CN113146274B - Vibration amplitude sensorless detection and control system and method of vibration-assisted cutting device - Google Patents
Vibration amplitude sensorless detection and control system and method of vibration-assisted cutting device Download PDFInfo
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- B23P25/00—Auxiliary treatment of workpieces, before or during machining operations, to facilitate the action of the tool or the attainment of a desired final condition of the work, e.g. relief of internal stress
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Abstract
The invention discloses an amplitude sensorless detection and control system and method of a vibration-assisted cutting device, and belongs to the field of vibration-assisted cutting machining. The invention acquires and obtains the voltage V (t) and the current I (t) on the vibration auxiliary cutting device, and the voltage V (t) and the current I (t) are transmitted to the vibration auxiliary cutting device after DA conversionIn the controller; according to the conversion relation established in the nonlinear electromechanical model, the voltage V (t) and the current I (t) are calculated to obtain the added charge Q (t) and the hysteresis voltage V at the current moment H Calculating to obtain the current output displacement x of the piezoelectric driver; calculating the displacement x to obtain the amplitude A and the expected amplitude A r Comparing and making difference, and adding difference value e A (k) Inputting the voltage into a PID controller to obtain estimated deviation voltage delta V (k); finally, the initial voltage V is adjusted 0 And adding the output voltage V and the deviation voltage delta V (k) of the deviation control module to obtain an output voltage V, and finally, performing AD conversion on the generated new excitation signal, amplifying the new excitation signal by a voltage amplifier and applying the amplified new excitation signal to the vibration auxiliary cutting device. The invention improves the stability of the vibration-assisted cutting state, improves the processing quality and reduces the complexity of the system.
Description
Technical Field
The invention belongs to the field of vibration-assisted cutting machining, and particularly relates to an amplitude sensorless detection and control system and method of a vibration-assisted cutting device.
Background
With the development of aerospace, defense industry, marine shipbuilding, and integrated circuit and semiconductor industries, many critical parts require extremely high precision and quality, and therefore higher requirements are put forward for precision machining. The ultrasonic elliptic vibration cutting is used as a precision machining method, has the advantages that various conventional cutting methods do not have, can effectively reduce cutting force and cutting heat, improve the surface quality of machined products, reduce burrs, and realize the machining of micron-scale micro pits, micro grooves and other structures on the surface of a workpiece.
The ultrasonic elliptic vibration auxiliary cutting machining technology is an improved type based on the traditional machining technology and aims to reduce cutting force, improve the machining quality of a machined surface and prolong the service life of a cutter. The ultrasonic elliptical vibration machining mainly utilizes high-frequency vibration to enable a cutter to rapidly cut into a machined workpiece and rapidly cut out, the tool point of the cutter for machining cuts the workpiece in multiple times in one-time cutting machining at very high vibration frequency, and the cutting track is in an elliptical track form, so that the abrasion of the cutter can be reduced by reducing friction time.
The ultrasonic elliptical vibration is generated by the vibration of the ultrasonic elliptical vibration auxiliary cutting device under the natural frequency, but the ultrasonic elliptical vibration auxiliary cutting device can be subjected to a certain cutting load in the cutting process, so that the working frequency of the cutting device deviates from the natural frequency, the working state of the cutting device also deviates from the resonance state, and in addition, the displacement of the tool nose of the device can be fluctuated under the influence of the cutting load, so that the amplitude of the ultrasonic elliptical vibration auxiliary cutting is reduced. When the machining parameters are changed, the cutting load applied to the tool nose is different, and the frequency deviation degree and amplitude reduction amplitude of the device are different, so that the machining quality is not uniform. In addition, during the ultrasonic elliptical vibration cutting process, some unknown disturbances, such as hysteresis nonlinearity of the vibration-assisted cutting device, vibration of a machine tool, external noise and the like, exist, and under the influence of the factors, the stability of the ultrasonic elliptical vibration-assisted cutting state fluctuates, so that the processing quality is finally influenced. Therefore, in order to improve the stability of the ultrasonic elliptical vibration cutting machining state, it is necessary to avoid or reduce the influence of unknown disturbances such as cutting load on the machining process of the ultrasonic elliptical vibration cutting.
