超长工件的多工位加工控制方法及其优化技术

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摘要

重型装备的设计与制造是现代制造业技术竞争的关键领域。超长工件是重型

装备需要用到的重要功能部件，其质量的好坏直接影响重型装备的性能。超长工

件尺寸长、质量大，加工具有一定的复杂性。本文研究内容针对超长钢轨整形多

工位加工具体实现案例，探讨了超长工件的加工方法及其监控技术，给出了一种

多工位同时加工的多目标切削参数优化方法，对于提高超长工件的加工水平有着

重要的意义。

本文的主要研究内容包括：

1．分析了超长工件进给输送系统现状及存在的问题，设计了一种基于

SIMODRIVE 611D(简称，611D)驱动的双机械手推拉交替式的超长工件进给输送系

统，给出了输送机械手的工作结构原理，探讨工件输送过程中输送阶段的划分办

法，围绕每个阶段两机械手交替接手过程的 TRAILON 耦合控制绑定方法和控制过

程的系统协作机制展开论述，通过对 500m 长钢轨整形加工过程的具体输送应用表

明，设计的进给输送系统具有速度快、过程平稳和接手无扰动等优点。

2．分析超长工件在数控平台上完成多个工位及其功能体协作监控的技术要

求，围绕 SINUMERIK 840D(简称，840D)数控系统为控制平台，设计了超长工件

多轴协作的控制实现原理，给出了加工过程监控系统的实时数据库构建方法与主

轴自动定位控制原理，探讨了监控系统中各功能部件在数控平台上实现步骤，通

过应用 Visual Studio 和 840D OEM 为混合工具，开发实现了基于数控平台的超长

工件监控系统。系统在 500m 长钢轨整形加工中应用的具体实例，结果表明给出的

多功能协作的监控技术在超长工件加工控制中应用的可行性。

3．研究了双工位加工切削参数优化方法，根据粒子群算法及 Pareto 准则，给

出了一种基于迁移子的多目标优化方法及其实现步骤。以 500m 超长钢轨整形为实

例，建立了以进给速率和主轴转速为优化变量，以功率和加工时间为优化目标的

数学模型，给出了优化方法的具体实现过程，利用 COM 组件技术，将其应用到超

长工件监控系统中。

关键词：超长工件铣削加工进给控制优化技术

ABSTRACT

The design and manufacturing of heavy equipment is the key of modern

manufacturing technology competition. Extra-long workpiece is one of the most

important components in heavy equipment, and make influence of the property in heavy

equipment. The processing of the extra-long workpiece is the complexity involved in

machine because of the extra length and heavy weight. For the problem of shape

maching of extra-long rails in milling process, analysis the method of maching and

technique of supervisory, proposed a method for multi-objective optimization of

multi-position milling machine.

The main contents are listed as follows:

1. Propose a push-pull long rail feeding system with dual manipulators alternation

control based on SIMODRIVE 611D (611D). Firstly, some problems and the current

situation about the feeding system in long rails machining were analyzed and discussed.

The structure and alternation principle of the manipulator were presented. Then the

feeding method of the system was divided into five steps. The process of double

manipulators alternation in each steps were realized through a coupled motion control to

bind synchronous. System cooperation mechanism, specific control steps and

development effectiveness of the feeding system were presented in the end of the paper.

The application of the system for feeding 500-meter long rails in milling process shows

that the proposed feeding system has good performance with high feed-rate, good

runtime stability and stable alternation action.

2. Shape machining for supper long work-piece is a complicate multi-station

machining technique with multiple function cooperation. Firstly, the machining

supervisory control system technique requirement was analyzed based on NC platform.

Then the control principle for multi-axis cooperation was presented on the base of

SINUMERIK 840D (840D) NC control system. With the control principle the real-time

database and automatic spindle positioning method were showed to explain the

supervisory control technique. The procedure of the establishment of the supervisory

system was also given out in the following presentation. With Visual studio and 840d

OEM development tools the supervisory control system was established under the

presented method and principles. In the end, an application of the system for shape

machining of 500-meter long rails in milling process was proposed to show the

feasibility of the proposed technique.

3. Analysised a method for optimizing parameter of double-station milling machine.

According to the principles of particle swarm optimization algorithm and Pareto,

proposed a multi-objective optimization method based on transposon operation. An

application of the system of shape maching of 500-meter long rails in milling process is

propsed to establish optimizing power model and production time module, With Some

cutting parameters such as feedrate and spindle speed are taken as variables in the

model, gives realizing methods of optimization approaches, embed to the monitor

system in extra-long workpiece system with the technique of COM.

