WO2020155227A1 - 数控机床几何/热误差在线测量与补偿系统 - Google Patents

数控机床几何/热误差在线测量与补偿系统 Download PDF

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WO2020155227A1
WO2020155227A1 PCT/CN2019/075711 CN2019075711W WO2020155227A1 WO 2020155227 A1 WO2020155227 A1 WO 2020155227A1 CN 2019075711 W CN2019075711 W CN 2019075711W WO 2020155227 A1 WO2020155227 A1 WO 2020155227A1
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compensation
geometric
error
measurement
thermal
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French (fr)
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刘阔
李特
甘涌泉
韩伟
厉大维
刘志松
王永青
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Dalian University of Technology
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Dalian University of Technology
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q23/00—Arrangements for compensating for irregularities or wear, e.g. of ways, of setting mechanisms
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Program-control systems
    • G05B19/02—Program-control systems electric
    • G05B19/18—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 program data in numerical form
    • G05B19/404—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 program data in numerical form characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q11/00—Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling work; Safety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
    • B23Q11/0003—Arrangements for preventing undesired thermal effects on tools or parts of the machine
    • B23Q11/0007—Arrangements for preventing undesired thermal effects on tools or parts of the machine by compensating occurring thermal dilations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
    • G01K15/00—Testing or calibrating of thermometers
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/49—Nc machine tool, till multiple
    • G05B2219/49207—Compensate thermal displacement using measured distance

Definitions

  • the invention belongs to the technical field of error testing and compensation of numerical control machine tools, and is specifically a geometric/thermal error online measurement and compensation system of numerical control machine tools.
  • the comprehensive error of CNC machine tools mainly includes geometric error, thermal error, control error and force error.
  • geometric errors and thermal errors have the greatest impact on machine tools.
  • Geometric errors not only affect the position accuracy, but also the accuracy of the curve trajectory.
  • Thermal errors not only affect the position accuracy, but also affect the stability of the accuracy.
  • measures are generally taken to improve the accuracy of machine tool components and assembly accuracy, full closed loop control and timing cooling. Although these measures will have a certain effect, the cost of the machine tool will increase.
  • the error compensation technology can effectively reduce geometric errors and thermal errors at a relatively low cost.
  • the laser tracker is used to identify the geometric errors of the machine tool by testing at four different positions;
  • a rapid measurement method for the geometric error of the translational axis of a machine tool based on a laser interferometer (application number: CN201710231122.5), based on the laser interferometer, the linearity and angle of the translational axis are obtained by testing at two different positions error.
  • thermal error compensation device and method for CNC machine tools application number: CN201510800430.6
  • real-time thermal error is predicted based on temperature data and thermal error model
  • thermal error compensation is achieved based on piezoelectric ceramic micro-displacement actuators .
  • the present invention proposes a geometric/thermal error online measurement and compensation system for CNC machine tools, which can realize online testing and real-time compensation of geometric errors and thermal errors.
  • the online measurement and compensation system for geometric/thermal errors of CNC machine tools is mainly composed of measurement and compensation system hardware and measurement and compensation system software;
  • the measurement and compensation system hardware includes unidirectional acceleration sensor, digital IC-type high-precision temperature sensor, and multi-channel Temperature data collector and geometric/thermal error measurement and compensation host;
  • measurement and compensation system software runs in the geometric/thermal error measurement and compensation host to realize geometric/thermal error data processing and compensation, as well as communication and data reading with the CNC system write;
  • the unidirectional acceleration sensor is connected to the geometric/thermal error measurement and compensation host through a coaxial shielded cable, and the acceleration signal is sent to the geometric/thermal error measurement and compensation host in analog form;
  • the digital IC-type high-precision temperature sensor is through a four-core shielded cable Connect to a multi-channel temperature data collector, and send temperature data to a multi-channel temperature data collector based on a single-wire two-way communication protocol; a multi-channel temperature data collector can connect up to ten temperature sensors; the multi-channel temperature data collector is shielded by three cores
  • the cable is connected to the geometric/thermal error measurement and compensation host.
