TW201304900A - Learning control method for simultaneously increasing processing speed and reducing processing error - Google Patents
Learning control method for simultaneously increasing processing speed and reducing processing error Download PDFInfo
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本發明係關於一種學習控制方法，尤指一種用於重複性機械加工且可同步提高加工速度與降低加工誤差之學習控制方法者。The present invention relates to a learning control method, and more particularly to a learning control method for repetitive machining that can simultaneously increase the processing speed and reduce the machining error.
按，在機械加工場合中常見許多重複性的加工動作，這類重複性機械加工之命令即為一週期性的訊號，因此，機械加工機台通常被要求對於此週期性訊號進行追蹤控制，其中以剛性攻牙機為例，現有剛性攻牙機從進刀、攻牙、結束、逆轉退刀及停止加工，即可完成一個螺孔，並且繼續重複同樣的動作來加工出複數個螺孔，由於現代工業要求高產值與高效率，因此，高速加工與高精度是機械加工機台不變的發展趨勢，而現有的學習控制方法主要透過每一次的加工結果，來修正下一次加工的控制輸入或命令輸入(主從式架構控制)，進而解決這類週期性追蹤控制問題；然而，現有學習控制方法僅能針對固定時間長度的加工命令進行追蹤及學習，藉以達到降低加工誤差的目的，而假若欲縮短加工時間來提高加工的速度，則必須重新啟動另一個學習循環，而先前的學習結果則將被拋棄不使用，大大地降低了學習控制方法的控制效率，誠有加以改良之處。Press, many repetitive machining operations are common in machining situations. The command of such repetitive machining is a periodic signal. Therefore, the machining machine is usually required to track and control the periodic signal. Taking a rigid tapping machine as an example, the existing rigid tapping machine can complete a screw hole from the infeed, tapping, ending, reversing and stopping the machining, and continue to repeat the same action to process a plurality of screw holes. Since modern industry requires high output value and high efficiency, high-speed machining and high precision are the constant development trend of machining machines, and the existing learning control method mainly corrects the control input of the next processing through each processing result. Or command input (master-slave architecture control) to solve such periodic tracking control problems; however, existing learning control methods can only track and learn for fixed-length processing commands, thereby reducing the processing error. If you want to shorten the processing time to increase the processing speed, you must restart another learning cycle, and Results of the study will not be abandoned, greatly reducing the efficiency of learning control method of control, honesty has to be improved place.
因此，本發明人有鑑於目前學習控制方法僅能針對固定時間長度之加工命令進行學習，而無法同時達到降低加工誤差及縮短加工命令時間的不足與問題，特經過不斷的研究與試驗，終於發展出一種能改進現有缺失之本發明。Therefore, the present inventors have in view of the fact that the current learning control method can only learn for a fixed length of processing command, and cannot simultaneously achieve the disadvantages and problems of reducing the processing error and shortening the processing command time, and finally develops through continuous research and experiment. An invention that improves upon existing deficiencies.
本發明之主要目的係在於提供一種同步提高加工速度與降低加工誤差之學習控制方法，其係用於重複性的機械加工上，能在學習控制的過程中，當加工精度滿足一定要求的條件下，讓使用者選擇啟用一速度學習運算程式，即可在下一週期的加工中，將原本的加工命令時間縮短，使整體的加工時間縮短，並不影響加工路徑且加工誤差仍能經由學習而降低，因此，可同步提高加工速度，且更有效率地完成加工程序，進而同時達到提高生產競爭力及降低加工誤差，進而提供一可同步提高加工速度與降低加工誤差之學習控制方法之目的者。The main object of the present invention is to provide a learning control method for simultaneously improving processing speed and reducing processing error, which is used for repetitive mechanical processing, and can be used in the process of learning control, when the processing precision satisfies certain requirements. In order to enable the user to enable a speed learning calculation program, the original machining command time can be shortened in the next cycle of processing, so that the overall machining time is shortened, the machining path is not affected, and the machining error can still be reduced by learning. Therefore, the processing speed can be simultaneously increased, and the processing procedure can be completed more efficiently, thereby simultaneously achieving the improvement of production competitiveness and processing error, thereby providing a learning control method capable of simultaneously increasing the processing speed and reducing the processing error.