The method adopts a mode of controlling vibration fluctuation of the machining process by using mechanical feedback as ultrasonic elliptical vibration cutting, measures the output track of an ultrasonic elliptical vibration cutting device by using a special sensor, and can effectively improve the stability of vibration by using the signal of the sensor as an adjustment index of a control system. However, this method has the following problems: (1) high-resolution displacement sensors are usually expensive, heavy and bulky, and the use of such dedicated sensors inevitably results in bulky and complex whole processing systems, increasing processing costs; (2) the direct measurement of the displacement of the actuator often imposes strict constraints on the mechanical design, the actual position and direction of the end actuator must be calculated by positive kinematics, and the positive kinematics has uncertain precision due to the machining precision of the mechanical structure; (3) the arrangement is inconvenient to use under industrial conditions, and under strict processing conditions, due to long-time high-frequency vibration, the probe of the sensor and a contacted measuring surface are difficult to ensure that the position of the probe of the sensor is always in a fixed position after long-time collision; (4) in order to directly reflect the vibration state of the ultrasonic vibration cutting processing system, the sensor is arranged at the tail end of the vibration actuator or the tool nose of the cutting tool, which is close to the cutting area, and because the sensor is arranged in the cutting area, the sensor or the wiring of the control system occupies the installation space of the cutting tool and the processing workpiece, which brings inconvenience to the processing. Therefore, in order to improve the machining precision of ultrasonic elliptical vibration cutting and expand the advantages of the ultrasonic elliptical vibration cutting in precision machining, how to eliminate the influence of the factors on the ultrasonic elliptical vibration cutting, a piezoelectric driving workbench driving device which does not relate to a position or displacement sensor is developed, and the problems to be solved in the industries of precision manufacturing and the like are urgently solved.
Disclosure of Invention
The purpose of the invention is as follows: provided are an amplitude sensorless detection and control system and method for a vibration-assisted cutting device, which can detect the output displacement of the vibration-assisted cutting device without a sensor, control the device amplitude, and improve the stability of vibration.
The technical scheme is as follows: in order to realize the purpose, the invention adopts the following technical scheme:
the utility model provides an amplitude does not have sensing detection control system of vibration auxiliary cutting device which characterized in that:
the device comprises a controller, a DA conversion module, a voltage amplifier, a vibration auxiliary cutting device, a voltage induction resistor, a current induction resistor and an AD conversion module;
the output end of the controller is connected with the vibration auxiliary cutting device after sequentially passing through the DA conversion module and the voltage amplifier; the group of voltage sensing resistors are connected with the vibration auxiliary cutting device in parallel, wherein the voltage sensing resistor at the lowest potential is connected with the first input end of the AD conversion module; the current sensing resistor is connected with the vibration auxiliary cutting device in series and is connected with the second input end of the AD conversion module; the AD conversion module is connected with the controller;
the controller comprises an integration module, a hysteresis compensation module, a displacement estimation module, an amplitude detection module, a deviation control module, a first voltage calculator and a second voltage calculator;
the input end of the integration module is connected with the current signal which is converted and AD converted, and the integration module comprises a first output end and a second output end; the first output end of the integration module is connected with the input end of the hysteresis compensation module, the output end of the hysteresis compensation module is connected with the first input end of a first voltage calculator, the second input end of the first voltage calculator is connected with a voltage signal which is converted and subjected to AD conversion, the first voltage calculator is connected with the first input end of the displacement estimation module, the second input end of the displacement estimation module is connected with the second output end of the integration module, the output end of the displacement estimation module is connected with the input end of the amplitude detection module, and the output end of the amplitude detection module is connected with the input end of the deviation control module; the output end of the deviation control module is connected with the first input end of a second voltage calculator, the second input end of the second voltage calculator is connected with the initial voltage, and the output end of the second voltage calculator is connected with the signal generator.
The method comprises the following steps:
step 2, integrating the total current I (t) to obtain an external charge Q (t);
step 3, calculating the hysteresis voltage V of the piezoelectric transducer by the additional charge Q (t) according to the hysteresis model H ；
Step 4, the excitation voltage V (t) acquired in the step 1 and the hysteresis voltage V acquired in the step 3 H Subtracting, and transmitting the calculation result to a displacement estimation module;
step 5, calculating the estimated displacement x of the vibration-assisted cutting device by using the external charges Q (t) obtained in the step 2 and the calculation result obtained in the step 4, wherein the correlation formula is as follows;
x＝ψ[Q(t)-C d (V(t)-V H )] (1)；
step 6, periodically calculating a group of estimated displacements x to obtain the current amplitude A of the group of data; the current amplitude A and the current desired set amplitude A r Obtaining the current amplitude deviation e of the device after difference A (k)；
Step 7, calculating the amplitude deviation e A (k) Calculating to obtain deviation voltage delta V (k) by using a deviation control module as an input quantity;
step 8, finally, the initial voltage V is applied 0 And adding the deviation voltage delta V (k) of the deviation control module to obtain an output voltage V, and applying the output voltage V to the vibration auxiliary cutting device after the output voltage V is amplified by a voltage amplifier.