  • the temperature data of each channel is sent to the geometric/thermal error measurement and compensation host through the RS485 communication interface; the geometric/thermal error measurement and compensation host is crossed by twisted pair
  • the cable is connected to the FANUC CNC system and communicates based on the FOCAS II network communication protocol;
  • feed axis geometric error identification algorithm Based on the acceleration signal, apply the feed axis geometric error identification algorithm to obtain the straightness error of the machine tool feed axis; the feed axis geometric error identification algorithm is as follows:
  • s(t) is the real-time displacement
  • a 0 is the DC component of the acceleration signal
  • a(t) is the real-time acceleration
  • is the speed running at a constant speed along the axial direction
  • x(t) is the real-time length of the axial direction
  • the two-end point connection method is used to calculate the straightness error of the feed axis according to s(x); the specific calculation method is as follows:
  • E s (x) is the straightness error
  • L is the total test stroke
  • x is the test stroke
  • s(end) is the displacement at the end of the test
  • s(0) is the displacement at the start of the test
  • the feed axis thermal error model Based on the position and temperature signals, apply the feed axis thermal error model to predict the thermal error in real time; the feed axis thermal error model divides the lead screw into N sections, each section having a length of l, and the thermal error calculation method is :
  • E f (m,t) is the calculated value of thermal error of the m-th screw at the current moment
  • T i (t) is the temperature of the i-th screw at the current moment
  • Q is the result of the nut passing through each screw Heat
  • T i (t- ⁇ t) is the temperature of the i-th screw at the previous moment
  • T f (t- ⁇ t) is the temperature of the air contacting the surface of the screw at the previous moment
  • ⁇ t is the sampling period
  • k, ⁇ , Both ⁇ and ⁇ are coefficients;
  • the measurement and compensation system software establishes a connection with it through the IP address and port number of the FANUC CNC system; after the connection is successful, reads the mechanical coordinates of the feed axis, and simultaneously collects the data of the unidirectional acceleration sensor and the temperature sensor, and calculates the geometry/heat Comprehensive error compensation value, write the error compensation value to the CNC system; the current geometric/thermal comprehensive error compensation value is calculated as follows:
  • the beneficial effects of the present invention are: the present invention realizes the rapid and efficient test of straightness error through the acceleration sensor without requiring expensive professional instruments; when the geometric accuracy of the machine tool changes, it can realize timely compensation.
  • the invention measures and compensates the geometric error and compensation of the machine tool, and improves the machining accuracy and accuracy stability of the machine tool without increasing excessive costs, thereby improving the yield and efficiency of the machine tool processing.
  • Figure 1 shows the hardware connection diagram of the geometric/thermal error online measurement and compensation system.
  • 1FANUC numerical control system 2geometric/thermal error measurement and compensation host; 3 multi-channel temperature data collector; 4 first temperature sensor; 5 second temperature sensor; 6 third temperature sensor; 7 fourth temperature sensor; 8 Fifth temperature sensor; 9 sixth temperature sensor; 10 seventh temperature sensor; 11 eighth temperature sensor; 12 ninth temperature sensor; 13 tenth temperature sensor; 14 first one-way acceleration sensor; 15 second one-way acceleration sensor .
  • Figure 2 shows the communication flow chart between the error online measurement and compensation system and the FANUC CNC system.
  • Figure 3 is a schematic diagram of communication based on the FOCAS II protocol.
  • Figure 4(a) is the straightness error test curve of the X axis along the Y direction
  • Figure 4(b) is the straightness error test curve of the X axis along the Z direction.
  • Figure 5(a) is the straightness error curve of the X axis along the Y direction after compensation
  • Figure 5(b) is the straightness error curve of the X axis along the Z direction after compensation.
  • Figure 6 shows the thermal error curve of the X-axis after compensation.
  • the basic information of the machine tool is: the maximum strokes of the X-axis, Y-axis and Z-axis are 710mm, 500mm and 350mm respectively, and their maximum feed speeds are respectively 32m/min, 32m/min and 30m/min; the maximum spindle speed is 15000r /min.
  • the hardware of the present invention is shown in Fig. 1, including unidirectional acceleration sensors 14 and 15, digital IC-type high-precision temperature sensors 4-13, multi-channel temperature data collector 3 and geometric/thermal error measurement and compensation host 2.
  • the connection and communication methods of each hardware are as follows:
  • the unidirectional acceleration sensors 14 and 15 are connected to the geometry/error measurement and compensation host 2 through coaxial shielded cables, and the acceleration signal is sent to the geometry/thermal error measurement and compensation host 2 in the form of analog quantity;
  • the multi-channel temperature data collector 3 is connected to the geometric/thermal error measurement and compensation host 2 through a three-core shielded cable. Based on the Modbus RTU communication protocol, the temperature data of each channel is sent to the geometric/thermal error measurement and compensation through the RS485 communication interface Host
  • the geometric/thermal error measurement and compensation host 2 is connected to FANUC numerical control system 1 through a twisted-pair crossover cable, and communicates based on the FOCAS II network communication protocol.