為達到上述目的，本發明係提供一種同步提高加工速度與降低加工誤差之學習控制方法，其係包含有：設定初始加工命令：於一機械加工機台的控制程式中設置一學習控制程式，其中該學習控制程式係設有一學習增益程式及一速度學習運算程式，於該機械加工機台的控制程式中設定一初始加工命令，其中該初始加工命令係根據不同的要求設定其加工速度，並使各軸的初始加工命令同步；實際機械加工：待設定好機械加工機台的初始加工命令，使各軸的初始加工命令為同步後，根據該初始加工命令進行實際的加工；加工誤差之量測與計算：待機械加工機台加工完成後，由各軸的馬達編碼器進行量測並輸出一訊號，計算出該機械加工機台的加工誤差；判斷是否終止學習：根據前述計算出的加工誤差與初始加工命令，來判斷是否終止學習，其中若達到學習終止條件，則停止該學習控制，並以目前的初始加工命令做為後續之加工命令進行加工，若未達到學習終止條件，則進行下一步驟的操作；更新加工命令：若未達到前述步驟之學習終止條件，則利用本次的加工命令、加工誤差及先前藉由該學習控制所求得的學習增益矩陣，透過該學習控制程式的一線性學習控制法則計算出下一次加工的輸入命令；判斷是否開啟速度學習運算：根據前述計算出的加工誤差與初始加工命令，來判斷是否開啟速度學習程式，其中若不滿足速度學習開啟條件，則以前一步驟經濾波後的加工命令輸入機械加工機台中進行下一次的實際機械加工，而若滿足速度學習開啟條件，則進行下一步驟的操作，速度學習運算：若滿足上述的速度學習開啟條件後，則進入該速度學習運算程式中並透過一速度學習法則進行運算，藉以求出新的加工命令，將該求得的加工命令輸入該機械加工機台的控制程式中，進行實際機械加工，如此重複執行直到符合前述的學習終止條件。In order to achieve the above object, the present invention provides a learning control method for simultaneously increasing processing speed and reducing processing error, which includes: setting an initial machining command: setting a learning control program in a control program of a machining machine, wherein The learning control program is provided with a learning gain program and a speed learning calculation program, and an initial machining command is set in the control program of the machining machine, wherein the initial machining command sets the machining speed according to different requirements, and The initial machining command of each axis is synchronized; the actual machining: the initial machining command of the machining machine is to be set, so that the initial machining command of each axis is synchronized, and the actual machining is performed according to the initial machining command; the measurement of the machining error is performed. And calculation: After the machining machine is finished, the motor encoder of each axis measures and outputs a signal to calculate the machining error of the machining machine; whether to terminate the learning: the machining error calculated according to the above And initial processing commands to determine whether to terminate the study, If the condition is terminated, the learning control is stopped, and the current initial processing command is used as the subsequent processing command for processing. If the learning termination condition is not reached, the next step is performed; and the processing command is updated: if the foregoing steps are not reached After learning the termination condition, the current processing command, the machining error, and the learning gain matrix previously obtained by the learning control are used to calculate the input command of the next processing through a linear learning control rule of the learning control program; Whether to enable the speed learning operation: according to the calculated machining error and the initial machining command, to determine whether to open the speed learning program, wherein if the speed learning opening condition is not satisfied, the previous step of the filtered machining command is input into the machining machine Perform the next actual machining, and if the speed learning start condition is satisfied, proceed to the next step of operation, and the speed learning operation: if the speed learning open condition is satisfied, enter the speed learning calculation program and pass a speed Learning the law to calculate Processing the command, the command input ascertained machining control program of the machining machine, the actual machining, so the learning is repeatedly executed until a termination condition is to satisfy the aforementioned.
進一步，該學習控制程式係為一命令式疊代學習控制程式。Further, the learning control program is an instructional iterative learning control program.
再進一步，該學習終止條件為絕對命令縮短比小於一定值以及絕對加工誤差比小於一定值。Still further, the learning termination condition is that the absolute command shortening ratio is less than a certain value and the absolute machining error ratio is less than a certain value.
