CN-122018442-A - Five-axis machining control method and system based on motion controller

CN122018442ACN 122018442 ACN122018442 ACN 122018442ACN-122018442-A

Abstract

The invention belongs to the technical field of numerical control, and provides a five-axis processing control method and a system based on a motion controller, wherein a continuous motion sequence of a rotating shaft is obtained, a micro reverse motion section is obtained and marked through the motion sequence, the micro reverse motion section is deleted, an end point parameter and a start point parameter of a front motion section and a back motion section adjacent to the micro reverse motion section are extracted, the end point parameter and the start point parameter are reconnected, generating an S-curve motion segment, acquiring an updated tool tip point track through a forward kinematics mechanism, comparing the updated tool tip point track with an original tool tip point track, acquiring track deviation, judging the effectiveness of the S-curve motion segment by combining a third threshold value, carrying out local smooth optimization according to a judgment result, acquiring an optimized S-curve motion segment, and controlling five-axis machining through the optimized S-curve motion segment. The invention optimizes five-axis processing control by optimizing the S-curve motion segment to replace micro reverse motion and combining forward kinematics to carry out track verification, thereby being beneficial to improving the processing precision.

Inventors

SHI BENYAN
Qu Shiquan
LIU JUNWEI

Assignees

佛山德玛特智能装备科技有限公司

Dates

Publication Date: 20260512
Application Date: 20260408

Claims (9)