  • the measurement and compensation software runs in the geometric/thermal error measurement and compensation host. Based on the acceleration signal, the software uses the feed axis geometric error identification algorithm to obtain the straightness error of the machine tool feed axis.
  • the feed axis geometric error identification algorithm is shown in equations (1)-(3); based on the position and temperature signals, Apply the feed axis thermal error model to predict the thermal error in real time.
  • the thermal error model of the feed axis is shown in equation (4).
  • the measurement and compensation software communicates with the FANUC numerical control system based on the FOCAS II protocol to realize the reading of machine coordinates and the writing of error compensation values.
  • the communication process is shown in Figure 2, and the communication diagram is shown in Figure 3.
  • FANUC CNC system realizes compensation based on the extended external mechanical coordinate origin offset function. Specific steps are as follows:
  • the measurement and compensation software establishes a connection with the FANUC CNC system based on its IP address 192.168.1.1 and port number 8193. After the connection is successful, the mechanical coordinates of the feed axis are read, and the data of the acceleration sensor and the temperature sensor are collected at the same time, the geometric/thermal comprehensive error compensation value is calculated, and the error compensation value is written to the CNC system.
  • the calculation method of the current error compensation value is shown in formula (5).
  • the above-mentioned CNC machine tool geometric/thermal error online measurement and compensation system is used to test the straightness errors of the X axis along the Y and Z directions, and 11 points are tested within the test range.
  • the straightness error test curve along the Y direction is shown in Fig. 4(a)
  • the straightness error test curve along the Z direction is shown in Fig. 4(b).