較佳地，該學習終止條件為絕對命令縮短比小於一定值、學習次數大於一定值且相對加工誤差比大於一定值。Preferably, the learning termination condition is that the absolute command shortening ratio is less than a certain value, the learning frequency is greater than a certain value, and the relative machining error ratio is greater than a certain value.
較佳地，在透過該學習控制程式的一線性學習控制法則計算出下一次加工的輸入命令後，將該加工輸入命令傳送至一低通濾波器中，藉以將多於的雜訊進行過濾。Preferably, after a linear learning control rule of the learning control program calculates an input command for the next processing, the processing input command is transmitted to a low pass filter to filter more noise.
較佳地，該速度學習開啟條件為相對加工誤差比小於一定值、絕對加工誤差比小於一定值以及絕對命令縮短比大於一定值。Preferably, the speed learning on condition is that the relative machining error ratio is less than a certain value, the absolute machining error ratio is less than a certain value, and the absolute command shortening ratio is greater than a certain value.
藉由上述的技術手段，本發明同步提高加工速度與降低加工誤差之學習控制方法，主要係當加工精度滿足一定要求的條件下，可讓使用者選擇啟用該速度學習運算程式，進而在下一週期的加工中，縮短原本的加工命令時間，可有效地讓整體的加工時間縮短，且不影響加工路徑，再者，仍可經由該學習增益程式而達到降低加工誤差的效果，藉以提供一可同步提高加工速度與降低加工誤差之學習控制方法者。According to the above technical means, the learning control method for synchronously increasing the processing speed and reducing the processing error mainly enables the user to select and enable the speed learning operation program under the condition that the processing precision satisfies certain requirements, and then in the next cycle. In the processing, the original machining command time is shortened, the overall machining time can be shortened effectively, and the machining path is not affected. Furthermore, the learning gain program can still achieve the effect of reducing the machining error, thereby providing a synchronizable effect. A learning control method that increases processing speed and reduces machining errors.
為能詳細瞭解本發明的技術特徵及實用功效，並可依照說明書的內容來實施，玆進一步以圖式所示的較佳實施例，詳細說明如後：本發明之目的在於提供一同步提高加工速度與降低加工誤差之學習控制方法，其係安裝於一機械加工機台上，主要係透過偵測機械加工機台的平台及主軸的作動情形並對其進行訊號處理，進而提供一可同步提高加工速度與降低加工誤差之學習控制方法者。In order to understand the technical features and practical effects of the present invention in detail, and in accordance with the contents of the specification, the detailed description of the preferred embodiments shown in the drawings will be further described as follows: The purpose of the present invention is to provide a synchronous improvement process. The learning control method for speed and reducing machining error is installed on a machining machine, mainly by detecting the operation of the platform and the spindle of the machining machine and performing signal processing on the machine, thereby providing a synchronous improvement. Processing speed and learning control method to reduce machining error.
本發明係一種同步提高加工速度與降低加工誤差之學習控制方法，請配合參看如圖1所示，該同步提高加工速度與降低加工誤差之學習控制方法係包含有：The invention relates to a learning control method for simultaneously improving the processing speed and reducing the processing error. Please refer to FIG. 1 together, the learning control method for improving the processing speed and reducing the processing error by synchronizing includes:
(A)、設定初始加工命令：於一機械加工機台的控制程式中設置一學習控制(Learning Control)程式，其中該學習控制程式係設有一學習增益程式及一速度學習運算程式，較佳地，該學習控制程式係為一命令式疊代學習控制(Iterative Learning Control；ILC)程式，該機械加工機台可為一多軸(X軸、Y軸及Z軸)同動控制的機台或者為一剛性攻牙機，於該機械加工機台的控制程式中設定一初始加工命令，其中該初始加工命令係根據不同的要求設定其加工速度，通常可以梯形加減速或S形加減速作為機械加工機台加減速的規劃，其中若為多軸同動控制的機械加工機台，則各軸的初始加工命令需根據加工路徑進行設定使其同步；再者，如以一剛性攻牙機為例，則先設定主軸的初始加工命令，而Z軸的初始加工命令係由該主軸的初始加工命令乘上所欲攻牙之節距而得，使兩軸的初始加工命令同步；(A) setting an initial processing command: a learning control program is provided in a control program of a machining machine, wherein the learning control program is provided with a learning gain program and a speed learning operation program, preferably The learning control