives CLC + DIR signals sent by the motion control module 2 and then sends the CLC + DIR signals to the driving module 3 through the signal sending unit, and the driving module 3 respectively sends the signals to the horizontal shaft 9 motor, the vertical shaft 4 motor, the horizontal turntable 8 motor and the pitching turntable 5 motor to carry out corresponding motion; the PID tuning unit tunes the gain parameter from small to large by adjusting the gain parameter of the position loop until the overshoot stability value of the vibration does not occur, and sets the gain parameter as an optimal value, so that the signal output by the driving module 3 is more stable.
The data acquisition and processing module respectively acquires and processes data of the horizontal shaft 9, the vertical shaft 4, the horizontal turntable 8, the pitching turntable 5 and the Z-axis dynamic focusing unit 6.
The human-computer interaction module is respectively connected with the motion control module 2 and the data acquisition and processing module, and comprises a system initialization unit, a parameter setting unit, a real-time display unit and a data monitoring unit. The system initialization unit and the parameter setting unit initialize the whole electric control system and set various parameters, the data monitoring unit judges whether the data exceeds the specified error range after receiving the data acquired and processed by the data acquisition and processing module, and sends alarm information after the data exceeds the specified error range to remind a worker to send a motion instruction to the motion control module 2 for error compensation; the real-time display unit adopts a three-dimensional graph display mode to display the progress of the curved surface positioning etching in real time.
Furthermore, two ends of the horizontal shaft 9 and the vertical shaft 4 are provided with limit protection devices, so that the working table is prevented from exceeding the range during moving.
Further, the Z-axis dynamic focusing unit 6 is a light path tube which is adjusted by rotation, and is adjusted to a distance within a range of 10 mm.
A working method of a PMAC-based five-axis high-precision positioning control system comprises the following steps:
A. parameter entry
Setting various parameters on a human-computer interaction interface on the upper computer 1;
B. data entry
The displacement sensor 7 is matched with the horizontal shaft 9, the vertical shaft 4, the horizontal rotary table 8 and the pitching rotary table 5 to scan the workpiece curved surface contour data of the workpiece to be processed, the workpiece curved surface contour data are subjected to simulation arrangement by using an array arrangement algorithm to generate a space coordinate data table, and the space coordinate data table is sent to a DPRAM dual-port communication unit in the PMAC multi-axis motion controller;
C. five-axis motion positioning
The upper computer 1 sends an instruction to the motion control module 2, the motion control module 2 converts the instruction into a CLK + DIR signal and sends the CLK + DIR signal to the driving module 3, and the driving module 3 respectively sends the CLK + DIR signal to the horizontal axis motor, the vertical axis motor, the horizontal turntable motor and the pitching turntable motor; when the device works, firstly, the horizontal shaft motor operates to drive a workpiece on the horizontal shaft 9 to make linear motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then the vertical axis motor runs to drive the scanning component on the vertical axis 4 to make linear motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then the horizontal turntable motor operates to drive the workpiece on the horizontal turntable 8 to do circular motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the angle specified by the CLC + DIR signal; finally, the pitching turntable motor operates to drive the scanning component on the pitching turntable 5 to do circular motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the angle specified by the CLC + DIR signal; the Z-axis dynamic focusing unit 6 rotationally adjusts an optical path tube according to data sent by the upper computer 1 to ensure that a light spot focus is on an etching point;
D. data acquisition and processing
Data acquisition and processing of D1, horizontal axis 9, vertical axis 4, horizontal turntable 8, and pitch turntable 5
