- 學位論文
CNC工具機控制器智能化功能模組之研究與開發
The Study and Development of Intelligent Module for Multi-axis Machine Tools Controller
摘要
CNC工具機控制器之關鍵應用技術影響了機器新功能或精度與效率改善的研發。有鑒於此，本研究主要在於研發一套智能化功能模組並植入CNC控制器中，其可藉由線上參數調教之方式有效減少因平台負載引起之伺服誤差，同時也可依機台所在實際位置即時修正背隙補償值，來提升工具機的加工精度。另外，模組中所建立之高效率/高精度切削輔助功能，則可協助使用者調整設定最佳切削條件，以達高效率或高精度加工的目的。線上調教參數功能之研發，首先係以Grid Encoder實驗方式分析瞭解滯滑摩擦效應及相關控制器參數之功能，並與平台負載對機台摩擦之影響做比較，歸納出可用之控制參數，並分析不同負載重量下之最佳參數值組合，再以曲線擬合之方式求得參數特性方程式，作為自動調校時之依據。即時修正背隙補償值部分，則先利用HP 5529A雷射干涉儀測量三軸滾珠螺桿之全行程背隙分佈，經分析得各軸之背隙變化特性後，擬定區域背隙補正值由控制器進行線上即時補正。高效率/高精度切削輔助功能乃依材質與刀具規格自動計算切削條件提供使用者參考，並線上擷取伺服軸馬達電流對馬達負載作即時監控。上述功能皆利用MACRO EXECUTOR發展成可執行之G指令並植入CNC控制器中，加工者只需於NC程式中載明工件重量、刀具規格及選用切削模式等，控制器即可自動調校參數且即時修正背隙補償值，並在顯示器上顯示最大切削條件及馬達負載，達到控制器智能化之目的。
並列摘要
The use of CNC controller is one of the key factors that influence the accuracy and efficiency of a CNC machine tool. This study is mainly to develop an intelligent control module having three functions: (1) on-line tune the control parameters to eliminate the effects of stick-slip friction which is induced by different weight of workpiece; (2) real-position backlash compensation; (3) high efficiency/high accuracy function for optimal machining parameters set up. Grid encoder was first used to understand and analysis the effects of stick and slip friction and the function of relative control parameters. After the relationship between weights of workpieces and values of control parameters was obtained, curve fitting method was used to compute the characteristic equations of control parameters that were implanted into CNC controller for automatic parameter tuning. For real-position backlash compensation, backlash distribution of ball screws were measured and analyzed to form several error compensation zones. Backlash value compensated is decided depending on which error compensation zone the machine table locates. According to specification of cutter and material, high efficiency/high accuracy function provides information for user to set up the optimal machining parameters for better machining efficiency or accuracy. Using MARCO EXECUTOR, the three functions were converted as G-codes implanted into CNC controller. As the weight of workpiece, specification of cutter, and cutting mode are indicated in NC codes, the function can be automatically executed. Finally, several experiment tests were conducted and the results have shown the effectiveness of the developed control module.