目录
5.3.1 圆轨迹运动轮廓误差测量 .................................................................... 84 5.3.2 动态伺服误差与准静态误差的解耦 .................................................... 87 5.4 动态伺服误差模型参数辨识及误差预测 ................................................... 88 5.4.1 基于临界参数下圆轨迹误差的系统参数辨识 .................................... 88 5.4.2 机床圆轨迹误差预测 ............................................................................ 92 5.5 本章小结 ....................................................................................................... 92 第6章 综合误差模型精度验证与滑枕热漂移误差分析 .................................... 93 6.1 引言 ............................................................................................................... 93 6.2 综合误差模型预测精度验证 ....................................................................... 93 6.2.1 静态误差预测精度验证 ........................................................................ 93 6.2.2 几何与伺服误差的综合误差验证 ........................................................ 95 6.2.3 几何与热误差的综合误差验证 ............................................................ 96 6.3 滑枕热漂移误差的溯源分析 ..................................................................... 100 6.3.1 热漂移误差实验 .................................................................................. 100 6.3.2 仿真结果分析 ...................................................................................... 101 6.3.3 热漂移误差尺寸链及溯源 .................................................................. 102 6.3.4 其他仿真分析 ...................................................................................... 104 6.4 热漂移误差补偿方法研究 ......................................................................... 105 6.5 本章小结 ..................................................................................................... 106 第7章 重型数控落地铣镗床综合误差补偿实验验证 ...................................... 107 7.1 引言 ............................................................................................................. 107 7.2 静态误差补偿技术应用 ............................................................................. 107 7.2.1 误差补偿策略 ...................................................................................... 107 7.2.2 静态误差补偿 ...................................................................................... 108 7.3 动态伺服误差补偿技术应用 ..................................................................... 109 7.4 热漂移误差补偿技术应用 .......................................................................... 110 7.4.1 构建补偿系统 ....................................................................................... 110 7.4.2 系统标定 ............................................................................................... 112 7.4.3 基于PLC二次开发的补偿实现 .......................................................... 112 7.5 滑枕几何与热误差补偿试验验证 .............................................................. 114 7.5.1 热漂移误差补偿 ................................................................................... 114 7.5.2 斜率误差补偿 ....................................................................................... 115 7.5.3 综合误差补偿 ....................................................................................... 115 7.6 重型数控落地铣镗床加工精度检验 .......................................................... 116 7.6.1 加工过程 ............................................................................................... 116 7.6.2 检验结果 ............................................................................................... 118
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哈尔滨工业大学工学博士学位论文
7.7 本章小结 ...................................................................................................... 119 结 论 .................................................................................................................... 120 参考文献 ................................................................................................................ 122 攻读博士学位期间发表的论文及其他成果 ........................................................ 132 哈尔滨工业大学学位论文原创性声明和使用权限 ............................................ 133 致 谢 .................................................................................................................... 134 个人简历 ................................................................................................................ 135
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目录
Contents
Abstract (In Chinese)..............................................................................................? Abstract (In English)............................................................................................Ш Chapter 1 Introduction...........................................................................................1 1.1 Background, objective and significance of the subject....................................1 1.2 Status of error compensation technology of machine tool………..................2 1.2.1 Error measurement technology.................................................................3
1.2.2 Error prediction model ………...…………….........................................11 1.2.3 Error measurement uncertainty…………..............................................13
1.2.4 Servo error compensation technology…………………………………..14
1.3 Key technologies for error compensation of heavy-duty milling and boring
machine tool……………..…………………..…….........................................15 1.4 Main research contents of this subject...........................................................16 Chapter 2 Synthetical error analysis and error modeling of heavy duty NC Floor-typed milling and boring machine tool…..…………...…....17 2.1 Introduction..................................................................................................17 2.2 Error tracing analysis of heavy-duty milling and boring machine tool……...17 2.2.1 Structure of heavy-duty milling and boring machine tool.......................17
2.2.2 Analysis of machining error of heavy-duty milling and boring machine tool……………….…………………………..........................................18 2.2.3 Geometric error of heavy-duty milling and boring machine tool…….....19
2.2.4 Mechanism analysis of thermal error of heavy-duty milling and boring machine tool……………………………………………………............21 2.2.5 Servo error of heavy-duty milling and boring machine tool....................23 2.2.6 Backlash of heavy-duty milling and boring machine tool......................25 2.3 Synthetical volumetric error model...............................................................26