The horizontal grating ruler 10 collects the actual moving distance, speed and acceleration of the workpiece on the horizontal axis 9 and then transmits the actual moving distance, speed and acceleration to the A/D signal converter, and the vertical grating ruler 11 collects the actual moving distance, speed and acceleration of the scanning assembly on the vertical axis 4 and then transmits the actual moving distance, speed and acceleration to the A/D signal converter; the A/D signal converter converts the signals collected by the horizontal grating ruler 10 and the vertical grating ruler 11 into digital signals, and the digital signals are sent to the man-machine interaction module through the data sending unit. After the difference between the actual moving distance and the designated moving distance exceeds the set moving error range, the man-machine interaction module sends an instruction to the motion control module 2 to respectively control the horizontal axis 9 and the vertical axis 4 to carry out corresponding compensation, and the compensation method comprises the following steps: when the difference between the actual moving distance and the designated moving distance exceeds the set moving error range, the difference between the actual moving distance and the designated moving error is calculated, the difference is sent to the motion control module 2, and the horizontal shaft 9 and the vertical shaft 4 are controlled to move by the distance determined by the difference to complete compensation;
d2, data acquisition and processing of Z-axis dynamic focusing unit 6
The compensation data of the Z-axis dynamic focusing unit 6 collects the distance from light to the normal direction of the etching point on the surface of the curved surface of the workpiece through the displacement sensor 7, the compensation data is sent to the Z-axis dynamic focusing unit 6 through the data sending unit, and the Z-axis dynamic focusing unit 6 is controlled to adjust the distance for compensation. The compensation data calculation formula is as follows:
X2＝X-X1
where X2 is the compensation data, X is the focal length, and X1 is the normal direction distance.
The horizontal axis 9 and the vertical axis 4 receive a CLK + DIR signal sent by the driving module 3 and carry out corresponding movement according to the signal; the Z-axis dynamic focus unit 6 is composed of a dynamic focus unit controlled by an RTC5 board. The Z-axis dynamic focusing unit 6 sends compensation data X2 to dynamically adjust through the received data acquisition and processing module, so that the focal point of the light spot is on the etching point.
E. Human-computer interaction interface display
Judging whether the difference between the actual moving distance and the appointed moving distance and the difference between the focal length and the normal direction distance exceed respective specified error ranges, if so, sending alarm information at the man-machine interaction module to remind a worker to send a motion instruction to the motion control module 2 for error compensation; meanwhile, a three-dimensional graph display mode is adopted in the man-machine interaction module, and the progress of curved surface positioning etching is displayed in real time.
F. Judging whether all etching point positioning work is finished or not, and if so, closing the whole system; otherwise, turning to the step C.
The present invention is not limited to the embodiment, and any equivalent idea or change within the technical scope of the present invention is to be regarded as the protection scope of the present invention.
Claims (4)
1. A five-axis high-precision positioning control system based on PMAC is characterized in that: the device comprises a motion control module (2), a driving module (3), a five-axis motion module, a data acquisition and processing module and a human-computer interaction module;
the motion control module (2) comprises a PMAC multi-axis motion controller, the driving module (3) comprises three drivers, the three drivers are respectively a Naflange direct current servo driver, an Anchuan servo driver and an Aerotech driver, the five-axis motion module comprises a horizontal axis (9), a vertical axis (4), a horizontal turntable (8), a pitching turntable (5) and a Z-axis dynamic focusing unit (6), the data acquisition and processing module comprises a horizontal grating ruler (10), a vertical grating ruler (11), a displacement sensor (7), an A/D signal converter, a data transmitting unit and a data processing unit, the human-computer interaction module comprises an upper computer (1), and a five-axis high-precision positioning control program is installed in the upper computer (1);
