Research On The Control System Of5-Axis NC Electrochemical Manuafacturing Machine Tool Based On PMAC

With the rapid development of science and technology, complex parts made of component materials has been applied more and more widely in the field of aviation. To solve the problem of processing complex surfaces of component materials, and according to the characteristics of a self-developed five-axis NC electrochemical manufacturing machine tool, the open control system of this machine tool was designed and researched in this paper.The open CNC system with the structure of NC embedded PC is chose in this paper. The powerful Programmable Multi-Axis Controller (PMAC) is pluged into the expansion slot of Industrial Personal Computer (IPC) to compose the master-slave distributed control system. As the core of the whole control system, PMAC has many functions, such as completing servo interpolation, motion control, safety control, signal acquisition and so on. As a human-computer interaction platform, Industrial Personal Computer provides the platform of system software and management software for clients. The main research contents are as follows:1. Based on the research of PC-based open CNC system, the plan of the system using "IPC+motion controller" was determined, and according to the needs of electrolytic processing, the hardwares of the control system were chose.2. The control circuit connections of CNC system was completed, including the connection between PMAC and servo drive system, the connection of machine electrical control circuit, the connection between drive and motor, the connection of analog acquisition circuit and limit circuit. At last, the PID parameters and speed acceleration feedforward were tuned up to improve the stability of servo system, responsive speed and control accuracy of the system.3. Based on the connection of hardwares, the ECM software used for controlling the electrochemical manufacturing machine tool was developed, including the communication between the IPC and PMAC, man-machine interface and the development of various function modules. The function modules completed system initialization, parameter settings, manual control, automatic processing, status display, rate control, analog acquisition, data transmission and other functions.4. Based on the hardware and software of the control system, by the function of NC code error detection and tool path simulation, the experiment of electrochemical machining was finished. According to the experiment, the software, hardware and overall performance of the open CNC system can meet the requirements of the electrochemical machining.