| With sophisticated bending process requirements increase, labor costs and workersincreasingly enhance the work environment requirements, sheet metal manufacturingapplications with fast response, a high degree of energy saving and environmental protection,intelligent network, control accuracy excellent all-electric bender has become a trend. In somespecial processing industry, sheet parts size is larger, thicker and their accuracy requirement ishigh. The development of all-electric bending machine has more stringent requirements, notonly have a strong bending force, still must have superior multi-axis synchronizationperformance. Large-tonnage bending stress of the synchronous parallel output generally needmore than two motor drive to achieve, so the research of large-tonnage high-precisionall-electric bending machine servo synchronization control system and key technologies withindependent intellectual property rights in China for the development of a new generation ofall-electric bending machine industry to lay a solid foundation.According to comprehensive research on market demand and domestic and foreignall-electric bender development situation, this project proposes an high-power all-electricbending machine servo synchronization control system based on LinuxCNC2.5open CNCplatform. Focus on the system electrical control hardware, CNC system software as well asbending control process to make a detailed design and research. Design and research is mainlyfocused on the electric control system, CNC system software and hardware control bendingprocess. The scheme through real-time EtherCAT bus connects industrial PC and the servodriver, to achieve the optimal hardware structure streamline. CNC software usingLinuxCNC2.5platform has good robustness, scalability and control performance.Firstly, two kinds of system solutions is raised on the basis of analysis of the transmissionstructure and operating principle of the all-electric bending machine, one is based on DSP andFPGA embedded platform, form the special in the bending process of the special numericalcontrol system. Another is based on industrial PC and LinuxCNC2.5open control system,with the help of a PC’s powerful computing capacity and real-time Linux operating system toachieve the stronger and higher control precision. After multiple comparisons, this articleselects the latter design. Secondly, this paper carries on the detailed system hardware selection,including servo drives and motors, the position feedback transducer, and industrial PC.Thenusing these devices to form up a complete and stable hardware platform. Next, the CNCsoftware and key technology is designed and researched based on the analysis of real-timeLinux system and LinuxCNC2.5of architecture, including the EtherCAT master station module design, sigmoidal deceleration control algorithm and HAL for bending machineprocess configuration. According to analysis of four axis synchronous control difficulties, avariable structure synchronous drive control strategy and system which based on relativecoupling strategy and dynamic torque control technology is creatively proposed.Test fullydemonstrates that the strategy is effective and feasible. Finally, using PyQt and OpenGLtechnology to achieve perfect man-machine interface and3D graphical programmingfunction.Then focuses on the use of database technology and the least square method todesign the self-learning bending compensation algorithm.Prototype test show that the design is feasible and has satisfactory synchronizationperformance and machining precision, for high-power all-electric bending machine provides areasonable, reliable and efficient control method. |
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