R&D Of Precision Roller Lathe CNC System Based On UMAC

The microstructure surface has different physical functions because of its certain arrangement characteristics.Microstructures with different functions are now widely used in many fields such as display,new energy,communication,aerospace and so on.With the increasing demand for microstructures,traditional manufacturing processes can no longer meet the demand.The "roll-to-roll" imprinting is a processing technology which can complete a large number of replicating micro-structure surfaces in a short time,and it is also the most efficient processing technology for producing micro-structured surfaces.As the core part of the "roll-to-roll" processing technology,the roller die processing technology started late in China.At present,they all rely on imported foreign machine tools to satisfy the processing of large-size,high-precision,and high-complexity roll molds.In this paper,UMAC programmable multi-axis motion controller is used as a development platform to carry out research on key technologies of hardware design,software development,micro-structure processing and simulation of precision roller cylinder CNC system.The purpose is to process high-quality microstructure arrays.Firstly,combining the mechanical structure and processing features of the precision roller machine lathe,hardware structure of the CNC system was established,including industrial computers,motion controllers,linear motors,spindles,rapid arbors,actuators,and grating scales.In the aspect of the upper computer software,Qt4.8 is selected as the platform,and the UMAC API function is called to develop a human-machine interactive interface with simple operation and friendly interface.Secondly,the process of micro-structure processing on the cylindrical surface is analyzed,and the characterization and processing methods of the cylindrical surface micro-structure array are discussed theoretically.Using MATLAB,we modeled the 3D topography of the microstructure and generated the corresponding processing code.Using DIFFSYS,we simulated a roller part with sinusoidal microstructure array and spherical microstructure array.Simultaneously with the processing features,the UMAC is re-developed to realize a series of specific functions such as spindle C-axis mode switching,and G code analysis.Finally,the roller machine has the characteristics of large size and high precision.In order to ensure system reliability,we use the step signal and parabolic signal to adjust the relevant parameters of the control system,improve the dynamic characteristics and static characteristics,and achieve the optimization of PID parameters.Subsequently,the laser interferometer was used to measure the positioning accuracy and repeat positioning accuracy of each axis of the mechanical system,and the error of each axis was compensated by using the principle of positioning error compensation.Each axis finally obtained the micron-level accuracy and satisfied the processing requirements.