  • the testing process of the thermal error is: testing the X-axis full stroke positioning error in the cold state. After that, the X-axis performs a heating movement, specifically: the X-axis is within the mechanical coordinate range of -200mm to -600mm, and it performs linear reciprocating motion at a feed rate of 8000mm/min. The heating movement process lasts for 30 minutes. After that, the X-axis stops at the 0mm position of the mechanical coordinate for cooling, and the cooling process lasts for 20 minutes. The X-axis full stroke positioning error test is performed every 10 minutes during the entire heating and cooling process.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Human Computer Interaction (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Automatic Control Of Machine Tools (AREA)
  • Numerical Control (AREA)

Abstract

本发明提供了数控机床几何/热误差在线测量与补偿系统，属于数控机床误差测试与补偿技术领域。该数控机床几何/热误差在线测量与补偿系统包含硬件平台和测量与补偿软件两部分。硬件平台包括单向加速度传感器、数字IC式高精度温度传感器、多通道温度数据采集器和几何/热误差测量与补偿主机。测量与补偿软件在几何/热误差测量与补偿主机中运行，实现机床几何与热误差的测试与补偿，以及与FANUC数控系统通讯。本发明的优点在于通过加速度传感器实现了几何误差的快速高效测试，而不需要昂贵的专业仪器，并可以同时对几何和热误差进行在线实时补偿。

Description

数控机床几何/热误差在线测量与补偿系统 技术领域
本发明属于数控机床误差测试与补偿技术领域，具体为一种数控机床几何/热误差在线测量与补偿系统。
背景技术
数控机床的综合误差主要包括几何误差、热误差、控制误差和力误差。其中几何误差和热误差对机床的影响最大。几何误差不仅影响位置精度，还影响曲线轨迹精度。热误差不仅影响位置精度，还影响精度的稳定性。为了减小几何误差和热误差对机床加工精度的影响，一般采取提高机床部件精度和装配精度、全闭环控制和定时冷却等措施。这些措施虽然会起到一定效果，但机床成本会增加。而误差补偿技术能以较小的成本有效减小几何误差和热误差。
在专利“数控机床平动轴几何误差的测量装置及测量与辨识方法”(申请号：CN201310335401.8)中，采用激光跟踪仪通过在四个不同位置测试辨识出机床的各项几何误差；在专利“一种基于激光干涉仪的机床平动轴几何误差快速测量方法”(申请号：CN201710231122.5)中，基于激光干涉仪，在两个不同位置进行测试得出平动轴的线性和角度误差。在专利“一种数控机床热误差补偿装置及方法”(申请号：CN201510800430.6)中，基于温度数据和热误差模型预测实时热误差，基于压电陶瓷微位移致动器实现热误差的补偿。
通过对研究现状的分析发现，目前几何误差和热误差测量与补偿系统存在以下问题：
(1)目前几何误差测试均需采用激光干涉仪、激光跟踪仪等专业精密仪器，缺点为操作复杂、成本高；
(2)由于测量仪器只能进行离线测量，因此当几何精度发生变化后，无法 实现在机测量与补偿。
发明内容
本发明针对目前几何误差和热误差测量及补偿存在的问题，提出数控机床几何/热误差在线测量与补偿系统，该系统可实现对几何误差和热误差的在线测试及实时补偿。
本发明的技术方案：
数控机床几何/热误差在线测量与补偿系统，主要由测量与补偿系统硬件和测量与补偿系统软件两部分构成；测量与补偿系统硬件包括单向加速度传感器、数字IC式高精度温度传感器、多通道温度数据采集器和几何/热误差测量与补偿主机；测量与补偿系统软件在几何/热误差测量与补偿主机中运行，实现几何/热误差数据处理与补偿，以及与数控系统的通讯与数据读写；
单向加速度传感器通过同轴屏蔽电缆与几何/热误差测量与补偿主机连接，将加速度信号以模拟量形式发送给几何/热误差测量与补偿主机；数字IC式高精度温度传感器通过四芯屏蔽电缆与多通道温度数据采集器连接，将温度数据基于单线双向通信协议发送给多通道温度数据采集器；一个多通道温度数据采集器最多连接十个温度传感器；多通道温度数据采集器通过三芯屏蔽电缆与几何/热误差测量与补偿主机连接，基于Modbus RTU通讯协议将各通道温度数据通过RS485通讯接口发送给几何/热误差测量与补偿主机；几何/热误差测量与补偿主机通过双绞线交叉电缆与FANUC数控系统连接，基于FOCAS II网络通讯协议进行通讯；
测量与补偿系统软件：
(1)基于加速度信号，应用进给轴几何误差辨识算法得出机床进给轴的直线度误差；进给轴几何误差辨识算法具体如下所示：
Figure PCTCN2019075711-appb-000001
式中，s(t)为实时位移，