Wherein, the hysteresis voltage V in step 3 H The following expression is called the hysteresis inverse model, obtained by:
wherein, omega' i Is weight of hysteresis inverse model, r' i The two parameters are obtained by parameter identification as threshold values of the hysteresis inverse model.
The hysteresis inverse model is obtained by inverting a hysteresis positive model, and the adopted hysteresis positive model is as follows:
wherein Q (t) is the applied charge at time t output by PI model, U (t) is the input voltage at time t of PI model, ω i Is the weight of the PI model, r i Is a threshold value of the PI model, and r i ＝[r 0 ,…,r n ] T N is the number of Play operators, T is the time interval between two adjacent time points; acquiring input voltage U (t) of the vibration auxiliary cutting device in a working state, calculating corresponding additional charge Q (t), and solving various parameters required by the PI model according to the data;
wherein, the calculation formula of the deviation controller in step 7 is as follows:
where Δ V (k) is a change in the output of the PID controllerQuantity, i.e. offset voltage, e A (k) Is the input variable of the PID controller, represents the deviation signal of the control system, k represents the serial number of the sampling point, T represents the sampling period, g p 、g i 、g d Respectively representing the proportional link coefficient, the integral link coefficient and the differential link coefficient of the PID controller.
The vibration-assisted cutting device amplitude sensorless detection and control method is characterized by comprising the following steps of: the deviation voltage Δ V (k) and the initial voltage V in step 8 0 And obtaining a final output voltage V after superposition, namely:
V＝V 0 +ΔV(k) (5)；
has the advantages that: compared with the prior art, the invention has the following advantages:
1. after the current sensing resistor and the voltage sensing resistor are adopted to replace the traditional special sensor for detection, the complexity of the cutting processing system is reduced;
2. the established nonlinear electromechanical conversion model has a simple structure, is convenient to realize, and is suitable for most vibration-assisted cutting devices;
3. the influence of hysteresis nonlinearity is considered in the electromechanical conversion model and compensated, so that the robustness of the system is improved.
Drawings
FIG. 1 is a schematic view of the control system of the present invention;
fig. 2 is a connection diagram of the acquisition circuit of the present invention.
Detailed Description
The technical solution of the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the following examples are only illustrative of the technical idea of the present invention, and the scope of the present invention should not be limited thereby, and any modifications made on the technical idea of the present invention are within the scope of the present invention.
As shown in fig. 1, an amplitude sensorless detection and control system of a vibration assisted cutting apparatus includes: comprises an electric signal acquisition module, a nonlinear amplitude estimation module, a PID control module and a vibration assistantThe cutting-assisting device comprises an electric signal acquisition module, a nonlinear amplitude estimation module and a PID control module, wherein the electric signal acquisition module comprises a signal acquisition circuit, the nonlinear amplitude estimation module comprises a nonlinear electromechanical conversion model, and the PID control module comprises a PID controller; firstly, extracting and collecting an excitation voltage V (t) and a total current I (t) of the ultrasonic vibration cutting device by using a voltage sensing resistor and a current sensing resistor, and inputting the extracted and collected excitation voltage V (t) and the total current I (t) into a controller; the total current I (t) is integrated to obtain the additional charge Q (t), and the hysteresis voltage V of the piezoelectric transducer can be calculated by the additional charge Q (t) according to the hysteresis model H (ii) a After the data are calculated, the corresponding conversion coefficient psi can be selected according to the currently set excitation voltage amplitude, the estimated displacement x of the ultrasonic elliptical vibration cutting device is obtained through calculation, then the amplitude detection is carried out on the estimated displacement signal, the current amplitude A of the device and the currently expected set amplitude A are obtained r Obtaining the current amplitude deviation e of the device after the difference is made A (k) (ii) a Then, calculating by using a PID controller to obtain a voltage adjustment quantity delta V (k) by taking the amplitude deviation VA obtained by calculation as an input quantity; finally, the initial voltage V is adjusted 0 And adding the deviation voltage delta V (k) of the PID control module to obtain an output voltage V, and controlling the cutting device by the vibration auxiliary cutting device.
As shown in fig. 1, an amplitude sensorless detection and control method for a vibration-assisted cutting apparatus includes the following steps:
(1) collecting an excitation voltage V (t) on the vibration-assisted cutting device and a total current I (t) passing through by using a voltage collecting circuit;
as shown in fig. 2, an electrical signal acquisition circuit is connected to a vibration-assisted cutting device, a group of voltage sensing resistors are connected in parallel to two ends of the vibration-assisted cutting device to divide and measure the voltage of the vibration-assisted cutting device, a current sensing resistor is connected in series with the vibration-assisted cutting device to measure the current passing through the vibration-assisted cutting device, and the measured data is transmitted to a control system after being subjected to AD conversion.