2.3.1 Coordinates setting…………………………………………………....26 2.3.2 Error sources coupling………………..……….……………………....27 2.3.3 Sensitivity matrix of geometric error…………………………………….30 2.4 Brief Summary..............................................................................................32 Chapter 3 Analysis of error measurement uncertainty in large volume and measurement with workspace segment..............................................33 3.1 Introduction…….........................................………………….......................33 3.2 Measurement uncertainty of volumetric calibration of heavy duty NC
Floor-typed milling and boring machine tool……………………………….33
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哈尔滨工业大学工学博士学位论文
3.2.1 Tracing analysis of measurement uncertainty of machine tool................33 3.2.2 Measurement uncertainty of laser tracker.............................................34 3.2.3 Measurement uncertainty of heavy duty NC Floor-typed milling and
boring machine tool………………………………................................37 3.3 Measurement uncertainty estimation based on Monte Carlo method…….....39 3.3.1 Structure of measurement uncertainty estimation…….….......................40
3.3.2 Temperature monitoring during volumetric calibration...........................41 3.3.3 Verification of measurement uncertainty estimation...............................42 3.4 Optimization of location of measurement system…....................................43
3.4.1 Distribution of laser tracker………………….........................................44 3.4.2 Optimization of laser tracker position…….............................................45 3.4.3 Analysis of single factor optimization………….....................................46 3.5 Volumetric segment measurement of heavy-duty NC milling and boring
machine tool…………………………………………………………….........47 3.5.1 Coordinates transformation of measurement system..............................48 3.5.2 Simulation analysis of transformation accuracy……............................50 3.6 Verification of volumetric error measurenment in multi-station …………....53
3.6.1 Large volume segment………………...……...........................................53 3.6.2 Coordinates transformation....................................................................53 3.7 Brief Summary..............................................................................................54 Chapter 4 Research on geometric error identification of heavy-duty NC
milling and boring machine tool………….…………………............55 4.1 Introduction.........……………….……….……….….....................................55 4.2 Analysis of error potential sensitivity……….………….………....................55
4.2.1 Geometric error sensitivity coefficients.……………………………....55 4.2.2 Error sensitivity analysis………………..……….……………………....56 4.2.3 Effect of volumetric parameters on error sensitivity…….…………....59 4.3 Geometric error identification ……………...................................................64 4.3.1 Calibration of squareness error...............................................................64 4.3.2 Displacement geometric error identification based on linear motion….......66
4.3.3 Angle error of W-axis identification…………...….................................67 4.3.4 Angle error of Z-axis identification........................................................67
4.3.5 Angle error of X-axis and Y-axis identification based on PSO................68 4.4 Verification and analysis of geometric error measurement and
identification………………………………………………………………..72 4.4.1 Verification of geometric error identification………………...................72 4.4.2 Verification of geometric error measurement in multi-station…………..74
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4.4.3 Analysis of fitting accuracy of geometric error………….………………74 4.5 Brief Summary..............................................................................................78 Chapter 5 Parameters identificaton and Servo error prediction of heavy duty NC Floor-typed milling and boring machine tool……………….....79 5.1 Introduction……................................................…………............................79 5.2 Servo error modeling of machine tool.......……............................................79 5.2.1 Synthetical trajectory error of machine tool.......…................................79
5.2.2 Dynamic volumetric error model of machine tool..................................81 5.3 Servo error decoupling based on clock and anti-clock circle trajectory error.84 5.3.1 Measurement of circle trajectory error……..........................................84
5.3.2 Decoupling of servo error and quasi static error………………..............87 5.4 Parameters identification and prediction of dynamic servo error……….....88 5.4.1 Parameters identification based on trajector error based on critical
parameters…………....….……….………………...............................91
5.4.2 Prediction of circle trajectory error……………….……………............92 5.5 Brief Summary...........................................................................................92 Chapter 6 Tracing analysis of thermal drift error and research on
compensation technology..................…...............................................93 6.1 Introduction.............................................…..................................................93 6.2 Verification of prediction accuracy of synthetical error model.....................93 6.2.1 Verification of prediction accuracy of static error model........................93
6.2.2 Verification of of synthetical error model of geometrci and servo error..95 6.2.3 Verification of of synthetical error model of geometrci and thermal
error………………………………………………………………………..96
6.3 Tracing analysis of thermal drift error of ram…………...………….….…100
6.3.1 Experiment of thermal drift error..…...…...….......................................100 6.3.2 Analysis of simulation result…...…...........….......................................101
6.3.3 Thermal drift error chain and tracing analysis……….…...................102 6.3.4 Other condition simulation………………......................................... 104 6.4 Reaearch on thermal drift error compensation technology………..…….…105 6.5 Brief Summary........................................................................................... 106 Chapter 7 Verification of the synthetical error compensation of heavy duty NC
Floor-typed milling and boring machine tool by experiments........107
7.1 Introduction…….......................................…………...................................107 7.2 Verification of static error compensation...............................107 7.2.1 Strategy of error compensation…...………………............................107
7.2.2 Static volumetric error compensation………..……….............108
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