program is a command-based Iterative Learning Control (ILC) program, and the machining machine can be a multi-axis (X-axis, Y-axis, and Z-axis) synchronous control machine or For a rigid tapping machine, an initial machining command is set in the control program of the machining machine, wherein the initial machining command sets the machining speed according to different requirements, and generally can be trapezoidal acceleration/deceleration or S-shaped acceleration/deceleration as a machine. The planning of the acceleration and deceleration of the processing machine, if the machining machine is multi-axis synchronous control, the initial machining command of each axis needs to be set according to the machining path to synchronize; further, such as a rigid tapping machine For example, the initial machining command of the spindle is set first, and the initial machining command of the Z-axis is obtained by multiplying the initial machining command of the spindle by the pitch of the desired tapping, so that the initial of the two axes is obtained. Synchronous command processing;
(B)、實際機械加工：待設定好機械加工機台的初始加工命令，使各軸的初始加工命令為同步後，根據該初始加工命令進行實際的加工；(B) Actual machining: After the initial machining command of the machining machine is set, the initial machining command of each axis is synchronized, and the actual machining is performed according to the initial machining command;
(C)、加工誤差之量測與計算：待機械加工機台加工完成後，由各軸的馬達編碼器(encoder)進行量測並輸出一訊號，計算出該機械加工機台的加工誤差，其中若為多軸同動之控制，則其加工誤差即為輪廓誤差，而若為剛性攻牙機，則為Z軸與主軸的同步誤差；(C) Measurement and calculation of machining error: After the machining machine is finished, the motor encoder of each axis measures and outputs a signal to calculate the machining error of the machining machine. If the control is multi-axis synchronous, the machining error is the contour error, and if it is the rigid tapping machine, the synchronization error between the Z-axis and the main shaft;
(D)、判斷是否終止學習：根據前述計算出的加工誤差與初始加工命令，來判斷是否終止學習，其中若達到學習終止條件，則停止該學習控制，並以目前的初始加工命令做為後續之加工命令進行加工，若未達到學習終止條件，則進行下一步驟的操作，其中該學習終止條件為：(D) determining whether to terminate the learning: determining whether to terminate the learning according to the calculated machining error and the initial machining command, wherein if the learning termination condition is reached, the learning control is stopped, and the current initial machining command is used as a follow-up The processing command is processed, and if the learning termination condition is not reached, the next step is performed, wherein the learning termination condition is:
1. 絕對命令縮短比小於一定值；以及1. The absolute command shortening ratio is less than a certain value;
2. (絕對加工誤差比小於一定值)或(學習次數大於一定值且相對加工誤差比大於一定值)；2. (The absolute machining error ratio is less than a certain value) or (the number of learning times is greater than a certain value and the relative machining error ratio is greater than a certain value);
(E)、更新加工命令：若未達到前述步驟之學習終止條件，則利用本次的加工命令、加工誤差及先前藉由該學習控制所求得的學習增益矩陣(L)，透過該學習控制程式的一線性學習控制法則計算出下一次加工的輸入命令，其中該線性的學習控制法則為：(E), updating the processing command: if the learning termination condition of the foregoing step is not reached, the learning command, the machining error, and the learning gain matrix ( L ) previously obtained by the learning control are used to pass the learning control. The linear learning control rule of the program calculates the input command for the next processing, wherein the linear learning control rule is:
r j = r j -1+L ε j -1 (1) r j = r j -1 + L ε j -1 (1)
其中 r j 代表第j次加工時整個完整週期的輸入命令向量，ε j 則代表第j次加工時之整個週期加工誤差之向量，其中：Where r j represents the input command vector for the entire complete cycle of the jth process, and ε j represents the vector of the entire cycle of the machining error for the jth process, where:
ε j =(I-PL)ε j -1 (2) ε j =(I-PL) ε j -1 (2)
其中I為一p×p之單位矩陣，而P為一系統動態相關之矩陣：Where I is a unit matrix of p × p , and P is a matrix of system dynamic correlation:
L為一學習增益矩陣： L is a learning gain matrix:
較佳地，該學習增益矩陣(L)係為一下三角矩陣：Preferably, the learning gain matrix ( L ) is a lower triangular matrix:
將方程式(5)代入方程式(2)中可得到：Substituting equation (5) into equation (2) yields:
其中收斂條件為方程式(6)的所有特徵值大小皆小於1，亦即：The convergence condition is that all eigenvalues of equation (6) are less than 1, that is:
將方程式(7)、(6)與(2)帶入方程式(1)中，可計算得到一加工輸入命令，較佳地，將該加工輸入命令傳送至一低通濾波器中，藉以將多於的雜訊進行過濾，其中該低通濾波器係可自行設定一截止頻率；By introducing equations (7), (6), and (2) into equation (1), a machining input command can be calculated, and preferably, the machining input command is transmitted to a low-pass filter, thereby The noise is filtered, wherein the low pass filter can set a cutoff frequency by itself;
(F)、判斷是否開啟速度學習運算：根據前述計算出的加工誤差與初始加工命令，來判斷是否開啟速度學習程式，其中若不滿足速度學習開啟條件，則以前一步驟經濾波後的加工命令輸入機械加工機台中進行下一次的實際機械加工，而若滿足速度學習開啟條件，則進行下一步驟的操作，其中該速度學習開啟條件為：(F), determining whether to enable the speed learning operation: determining whether to open the speed learning program according to the calculated machining error and the initial machining command, wherein if the speed learning opening condition is not satisfied, the previous step filtered processing command The next actual machining is performed in the machining machine, and if the speed learning opening condition is satisfied, the next step is performed, wherein the speed learning opening condition is:
1. 相對加工誤差比小於一定值；1. The relative machining error ratio is less than a certain value;
2. 絕對加工誤差比小於一定值；以及2. The absolute machining error ratio is less than a certain value;
3. 絕對命令縮短比大於一定值；3. The absolute command shortening ratio is greater than a certain value;
(G)、速度學習運算：若滿足上述的速度學習開啟條件後，則進入該速度學習運算程式中並透過一速度學習法則進行運算，藉以求出新的加工命令，將該求得的加工命令輸入該機械加工機台的控制程式中，進行實際機械加工，如此重複執行直到符合前述的學習終止條件，其中假設整個加工週期包括有p個取樣時間，則 r j 與ε j 皆為長度為p之向量，L則為p×p之矩陣，將該速度學習法則代入方程式(1)中，則該學習控制法則成為：(G), speed learning operation: if the above-described speed learning on condition is satisfied, the speed learning calculation program is entered and calculated by a speed learning rule to obtain a new machining command, and the obtained machining command is obtained. Entering the control program of the machining machine, performing actual machining, and repeating the execution until the above-mentioned learning termination condition is satisfied, wherein if the entire machining cycle includes p sampling times, both r j and ε j are of length p The vector, L is the matrix of p × p , and the speed learning rule is substituted into equation (1), then the learning control law becomes:
r j =V j ( r j -1+L ε j -1) (8) r j = V j ( r j -1 + L ε j -1 ) (8)
其中V j 是第j次速度學習矩陣，其係可分為兩部份，其中上半部係為將原始命令點內插為新命令點所需的調整矩陣，而下半部則為0矩陣，亦即將命令縮短後之多餘時段的命令值補為0，亦即V j 為：Where V j is the jth speed learning matrix, which can be divided into two parts, wherein the upper half is the adjustment matrix required to interpolate the original command point into a new command point, and the lower half is the 0 matrix. , and the command value of the redundant period after the shortening is ordered to be zero, that is, V j is:
其中ρ j 代表第j次加工對應於原始命令之速度提昇倍數，V*即為將原始命令點內插為新命令點所需之調整矩陣，而1/ρ代表速度學習係數，其中速度學習係數是指把初始命令以多少的倍率做縮減，例如速度學習係數0.8表示學習後命令的點資料數目將是未學習命令的點資料數目0.8倍；Where ρ j represents the speed increase multiple of the original command corresponding to the jth process, V * is the adjustment matrix required to interpolate the original command point into a new command point, and 1 / ρ represents the velocity learning coefficient, wherein the velocity learning coefficient It refers to how many times the initial command is reduced. For example, the speed learning coefficient of 0.8 means that the number of points of the post-learning command will be 0.8 times the number of points of the unlearned command;