the human-computer interaction module is respectively connected with the motion control module (2), the Z-axis dynamic focusing unit (6), the displacement sensor (7), the horizontal grating ruler (10) and the vertical grating ruler (11) through data lines; the motion control module (2) is respectively connected with a horizontal shaft (9), a vertical shaft (4), a horizontal rotary table (8) and a pitching rotary table (5) through a driving module (3);
the horizontal shaft (9) is arranged on the front side of the base, the horizontal rotary table (8) is arranged on the horizontal shaft (9) through a sliding block, and a workpiece is arranged on the horizontal rotary table (8); the vertical shaft (4) is arranged at the rear side of the base, the pitching rotary table (5) is arranged on the vertical shaft (4) through a sliding block, and the scanning assembly is arranged on the pitching rotary table (5);
a horizontal grating ruler (10) is installed on the horizontal shaft (9), a vertical grating ruler (11) is installed on the vertical shaft (4), the Z-axis dynamic focusing unit (6) is installed on the pitching turntable (5), and the displacement sensor (7) is installed on the Z-axis dynamic focusing unit (6);
the motion control module (2) is composed of an instruction receiving unit, a DPRAM communication unit and a signal sending unit, and the motion control module (2) is connected with the human-computer interaction module through a network cable; the human-computer interaction module sends a special motion instruction and workpiece curved surface contour data to the motion control module (2), the special motion instruction is received by the instruction receiving unit, the workpiece curved surface contour data is received and stored by the DPRAM communication unit, the motion control module (2) converts the special motion instruction and the workpiece curved surface contour data into a CLK + DIR signal, and the CLK + DIR signal is sent to the driving module (3) through the signal sending unit;
three drivers in the driving module (3) are respectively composed of a signal receiving unit, a PID debugging unit and a signal sending unit; the driving module (3) is physically connected with the motion control module (2) through an RS232 interface, the signal receiving unit receives CLC + DIR signals sent by the motion control module (2), and then the CLC + DIR signals are sent to the driving module (3) through the signal sending unit, and the driving module (3) respectively sends the signals to the horizontal shaft (9) motor, the vertical shaft (4) motor, the horizontal turntable (8) motor and the pitching turntable (5) motor to perform corresponding motions; the PID debugging unit adjusts the gain parameter from small to large in a mode of adjusting the position loop gain parameter until the overshoot stable value of vibration does not appear, and the gain parameter is set as an optimal value so that the signal output by the driving module (3) is more stable;
the data acquisition and processing module is used for acquiring and processing data of a horizontal shaft (9), a vertical shaft (4), a horizontal turntable (8), a pitching turntable (5) and a Z-axis dynamic focusing unit (6) respectively;
the human-computer interaction module is respectively connected with the motion control module (2) and the data acquisition and processing module and comprises a system initialization unit, a parameter setting unit, a real-time display unit and a data monitoring unit; the system initialization unit and the parameter setting unit initialize the whole electric control system and set various parameters, the data monitoring unit judges whether the data exceeds a specified error range after receiving the data acquired and processed by the data acquisition and processing module, and sends alarm information after the data exceeds the specified error range to remind a worker to send a motion instruction to the motion control module (2) for error compensation; the real-time display unit adopts a three-dimensional graph display mode to display the progress of the curved surface positioning etching in real time.
2. The PMAC-based five-axis high-precision positioning control system according to claim 1, characterized in that: and limiting protection devices are arranged at two ends of the horizontal shaft (9) and the vertical shaft (4) to prevent the workbench from exceeding the range during movement.
3. The PMAC-based five-axis high-precision positioning control system according to claim 1, characterized in that: the Z-axis dynamic focusing unit (6) is a light path tube which is adjusted in a rotating mode, and the distance within a range of 10mm is adjusted.
