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Abstract
In the past decades the number of CNC systems has grown tremendously in almost every field of
manufacturing. A common drawback of these systems is that their operating parameters, such as cutting speeds
and feedrates are prescribed by part programmer and depend on his experience and knowledge. By contrast,
the main idea in adaptive control is the improvement of the production rate, or the reduction of machining cost,
by calculation and setting of the optimal operating parameters in the machining process itself. In fact, the
adaptive control of metal-cutting processes is presented as a logical extension of the CNC systems. In this paper
we describe the AC system made in Department of Machine-tools and Robotics of Military Technical Academy.
Some results of experimental studies based on this system are represented as well.
sut gia cng c AC tng 20-80%, cn chi ph gia cng ch bng 40-50% so vi gia cng
CNC thng thng. Li ch r nht ca AC thy c khi gia cng vi chiu su ct thay
i trong phm vi rng.
2. Nghin cu mt vi m hnh AC c
B AC u tin c thc hin ti Bendix Research Liboratories vo khong nm
1962-1964, di s bo tr ca Khng lc M. Vo khong thi gian , hng Cincinnati
Milacron cng xy dng mt h tng t. C hai ni u nhn ra rng khng th to ra mt
h thng c kh nng o trc tuyn ch tiu hiu qu (Performance Index - PI) ca qu
trnh. Mt khc cc h AC ny u qu t c th ng dng trong cng nghip. Cc
cng trnh nghin cu sau tp trung vo tm kim cc m hnh n gin, r tin hn.
C th phn cc h AC thnh 2 loi: (1) iu khin thch nghi ti u (Adaptive
Control With Optimization - ACO) v (2) iu khin thch nghi theo iu kin gii hn
(Adaptive Control With Constraints - ACC). H ACO iu khin cc thng s cng ngh
theo PI xc nh (thng l ch tiu kinh t), ng thi tha mn cc iu kin rng buc.
H ACO c nhc n nhiu nht l h Bendix. H gm c mt my phay NC, khi
sensor v b AC. Khi sensor o momen ct, nhit li ct v dao ng ca my. l
cc thng s u vo xc nh lng chy dao v tc ct ti u. PI c dng trong
h ny l hm ca t s gia th tch kim loi c ct (MRR) vi lng mn dao (TWR)
trong mt n v thi gian.
PI = f(MRR/TWR)
Mc tiu iu khin l m bo gi tr ln nht c th c ca PI m khng ph v h
iu kin rng buc. Cc rng buc ca h Bendix l vn tc ct ln nht v nh nht,
momen ct ln nht, lng chy dao ln nht, nhit ln nht v bin dao ng ln nht.
Gn y, mt h ACO mang tn MEL-Master c xy dng ti phng th nghim c
kh (Mechanical Laboratory - MEL) ca Nht [3], nhm t ng ha vic ra quyt nh ch
ct thay cho k thut lp trnh NC thng thng. H gm mt trung tm gia cng CNC
v 3 phn h m phng, cm nhn trng thi ca qu trnh (Process Sensing) v iu
khin s. Khi h thng nhn ra iu kin lm vic khng bnh thng th n thng bo cho
b CNC. Cc thng s cng ngh s c hiu chnh theo mt chin lc do b CNC xc
nh. MEL-Master dng h chuyn gia x l theo thi gian thc. B m phng lm vic
Off-line, gip cho ngi vn hnh quyt nh v kim tra ch gia cng ti u.
H MEL-Master tin b hn h Bendix v k thut tnh ton. Cc chc nng tnh ton
n l c tp trung vo my tnh ca b CNC. Khc vi h Bendix, dng phng php
gradient tnh ch ct ti u, h MEL-Master dng tr tu nhn to v h chuyn gia.
Mc tiu ca hu ht cc h ACC l tng nng sut ct (MRR), nh cc i ha mt
hay nhiu thng s cng ngh trong mt min, c gii hn bi cc rng buc. Hng
nghin cu c tin hnh nhiu nht nc ngoi l lm cc i lng chy dao vi iu
kin lc ct khng vt qu gii hn cho php.
Kh khn ln nht trong ng dng thc t ca ACO l o trc tuyn mt s thng s
ti u ha ch ct, nh lng mn dao, nhm b mt gia cng,... Hy vng rng
cng vi s tin b ca k thut o lng v iu khin, cc kh khn trn s dn c
khc phc. Khi , chc chn ACO s c a chung. Tuy nhin, cho n nay, v cc l
do kinh t v k thut ni trn m hu ht cc b AC dng trong cng nghip l ACC v rt
t h c kh nng iu khin qu 1 thng s [2].
3. Nghin cu ng dng AC ti Hc Vin KTQS
V hnh thc, h AC ging mt h iu khin c phn hi ch mt hay nhiu thng
s ra c o, lm cn c iu khin cc thng s cng ngh. V lut iu khin, AC c
nt ging nh iu khin ti u, v cc thng s cng ngh c iu khin theo ch tiu ti
u v h iu kin rng buc xc nh. Ci khc c bn ca AC so vi 2 loi trn l h
thng lm vic vi cc thng s mi trng bin ng theo thi gian thc.
3.2. o v x l tn hiu lc ct
Mi phng php gia cng c kh u da vo s tng tc vt l gia dng c v i
tng gia cng. S tng tc c th hin bi cc i lng vt l, nh lc, momen,
nhit ,... Lc ct l thng s quan trng bc nht kho st, ti u ha, iu khin qu
trnh cng ngh gia cng c kh. V vy mt h AC khng th thiu c sensor o lc ct.