Key Words: extra long workpiece, milling process, feed control,

optimization technique

中文摘要

ABSTRACT

第一章绪论....................................................................................................... 1

§1.1 课题的研究意义及来源 ......................................................................... 1

§1.1.1 课题的研究意义 ................................................................................ 1

§1.1.2 课题来源 ............................................................................................ 2

§1.2 超长工件加工方法的研究现状.............................................................. 2

§1.2.1 超长工件的精密测量技术 ................................................................. 2

§1.2.2 分段加工及连接技术 ........................................................................ 3

§1.2.3 设备改造技术 .................................................................................... 3

§1.2.4 切削参数优化技术 ............................................................................ 3

§1.3 本论文研究内容 ..................................................................................... 4

§1.3.1 研究目标 ............................................................................................ 4

§1.3.2 论文内容的组织结构 ........................................................................ 4

第二章超长工件的进给方式及其控制方法 ...................................................... 6

§2.1 超长工件的进给方式 ............................................................................. 6

§2.2 进给控制原理 ........................................................................................ 8

§2.2.1 系统协作机制 .................................................................................... 8

§2.2.2 进给位置划分方法 .......................................................................... 10

§2.3 进给过程的换手方法 ........................................................................... 11

§2.3.1 机械手同步 ...................................................................................... 11

§2.3.2 换手方法 .......................................................................................... 11

§2.4 超长钢轨进给输送实例 ....................................................................... 13

§2.4.1 超长钢轨整形过程 .......................................................................... 13

§2.4.2 超长钢轨整形进给位置划分方法 ................................................... 14

§2.4.3 超长钢轨整形进给技术性能 ........................................................... 14

§2.5 本章小结 .............................................................................................. 15

第三章超长工件加工监控技术 ........................................................................ 16

§3.1 840D 数控平台二次开发技术简介 ..................................................... 16

§3.2 系统内部通讯原理 ............................................................................... 18

§3.2.1 DDE 动态数据交换 .......................................................................... 18

§3.2.2 HMI 与NCK/PLC 通讯接口 ............................................................ 19

§3.3 OEM 结构及开发流程 ......................................................................... 20

§3.3.1 顺序控制 .......................................................................................... 20

§3.3.2 界面设计 .......................................................................................... 22

§3.3.3 语言链接库的创建 .......................................................................... 22

§3.3.4 OEM 应用程序嵌入方法 .................................................................. 23

§3.4 超长工件加工过程的监控原理............................................................ 24

§3.4.1 多功能体部件协作机理................................................................... 24

§3.4.2 监控实时库的构建 .......................................................................... 25

§3.4.3 主轴自动定位 .................................................................................. 26

§3.4.4 监控系统开发实现流程................................................................... 27

§3.5 超长钢轨整形进给的具体应用............................................................ 27

§3.6 本章小结 .............................................................................................. 31

第四章超长工件切削用量优化方法 ................................................................ 32

§4.1 双工位铣削优化模型 ........................................................................... 32

§4.1.1 数学模型 .......................................................................................... 32

§4.1.2 子目标函数 ...................................................................................... 33

§4.1.3 约束 ................................................................................................. 34

§4.2 Pareto 准则 ........................................................................................... 35

§4.3 模型优化方法 ...................................................................................... 36

§4.3.1 模型求解方法 .................................................................................. 36

§4.3.2 迁移子 ............................................................................................. 38

§4.3.3 多目标 Pareto 优化求解方法 ........................................................... 39

§4.4 本章小结 .............................................................................................. 40

第五章超长工件的切削用量优化实例 ............................................................ 41

§5.1 超长钢轨整形加工切削参数优化 ........................................................ 41

§5.1.1 拟定加工参数 .................................................................................. 41

§5.1.2 优化结果及讨论 .............................................................................. 42

§5.2 优化算法的工程应用 ........................................................................... 44

§5.2.1 MATLAB 与VB 接口 ...................................................................... 44

§5.2.2 COM 组件创建步骤 ......................................................................... 46

§5.2.3 COM 组件的发布 ............................................................................. 47

§5.3 在整形机监控系统中的具体应用 ........................................................ 47

§5.4 本章小节 .............................................................................................. 49

第六章总结与展望 ........................................................................................... 50

§6.1 总结 ...................................................................................................... 50

§6.2 进一步的工作与展望 ........................................................................... 50

附录一：铣削模型系数 ..................................................................................... 52

附录二：PSO 多目标优化 MATLAB 程序 ....................................................... 53

参考文献 ............................................................................................................ 63

在读期间公开发表的论文和参与科研项目及取得成果 ................................... 67

致谢 .................................................................................................................... 68

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摘要：

摘要重型装备的设计与制造是现代制造业技术竞争的关键领域。超长工件是重型装备需要用到的重要功能部件，其质量的好坏直接影响重型装备的性能。超长工件尺寸长、质量大，加工具有一定的复杂性。本文研究内容针对超长钢轨整形多工位加工具体实现案例，探讨了超长工件的加工方法及其监控技术，给出了一种多工位同时加工的多目标切削参数优化方法，对于提高超长工件的加工水平有着重要的意义。本文的主要研究内容包括：1．分析了超长工件进给输送系统现状及存在的问题，设计了一种基于SIMODRIVE611D(简称，611D)驱动的双机械手推拉交替式的超长工件进给输送系统，给出了输送机械手的工作结构原理，探讨工件输送过程中输送阶段的...

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