基于三阶误差估计的复杂密集型刀路光顺与轮廓控制研究

This project is inspired by the challenge to guarantee the machining efficiency and quality of complex surface parts, and plans to achieve the toolpath smoothing, the look-ahead acceleration/deceleration scheduling and the contour control by profound research on four aspects: (1) Feature point selection of complex and dense toolpath, and approximation error modeling of toolpath polygon edge; (2) Compensation modeling of contour error, and look-ahead acceleration/deceleration scheduling with adaptive compensation of contour error; (3) Contour error estimation based on curvature, torsion and curvature variation, and contouring controller design; (4) Toolpath smoothing, look-ahead acceleration/deceleration scheduling, interpolation and contour contouring control modules for complex and dense toolpath are developed and integrated into numerical control kernel unit. On this basis, an approximation curve with fewer control points, smaller energy density and higher approximation accuracy will be constructed. Interpolation trajectory scheduling considering dynamics of machine tool will be achieved by adaptive compensation of contouring error, and high accuracy contour control for complex contour will be also achieved by osculating helix. The outcomes will bring about significant improvements on the capacity and level of complex surface part machining, which are urgently needed by the hybrid CNC equipment.

本项目针对复杂曲面零件的加工效率和质量保障难题，围绕路径光顺、前瞻加减速规划和轮廓控制三方面展开研究，具体研究内容为：（1）复杂密集型刀路的特征点选择方法与路径多边形边逼近误差建模；（2）轮廓误差补偿建模与轮廓误差自适应补偿前瞻加减速规划；（3）融合曲率、挠率和曲率变化的轮廓误差估算新方法及轮廓控制器设计；（4）开发出面向复杂密集型刀路的路径光顺、前瞻加减速规划、插补和轮廓控制模块并将其集成到数控内核单元。预期将构造控制点个数较少、能量密度较小和逼近精度较高的逼近曲线，通过轮廓误差自适应补偿的方式实现考虑机床动力学特性的插补轨迹规划，通过密切螺旋线的方式实现复杂轮廓的高精轮廓控制。研究结果对推动我国亟需的复杂曲面零件制造能力和水平的突破，促进混联数控装备的发展具有重要意义。

本项目针对复杂曲面零件的加工效率和质量保障难题，围绕局部路径光顺、全局路径光顺和轮廓控制三方面展开研究，具体研究内容为：（1）考虑小线段刀具路径的几何学特性，建立NURBS曲线权重模型；（2）考虑微小线段刀具路径的几何学特性，建立双弓高误差检测机制；（3）考虑路径多边形与逼近曲线间的几何学特性，建立逼近误差模型；（4）基于密切曲线，建立轮廓误差实时估算模型；（5）设计同时考虑速度跟踪误差和轮廓误差的滑模控制器。基于上述研究内容，分别构造NURBS曲线局部光顺小线段刀具路径和B样条曲线全局光顺微小线段刀具路径，同时通过密切曲线的方式实现轮廓的高精度控制。研究结果对推动我国亟需的复杂曲面零件制造能力和水平的突破，促进数控装备的发展具有重要意义。