(2) Calculating the collected current I (t) and voltage V (t) to obtain a plurality of parameters for calculating and estimating the displacement x;
integrating the collected current I (t) to obtain an external charge Q (t) passing through the vibration-assisted cutting device; compensating the hysteresis characteristic of the vibration cutting device based on the PI model, and utilizing the hysteresis voltage V of the vibration auxiliary cutting device H The relation between the voltage and the external charge Q (t) is calculated to obtain the hysteresis voltage V H (ii) a Subtracting hysteresis voltage V from collected excitation voltage V (t) H Obtaining the voltage V actually acting on the vibration-assisted cutting device t (ii) a Using measured static capacitance values C d And voltage V t Multiplying to obtain a charge Q consumed by the vibration-assisted cutting device to charge the equivalent capacitor d (ii) a Subtracting the charge Q consumed by charging the equivalent capacitor from the applied charge Q (t) d Obtaining a deformation charge Q for displacing the vibration-assisted cutting device t (ii) a Deformation charge Q t The estimated displacement x of the vibration assisted cutting apparatus can be obtained by multiplying the value of (a) by the conversion coefficient ψ identified by experimental data.
Wherein, the expression of the positive hysteresis model is as follows:
wherein Q (t) is the output charge of the PI model at time t, U (t) is the input voltage of the PI model at time t, ω i Is the weight of the PI model, r i Is a threshold value of the PI model, and r i ＝[r 0 ,…,r n ] T N is the number of Play operators, T is the time interval between two adjacent time points; acquiring input voltage U (t) of the vibration auxiliary cutting device in a working state, calculating corresponding additional charge Q (t), and solving various parameters required by the PI model according to the data;
and (3) inverting the model based on the PI model expression to obtain a hysteresis inversion model as follows:
wherein, omega' i Is weight of hysteresis inverse model, r' i The two parameters are obtained by parameter identification and are threshold values of the hysteresis inverse model;
(3) periodically, a set of estimated displacements x is calculated to obtain the amplitude a of the set of data, and the initial voltage V is measured by a PID controller 0 Correcting;
detecting the amplitude of the signal of the estimated displacement x, and calculating the amplitude A and the set amplitude A r Difference e of A (k) The voltage is continuously transmitted to a deviation controller, the deviation controller calculates output deviation voltage delta V (k), and the calculation formula of the deviation controller is as follows:
where Δ V (k) is the output variable of the PID controller, i.e., the adjustment amount of the frequency parameter, e A (k) Is the input variable of the PID controller, represents the deviation signal of the control system, k represents the serial number of the sampling point, T represents the sampling period, g p 、g i 、g d Respectively representing the proportional link coefficient, the integral link coefficient and the differential link coefficient of the PID controller.
The deviation voltage Δ V (k) is compared with the initial voltage V 0 After the voltage V is superposed, the final output voltage V is obtained and then transmitted to a vibration auxiliary cutting device;
the voltages input to the vibration assisted cutting apparatus were:
V＝V 0 +ΔV(k)；
the output amplitude of the vibration-assisted cutting device is stabilized, when the output displacement of the cutting device fluctuates due to unknown disturbance such as cutting load in the machining process, the current displacement of the tool nose of the device can be detected under the condition that a special displacement sensor is not suitable, and a deviation voltage can be generated by a PID controller to correct the initial voltage, so that the stability and the precision of the output are improved. The method can be used for reducing vibration track errors caused by fluctuation of cutting load, improving the precision of the output track of the cutting device, reducing the dependence of a cutting processing system on a sensor and reducing the cost and the complexity of the processing system.