Figure PCTCN2019075711-appb-000002
为垂直方向的初始位移，
Figure PCTCN2019075711-appb-000003
为垂直于轴向的初始速度，a 0为加速度信号直流分量，a(t)为实时加速度，v ||为沿轴向匀速运行的速度，x(t)为轴向实时长度；
对式(1)求解，得到实时位移s(t)随轴向测试行程x的关系：
Figure PCTCN2019075711-appb-000004
然后，应用两端点连线法，根据s(x)计算进给轴的直线度误差；具体计算方法如下：
Figure PCTCN2019075711-appb-000005
式中，E s(x)为直线度误差，L为测试总行程，x为测试行程，s(end)为在测试终点的位移，s(0)为在测试起点的位移；
(2)基于位置和温度信号，应用进给轴热误差模型，对热误差进行实时预测；进给轴热误差模型将丝杠等分为N段，每段长度为l，热误差计算方法为：
Figure PCTCN2019075711-appb-000006
式中，E f(m,t)为当前时刻第m段丝杠的热误差计算值，T i(t)为第i段丝杠当前时刻的温度，Q为螺母经过每段丝杠产生的热量，T i(t-Δt)为第i段丝杠前一时刻的温度，T f(t-Δt)为前一时刻与丝杠表面接触的空气温度，Δt为采样周期，k、α、β和γ均为系数；
(3)基于FOCAS II协议与FANUC数控系统进行通讯，实现机床机械坐标的读取和误差补偿值的写入，基于扩展的外部机械坐标原点偏移功能实现补偿；步骤如下：
1)在FANUC数控系统中设置“内嵌/PCMCIA”为有效的以太网设备；
2)设置“扩展的外部机械坐标原点偏移功能”相关参数，并开启该功能；
3)测量与补偿系统软件通过FANUC数控系统的IP地址和端口号与其建立连接；连接成功后，读取进给轴机械坐标，并同时采集单向加速度传感器、温度传感器的数据，计算几何/热综合误差补偿值，向数控系统写入误差补偿值；当前几何/热综合误差补偿值的计算如下：
C(x，t)＝-[E s(x)+E f(m，t)]   (5)。
本发明的有益效果为：本发明通过加速度传感器实现了直线度误差的快速高效测试，而不需要昂贵的专业仪器；当机床的几何精度发生变化后，可实现及时补偿。本发明针对机床几何误差和补偿进行测量和补偿，在不增加过多成本的前提下，提高了机床的加工精度和精度稳定性，从而提高了机床加工的良品率和效率。
附图说明
图1为几何/热误差在线测量与补偿系统硬件连接图。图中：1FANUC数控系统；2几何/热误差测量与补偿主机；3多通道温度数据采集器；4第一温度传感器；5第二温度传感器；6第三温度传感器；7第四温度传感器；8第五温度传感器；9第六温度传感器；10第七温度传感器；11第八温度传感器；12第九温度传感器；13第十温度传感器；14第一单向加速度传感器；15第二单向加速度传感器。
图2为误差在线测量与补偿系统与FANUC数控系统通讯流程图。
图3为基于FOCAS II协议的通讯示意图。
图4(a)为X轴沿Y方向的直线度误差测试曲线，图4(b)为X轴沿Z方向的直线度误差测试曲线。
图5(a)为补偿后X轴沿Y方向的直线度误差曲线，图5(b)为补偿后X轴沿Z方向的直线度误差曲线。
图6为补偿后X轴的热误差曲线。
具体实施方式
为了使本发明的目的、技术方案和优点更加清晰明了，下面结合附图，并以某型配置FANUC 0i MD数控系统的立式加工中心为例，详细说明本发明的实施方式。
机床的基本信息为：X轴、Y轴和Z轴的最大行程分别为710mm、500mm和350mm，它们的最大进给速度分别为32m/min、32m/min和30m/min；主轴最高转速为15000r/min。
本发明的硬件如图1所示，包含单向加速度传感器14和15、数字IC式高精度温度传感器4～13、多通道温度数据采集器3和几何/热误差测量与补偿主机2。各硬件的连接和通讯方式如下：
(1)单向加速度传感器14和15通过同轴屏蔽电缆与几何/误差测量与补偿主机2连接，将加速度信号以模拟量形式发送给几何/热误差测量与补偿主机2；
(2)数字IC式高精度温度传感器4～13通过四芯屏蔽电缆与多通道温度数据采集器3连接，将温度数据基于单线双向通信协议发送给多通道温度数据采集器3；
(3)多通道温度数据采集器3通过三芯屏蔽电缆与几何/热误差测量与补偿主机2连接，基于Modbus RTU通讯协议将各通道温度数据通过RS485通讯接口发送给几何/热误差测量与补偿主机；
(4)几何/热误差测量与补偿主机2通过双绞线交叉电缆与FANUC数控系统1连接，基于FOCAS II网络通讯协议进行通讯。
测量与补偿软件在几何/热误差测量与补偿主机中运行。该软件基于加速度信号，应用进给轴几何误差辨识算法得出机床进给轴的直线度误差，进给轴几何误差辨识算法如式(1)-(3)所示；基于位置和温度信号，应用进给轴热误差模型，对热误差进行实时预测。进给轴热误差模型如式(4)所示。
测量与补偿软件与FANUC数控系统基于FOCAS II协议进行通讯，实现机床机械坐标的读取和误差补偿值的写入，通讯流程如图2所示，通讯示意图如图3所示。FANUC数控系统基于扩展的外部机械坐标原点偏移功能实现补偿。具体步骤如下：
(1)在FANUC数控系统中设置“内嵌/PCMCIA”为有效的以太网设备；