Ni cch khc, nu h AC ch gim st mt thng s ra (a s cc h hin nay l nh vy)
th thng s phi l lc ct.
H thng o lc ct (hnh 4) m chng ti s dng gm:
1. Lc k 3 thnh phn o lc ct (Px, Py, Pz). Lc phi o trong trng hp ny l
lc ng nn chng ti chn sensor kiu p in. Ngoi u th tuyt i v kh nng o lc
ng, sensor p in cn c cc u im khc, nh gn, lm vic tin cy, cng vng c
hc cao, tn s dao ng ring cao, t nhy cm vi s thay i nhit mi trng,... Vt
liu lm sensor y l thch anh (quartz). So vi cc vt liu p in khc, cc thng s
cht lng ca thch anh cn cao hn, v d theo [4]:
- cng vng cao. Modul n hi vo khong 35 40 N/m2.
- Nhit lm vic n 500 oC. Nu k thut gia cng tt, nhy gn nh khng
i trong khong -200 n 350 oC.
- cch in cao, in tr sut ti 1014.
- tuyn tnh cao v tr khng ng k.
Tnh nng k thut chnh ca lc k 9257BA nh sau:
Gii hn o
Di 1
Px, Py
Pz
Di 2
Px, Py
Pz
Di 3
Px, Py
Pz2
Di 4
Px, Py
Pz
Qu ti
Px, Py
cho php Pz
nhy
kN
kN
-0,50,5
-11
-11
-22
-22
-55
-55
-510
-7,5/7,5
-7,5/15
tuyn tnh
tr
Cross talk
cng vng
Dao ng ring
N. lm vic
tri ( 25 oC)
Px, Py
Pz
Cx, Cy
Cz
fo(x, y)
fo(z)
mV/N
%FSO
%FSO
%
kN/m
kHz
o
C
N/s
10
5
1
0,5
3
>1
>2
2,0
3,5
0 60
0,01
Vi iu kin Fx v Fy 0,5Fz
3.3. Th nghim vi AC
H AC m t trn c th nghim ti B mn My v Robot, Hc vin KTQS
bng cc loi phi khc nhau. Phn ln cc phi u c to trc cc hc, rnh to ra
s khng ng u v kch thc, nh trn hnh 6.
Cc thng s cng
ngh th nghim nh sau:
- Vt liu phi: thp
45 khng nhit luyn,
cng HRC 35.
- Dao thp gi D=10.
- Tc trc chnh S
= 1000 v/ph.
- Chiu su ct danh
nh 2 mm.
- Gi tr t lc thay
i c nh con trt,
khi cn c th hiu chnh
ngay trong qu trnh gia
Hnh 6: Dng chi tit th gia cng trn my CNC c AC
cng.
Trn hnh 7 l nh mt my dng cho AC. th bn tri l gi tr tc thi ca 3
thnh phn lc ct, cha qua x l. th bn phi l cc tn hiu x l, gm gi tr tc
thi ca lc tng hp (ng mu hng), gi tr trung bnh lm trn (ng mu xanh),
in p ra cp cho b CNC (ng ). Bn di 2 th l cc khung hin s tng ng.
Nt pha di, bn phi dng t ngng lc ct iu khin.
Ct khng dng AC: Ct vi phi trn, lng chy dao lp trnh l FCNC = 60 mm/ph
(xem hnh 7). Kha AC bng cch t ngng iu khin lc ln cao (1000 N), v vy in
p iu khin c duy tr gi tr ti a, bng 5V. Nhn trn th, ta thy khi dao bt
u n vo phi, lc ct tng t bin (ti 500 N), sau gi n nh gi tr khong 420
N. di mt chu k ct khong 37 giy.
Ct c dng AC: M kha AC bng cch t ngng lc ct bng 250 N (xem hnh
8). Lng chy dao lp trnh FCNC = 90 mm/ph. Nhn th lc ct bn phi ta thy, lc u
xung lc rt ln, ti trn 900 N (ng mu hng). Sau khong 1 giy, in p iu khin
gim nhanh ti, lc ct gim xung 500 N v n nh dn 400 N. Trong on khng ct,
lc ct gim ti gn 0 v in p iu khin tng nhanh ln 5V, cho php tc chy dao
ti a. Trong chu k sau, lc ct c duy tr gi tr di 300 N. Chu k ct ln ny l 32
giy, gim 5 giy so vi trng hp kha AC.
Hnh 8: Trng thi h thng khi dng AC: Pset = 250 N, FCNC = 90 mm/ph.
3.4. nh gi kt qu nghin cu
Lng thc nghim cha nh gi v hiu qu ca vic dng AC. Tuy nhin,
vi cc kt qu ban u, chng ti nh gi kt qu nh sau:
- H AC xy dng trn c s my phay MFP320 CNC v b sensor o lc 9257BA
c thc hin thnh cng. H lm vic n nh, tin cy v cho kt qu ng nh d on.
- Phn mm gim st v x l tnh hung ng nh thut ton xy dng, c giao
din hp l v d s dng.
- Vi cng vng cao (ti 2 kN/m) v tn s dao ng ring cao (ti 3 kHz), vic
lp sensor hu nh khng nh hng n qu trnh ct gt. Khng nhn thy c s gim st
v cht lng b mt gia cng.
Vi phn cng v phn mm ni trn, h th hin y tnh nng ca mt ACC.