Claims (6)
1. The utility model provides an amplitude does not have sensing detection and control system of vibration auxiliary cutting device which characterized in that:
the device comprises a controller, a DA conversion module, a voltage amplifier, a vibration auxiliary cutting device, a voltage induction resistor, a current induction resistor and an AD conversion module;
the output end of the controller is connected with the vibration auxiliary cutting device after sequentially passing through the DA conversion module and the voltage amplifier; the group of voltage sensing resistors are connected with the vibration auxiliary cutting device in parallel, wherein the voltage sensing resistor at the lowest potential is connected with the first input end of the AD conversion module; the current sensing resistor is connected with the vibration auxiliary cutting device in series and is connected with the second input end of the AD conversion module; the AD conversion module is connected with the controller;
the controller comprises an integration module, a hysteresis compensation module, a displacement estimation module, an amplitude detection module, a deviation control module, a first voltage calculator and a second voltage calculator;
the input end of the integration module is connected with the current signal which is converted and AD converted, and the integration module comprises a first output end and a second output end; the first output end of the integration module is connected with the input end of the hysteresis compensation module, the output end of the hysteresis compensation module is connected with the first input end of a first voltage calculator, the second input end of the first voltage calculator is connected with a voltage signal which is converted and subjected to AD conversion, the first voltage calculator is connected with the first input end of the displacement estimation module, the second input end of the displacement estimation module is connected with the second output end of the integration module, the output end of the displacement estimation module is connected with the input end of the amplitude detection module, and the output end of the amplitude detection module is connected with the input end of the deviation control module; the output end of the deviation control module is connected with the first input end of a second voltage calculator, the second input end of the second voltage calculator is connected with the initial voltage, and the output end of the second voltage calculator is connected with the signal generator.
2. The method of the vibration-less sensing detection and control system of a vibration-assisted cutting apparatus of claim 1, characterized by comprising the processes of:
step 1, extracting and collecting excitation voltage V (t) and total current I (t) of an ultrasonic vibration cutting device by using a voltage sensing resistor and a current sensing resistor at the lowest potential, and inputting the extracted and collected excitation voltage V (t) and total current I (t) into a controller;
step 2, integrating the total current I (t) to obtain an external charge Q (t);
step 3, calculating the hysteresis voltage V of the piezoelectric transducer by the additional charge Q (t) according to the hysteresis model H ；
Step 4, the excitation voltage V (t) acquired in the step 1 and the hysteresis voltage V acquired in the step 3 H Subtracting, and transmitting the calculation result to a displacement estimation module;
step 5, calculating the estimated displacement x of the vibration-assisted cutting device by using the external charge Q (t) obtained in the step 2 and the calculation result obtained in the step 4, wherein a correlation formula is as follows;
x＝ψ[Q(t)-C d (V(t)-V H )] (1)；
wherein C is d The measured static capacitance value;
step 6, periodically calculating a group of estimated displacements x to obtain the current amplitude A of the group of data; the current amplitude A and the current desired set amplitude A r Obtaining the current amplitude deviation e of the device after difference A (k)；
Step 7, calculating the amplitude deviation e A (k) Calculating to obtain deviation voltage delta V (k) by using a deviation control module as an input quantity;
step 8, finally, the initial voltage V is applied 0 And adding the deviation voltage delta V (k) of the deviation control module to obtain an output voltage V, and applying the output voltage V to the vibration auxiliary cutting device after the output voltage V is amplified by a voltage amplifier.
3. The vibration of the vibration assisted cutting apparatus of claim 2The method for detecting and controlling the system without sensing amplitude is characterized in that: step 3, the hysteresis voltage V H The following expression is called the hysteresis inverse model, obtained by:
wherein, omega' i Is weight of hysteresis inverse model, r' i The two parameters are obtained by parameter identification as threshold values of the hysteresis inverse model.
4. A method of an amplitude sensorless detection and control system for a vibration assisted cutting apparatus as set forth in claim 3 wherein: the hysteresis inverse model is obtained by inverting the hysteresis positive model, and the adopted hysteresis positive model is as follows:
wherein Q (t) is the applied charge at time t output by PI model, U (t) is the input voltage at time t of PI model, ω i Is the weight of the PI model, r i Is a threshold value of the PI model, and r i ＝[r 0 ，...，r n ] T N is the number of Play operators, T is the time interval between two adjacent time points; by collecting the input voltage U (t) of the vibration auxiliary cutting device in a working state and calculating the corresponding additional charge Q (t), various parameters required by the PI model are solved according to the data.
5. The method of an amplitude sensorless detection and control system for a vibration assisted cutting apparatus of claim 2, wherein: in step 7, the calculation formula of the deviation control module is as follows:
where Δ V (k) is the output variable of the PID controller, i.e., the offset voltage, e A (k) Is the input variable of the PID controller, represents the deviation signal of the control system, k represents the serial number of the sampling point, T represents the sampling period, g p 、g i 、g d Respectively representing the proportional link coefficient, the integral link coefficient and the differential link coefficient of the PID controller.
6. The method of an amplitude sensorless detection and control system for a vibration assisted cutting apparatus of claim 2, wherein: the deviation voltage Δ V (k) and the initial voltage V in step 8 0 And obtaining a final output voltage V after superposition, namely:
V＝V 0 +ΔV(k) (5)。
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