(2)将参数1280设置为1000，即补偿数据对应的R参数的起始地址；
(3)将参数1203的第0位设置为1，即开启扩展的外部机械坐标原点偏移功能；
(4)测量与补偿软件基于FANUC数控系统的IP地址192.168.1.1和端口号8193与其建立连接。连接成功后读取进给轴机械坐标，并同时采集加速度传感器、温度传感器的数据，计算几何/热综合误差补偿值，向数控系统写入误差补偿值。当前误差补偿值的计算方法如式(5)所示。
为了验证本发明的实际效果，应用上述数控机床几何/热误差在线测量与补偿系统，分别对X轴沿Y、Z方向的直线度误差进行测试，在测试范围内测试11个点。其中，沿Y方向的直线度误差测试曲线如图4(a)所示，沿Z方向的直线度误差测试曲线如图4(b)所示。
然后，应用数控机床几何/热误差在线测量与补偿系统，对X轴的几何误差和热误差进行补偿。其中热误差的测试过程为：冷态下测试X轴全行程定位误差。之后X轴进行升温运动，具体为：X轴在机械坐标-200mm～-600mm范围内， 以8000mm/min进给速度进行直线往复运动，升温运动过程持续30min。之后X轴停止在机械坐标0mm位置进行降温，降温过程持续20min。在整个升温和降温过程中每隔10min进行一次X轴全行程定位误差测试。
补偿后X轴沿Y、Z方向的直线度误差曲线分别如图5(a)和图5(b)所示。补偿后的热误差曲线如图6所示。

Claims (1)

  1. 一种数控机床几何/热误差在线测量与补偿系统，主要由测量与补偿系统硬件和测量与补偿系统软件两部分构成；测量与补偿系统硬件包括单向加速度传感器、数字IC式高精度温度传感器、多通道温度数据采集器和几何/热误差测量与补偿主机；测量与补偿系统软件在几何/热误差测量与补偿主机中运行，实现几何/热误差数据处理与补偿，以及与数控系统的通讯与数据读写；
    其特征在于，
    单向加速度传感器通过同轴屏蔽电缆与几何/热误差测量与补偿主机连接，将加速度信号以模拟量形式发送给几何/热误差测量与补偿主机；数字IC式高精度温度传感器通过四芯屏蔽电缆与多通道温度数据采集器连接，将温度数据基于单线双向通信协议发送给多通道温度数据采集器；一个多通道温度数据采集器最多连接十个温度传感器；多通道温度数据采集器通过三芯屏蔽电缆与几何/热误差测量与补偿主机连接，基于Modbus RTU通讯协议将各通道温度数据通过RS485通讯接口发送给几何/热误差测量与补偿主机；几何/热误差测量与补偿主机通过双绞线交叉电缆与FANUC数控系统连接，基于FOCAS II网络通讯协议进行通讯；
    测量与补偿系统软件：
    (1)基于加速度信号，应用进给轴几何误差辨识算法得出机床进给轴的直线度误差；进给轴几何误差辨识算法具体如下所示：
    Figure PCTCN2019075711-appb-100001
    式中，s(t)为实时位移，
    Figure PCTCN2019075711-appb-100002
    为垂直方向的初始位移，
    Figure PCTCN2019075711-appb-100003
    为垂直于轴向的初始速度，a 0为加速度信号直流分量，a(t)为实时加速度，v ||为沿轴向匀速运行的速度，x(t)为轴向实时长度；
    对式(1)求解，得到实时位移s(t)随轴向测试行程x的关系：
    Figure PCTCN2019075711-appb-100004
    然后，应用两端点连线法，根据s(x)计算进给轴的直线度误差；具体计算方法如下：
    Figure PCTCN2019075711-appb-100005
    式中，E s(x)为直线度误差，L为测试总行程，x为测试行程，s(end)为在测试终点的位移，s(0)为在测试起点的位移；
    (2)基于位置和温度信号，应用进给轴热误差模型，对热误差进行实时预测；进给轴热误差模型将丝杠等分为N段，每段长度为l，热误差计算方法为：
    Figure PCTCN2019075711-appb-100006
    式中，E f(m,t)为当前时刻第m段丝杠的热误差计算值，T i(t)为第i段丝杠当前时刻的温度，Q为螺母经过每段丝杠产生的热量，T i(t-Δt)为第i段丝杠前一时刻的温度，T f(t-Δt)为前一时刻与丝杠表面接触的空气温度，Δt为采样周期，k、α、β和γ均为系数；
    (3)基于FOCAS II协议与FANUC数控系统进行通讯，实现机床机械坐标的读取和误差补偿值的写入，基于扩展的外部机械坐标原点偏移功能实现补偿；步骤如下：
    1)在FANUC数控系统中设置内嵌/PCMCIA为有效的以太网设备；
    2)设置扩展的外部机械坐标原点偏移功能相关参数，并开启该功能；
    3)测量与补偿系统软件通过FANUC数控系统的IP地址和端口号与其建立连接；连接成功后，读取进给轴机械坐标，并同时采集单向加速度传感器、温度传感器的数据，计算几何/热综合误差补偿值，向数控系统写入误差补偿值； 当前几何/热综合误差补偿值的计算如下：
    C(x，t)＝-[E s(x)+E f(m，t)]    (5)。
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