4. A working method of a five-axis high-precision positioning control system based on PMAC is characterized by comprising the following steps: the method comprises the following steps:
A. parameter entry
Setting various parameters on a human-computer interaction interface on the upper computer (1);
B. data entry
The displacement sensor (7) is matched with a horizontal shaft (9), a vertical shaft (4), a horizontal rotary table (8) and a pitching rotary table (5) to scan the workpiece curved surface contour data of the workpiece to be processed, the workpiece curved surface contour data are subjected to simulation arrangement by using an array arrangement algorithm to generate a space coordinate data table, and the space coordinate data table is sent to a DPRAM dual-port communication unit in the PMAC multi-axis motion controller;
C. five-axis motion positioning
The upper computer (1) sends an instruction to the motion control module (2), the motion control module (2) converts the instruction into a CLK + DIR signal and sends the CLK + DIR signal to the driving module (3), and the driving module (3) respectively sends the CLK + DIR signal to the horizontal axis motor, the vertical axis motor, the horizontal turntable motor and the pitching turntable motor; when the device works, firstly, the horizontal shaft motor operates to drive a workpiece on the horizontal shaft (9) to do linear motion at a set speed and an acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then the vertical axis motor runs to drive the scanning component on the vertical axis (4) to make linear motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the distance specified by the CLC + DIR signal; then a horizontal turntable motor operates to drive a workpiece on a horizontal turntable (8) to do circular motion at a set speed and acceleration according to the direction specified by the received CLC + DIR signal and move to the angle specified by the CLC + DIR signal; finally, the pitching rotary table motor operates to drive a scanning component on the pitching rotary table (5) to do circular motion at a set speed and acceleration according to the direction designated by the received CLC + DIR signal and move to the angle designated by the CLC + DIR signal; the Z-axis dynamic focusing unit (6) rotationally adjusts the light path tube according to the data sent by the upper computer (1) to ensure that the focus of the light spot is on the etching point;
D. data acquisition and processing
Data acquisition and processing of D1, horizontal axis (9), vertical axis (4), horizontal turntable (8), and pitch turntable (5)
The horizontal grating ruler (10) acquires the actual moving distance, speed and acceleration of the workpiece on the horizontal axis (9) and then transmits the actual moving distance, speed and acceleration to the A/D signal converter, and the vertical grating ruler (11) acquires the actual moving distance, speed and acceleration of the scanning assembly on the vertical axis (4) and then transmits the actual moving distance, speed and acceleration to the A/D signal converter; the A/D signal converter converts signals collected by the horizontal grating ruler (10) and the vertical grating ruler (11) into digital signals and sends the digital signals to the man-machine interaction module through the data sending unit; after the difference between the actual moving distance and the designated moving distance exceeds the set moving error range, the man-machine interaction module sends an instruction to the motion control module (2) to respectively control the horizontal axis (9) and the vertical axis (4) to carry out corresponding compensation, and the compensation method comprises the following steps: when the difference between the actual moving distance and the designated moving distance exceeds the set moving error range, the difference between the actual moving distance and the designated moving error is calculated, the difference is sent to a motion control module (2), and the horizontal axis (9) and the vertical axis (4) are controlled to move by the distance determined by the difference, so that compensation is completed;
d2, data acquisition and processing of Z-axis dynamic focusing unit (6)
The compensation data of the Z-axis dynamic focusing unit (6) are used for collecting the distance from light to the normal direction of an etching point on the surface of the curved surface of the workpiece through a displacement sensor (7), the compensation data are sent to the Z-axis dynamic focusing unit (6) through a data sending unit, and the Z-axis dynamic focusing unit (6) is controlled to adjust the distance for compensation; the compensation data calculation formula is as follows:
X2＝X-X1
wherein X2 is the compensation data, X is the focal length, X1 is the normal direction distance;
the horizontal axis (9) and the vertical axis (4) receive a CLK + DIR signal sent by the driving module (3) and carry out corresponding movement according to the signal; the Z-axis dynamic focusing unit (6) consists of a dynamic focusing unit controlled by an RTC5 board; the Z-axis dynamic focusing unit (6) sends compensation data X2 to perform dynamic adjustment through a received data acquisition and processing module, so that a light spot focus is on an etching point;
E. human-computer interaction interface display
Judging whether the difference between the actual moving distance and the appointed moving distance and the difference between the focal length and the normal direction distance exceed respective specified error ranges, if so, sending alarm information at a man-machine interaction module to remind a worker to send a motion instruction to a motion control module (2) for error compensation; meanwhile, a three-dimensional graph display mode is adopted in the man-machine interaction module, and the progress of curved surface positioning etching is displayed in real time;
F. judging whether all etching point positioning work is finished or not, and if so, closing the whole system; otherwise, turning to the step C.
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