假設，若於欲提高速度為ρ 1倍，則初原始命令r(t)必須調整為r(ρt)，由於取樣的時間固定，因此，原始取樣點在相同取樣頻率下不一定會被取樣到，所以，必須利用原始取樣點(即r(t)經取樣所得之r(k))以內插的方式估測得新的取樣點，如此，新取樣點數量將為原取樣點數量之1/ρ倍，例如，若ρ=1.5，而原始位置命令經時間取樣後有3000個位置點，則經速度調整之後，命令變成2000個點資料，但都還是在同一條命令軌跡上，所改變的是加減速與進給速度；請配合參看如圖2所示，其中原始命令為一實線，總共有6個取樣點，以實黑點表示，當令ρ=5/3時經速度調整後之命令為一虛線，原來的6個取樣點調整成白點，由圖中可明顯看出除前、後兩端點以外，其於的4個原取樣點都不位於取樣時間上，其中新命令在取樣時間上的點以星號表示，這些點必須利用原命令之取樣點內插求得，例如，A點須由P1及P2內插求得。Assume that if you want to increase the speed to ρ 1 time, the original original command r ( t ) must be adjusted to r ( ρt ). Since the sampling time is fixed, the original sampling point is not necessarily sampled at the same sampling frequency, so the original sampling point must be used ( i.e. r (t) obtained by the sampling r (k)) have estimated the interpolation manner new sampling point, so the number of new sampling points the number of points will be 1 / ρ times the original sample, for example, if ρ = 1.5 , and the original position command has 3000 position points after time sampling, after the speed adjustment, the command becomes 2000 points of data, but they are still on the same command track, and the acceleration and deceleration and feed rate are changed; See also Figure 2, where the original command is a solid line, there are a total of 6 sampling points, represented by solid black points, when the speed adjustment is ρ = 5/3, the command is a dashed line, the original 6 The sampling point is adjusted to white point. It can be clearly seen from the figure that the four original sampling points are not located in the sampling time except for the front and rear end points, and the point of the new command at the sampling time is indicated by an asterisk. These points must be interpolated using the sampling points of the original command. For example, point A must be interpolated from P1 and P2.
藉由上述的技術手段，本發明同步提高加工速度與降低加工誤差之學習控制方法，主要係當加工精度滿足一定要求的條件下，可讓使用者選擇啟用該速度學習運算程式，進而在下一週期的加工中，縮短原本的加工命令時間，可有效地讓整體的加工時間縮短，且不影響加工路徑，再者，仍可經由該學習增益程式而達到降低加工誤差的效果，藉以提供一可同步提高加工速度與降低加工誤差之學習控制方法者。According to the above technical means, the learning control method for synchronously increasing the processing speed and reducing the processing error mainly enables the user to select and enable the speed learning operation program under the condition that the processing precision satisfies certain requirements, and then in the next cycle. In the processing, the original machining command time is shortened, the overall machining time can be shortened effectively, and the machining path is not affected. Furthermore, the learning gain program can still achieve the effect of reducing the machining error, thereby providing a synchronizable effect. A learning control method that increases processing speed and reduces machining errors.
以上所述，僅是本發明的較佳實施例，並非對本發明作任何形式上的限制，任何所屬技術領域中具有通常知識者，若在不脫離本發明所提技術方案的範圍內，利用本發明所揭示技術內容所作出局部更動或修飾的等效實施例，並且未脫離本發明的技術方案內容，均仍屬於本發明技術方案的範圍內。The above is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any one of ordinary skill in the art can use the present invention without departing from the scope of the present invention. Equivalent embodiments of the invention may be made without departing from the technical scope of the present invention.
圖1係本發明同步提高加工速度與降低加工誤差之學習控制方法之操作流程方塊圖。1 is a block diagram showing the operation of the learning control method for synchronously increasing the processing speed and reducing the machining error according to the present invention.
圖2係本發明經速度學習運算後所得到的命令變化示意圖。FIG. 2 is a schematic diagram of command changes obtained after the speed learning operation of the present invention.
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