1. The five-axis machining control method based on the motion controller is characterized by comprising the following steps of: Acquiring a continuous motion sequence of a rotating shaft, and marking a motion segment with a motion distance smaller than a first threshold value, a motion direction opposite to the adjacent forward and backward motion directions and a tool tip displacement smaller than a second threshold value in the motion sequence as a tiny reverse motion segment; Deleting a micro reverse motion segment, extracting end point parameters and start point parameters of adjacent front and back motion segments of the micro reverse motion segment, and reconnecting based on the end point parameters and the start point parameters to generate an S-curve motion segment; acquiring an updated tool tip point track corresponding to the S-curve motion section based on a forward kinematics mechanism, and comparing the updated tool tip point track with the original tool tip point track to acquire track deviation; based on the track deviation, carrying out validity judgment on the S-curve motion segment by combining a third threshold value, and obtaining a judgment result; And carrying out local smooth optimization based on the judgment result, obtaining an optimized S-curve motion segment, and carrying out processing control on the five-axis numerical control machine tool based on the optimized S-curve motion segment by a motion controller.
2. The motion controller-based five-axis machining control method according to claim 1, wherein the step of acquiring a rotation axis continuous motion sequence, marking a motion segment with a motion distance smaller than a first threshold, a motion direction opposite to an adjacent forward-backward motion direction and a tool tip position smaller than a second threshold in the motion sequence as a micro reverse motion segment, comprises: Acquiring a CAM tool bit file, analyzing the CAM tool bit file through a motion controller, and extracting a continuous motion sequence of a rotating shaft, wherein the continuous motion sequence comprises a plurality of continuously connected motion segments; Respectively extracting a movement distance, a movement direction and a corresponding tool tip displacement of the movement sections in the movement sequence; Comparing the extracted movement distance with a first threshold value, comparing the movement direction with the movement direction of the adjacent front-back movement section, and comparing the knife point displacement with a second threshold value; When any motion segment simultaneously meets the condition that the motion distance is smaller than a first threshold value, the motion direction is opposite to the motion direction of the adjacent front-back motion segment, and the knife point displacement is smaller than a second threshold value, the micro reverse motion segment is marked.
3. The motion controller-based five-axis machining control method according to claim 1, wherein deleting the micro reverse motion segment, extracting an end point parameter and a start point parameter of a front and rear motion segment adjacent to the micro reverse motion segment, reconnecting based on the end point parameter and the start point parameter, and generating an S-curve motion segment, comprising: deleting a tiny reverse motion segment based on a motion controller, and extracting an end point parameter of a motion segment adjacent to a previous segment of the tiny reverse motion segment and a start point parameter of a motion segment adjacent to the next segment, wherein the end point parameter comprises an end point position and an end point speed, and the start point parameter comprises a start point position and a start point speed; And obtaining the distance between the end point of the adjacent previous section of motion segment and the start point of the adjacent next section of motion segment, and generating an S-curve motion segment by combining the speed and acceleration constraint of the rotating shaft.
4. The motion controller-based five-axis machining control method according to claim 3, wherein obtaining a distance between an end point of a motion segment of an adjacent previous segment and a start point of a motion segment of an adjacent next segment, and generating an S-curve motion segment in combination with a speed and acceleration constraint of a rotating shaft, comprises: Setting a distance threshold value, and if the distance is greater than or equal to the distance threshold value, generating an acceleration-constant speed-deceleration three-section S curve motion section, namely accelerating from the end speed of the adjacent previous section motion section to a preset intermediate speed and decelerating to the start speed of the adjacent next section motion section; and if the distance is smaller than the distance threshold value, adjusting the acceleration and jerk parameters of the S-curve motion segment.
5. The motion controller-based five-axis machining control method according to claim 1, wherein obtaining an updated tool tip point track corresponding to an S-curve motion segment based on a forward kinematics mechanism, comparing the updated tool tip point track with an original tool tip point track, and obtaining a track deviation comprises: Based on a forward kinematics mechanism, combining the rotation axis angle and the linear axis position parameter corresponding to the S-curve motion segment, forward recursion is carried out on a motion chain of the five-axis numerical control machine tool through a homogeneous coordinate transformation matrix, and an updated tool point track is obtained; extracting an original tool tip track in the CAM tool bit file, and comparing the updated tool tip track with the original tool tip track point by point coordinates to obtain track deviation.
6. The motion controller-based five-axis machining control method of claim 5, wherein extracting an original tool tip point track in a CAM tool bit file, comparing point-by-point coordinates of an updated tool tip point track with the original tool tip point track, and obtaining a track deviation comprises: The motion controller extracts an original tool point track when the micro reverse motion section is not deleted from the original CAM tool position file; and comparing the updated tool tip point track with the original tool tip point track point by point coordinates, obtaining the position deviation value of each corresponding point, taking the absolute value of all the position deviation values, and selecting the position deviation value with the largest absolute value as the track deviation.
7. The motion controller-based five-axis machining control method according to claim 1, wherein the performing validity judgment on the S-curve motion segment based on the track deviation in combination with a third threshold value to obtain a judgment result includes: Setting a third threshold value, and comparing the track deviation with the third threshold value; if the track deviation is smaller than or equal to a third threshold value, judging that the S curve motion segment is effective, and acquiring an effective judgment result; If the track deviation is greater than a third preset threshold value, judging that the S-curve motion segment is invalid, acquiring an invalid judgment result, and canceling the S-curve motion segment, and reserving an original motion sequence formed by the micro reverse motion segment and the adjacent front-back motion segment.
8. The motion controller-based five-axis machining control method according to claim 1, wherein the optimizing S-curve motion segment is obtained by performing local smoothing optimization based on the determination result, and the machining control of the five-axis numerical control machine tool is performed by the motion controller based on the optimizing S-curve motion segment, comprising: When the judging result is an effective judging result, carrying out local smooth optimization on a plurality of interpolation points before and after a reconnection point based on the motion controller to obtain an optimized S-curve motion segment, wherein the reconnection point is represented as a point where the S-curve motion segment is reconnected with an adjacent front and rear motion segment; Wherein the optimization objective is to minimize jerk peaks of the rotation axis motion; The optimized S-curve motion segment is fused into a rotation shaft motion sequence, and a control instruction is output through a motion controller to drive a five-axis numerical control machine tool to carry out machining operation; and when the judging result is an invalid judging result, executing processing operation based on the original motion sequence.
9. Five-axis machining control system based on motion controller is applied to five-axis numerical control machine tool's motion controller, and its characterized in that includes: the acquisition module is used for acquiring a rotating shaft continuous motion sequence; the marking module marks a moving section with the moving distance smaller than a first threshold value, the moving direction opposite to the adjacent front-back moving direction and the knife point displacement smaller than a second threshold value in the moving sequence as a tiny reverse moving section; The processing module is used for deleting the micro reverse motion segment, extracting the end point parameter and the starting point parameter of the adjacent front-back motion segment of the micro reverse motion segment, and reconnecting the end point parameter and the starting point parameter to generate an S-curve motion segment; The comparison module is used for acquiring an updated tool tip point track corresponding to the S-curve motion section based on a forward kinematics mechanism, and comparing the updated tool tip point track with the original tool tip point track to acquire track deviation; The judging module is used for judging the effectiveness of the S-curve motion segment based on the track deviation and combining a third threshold value to acquire a judging result; And the optimizing module performs local smooth optimization based on the judging result to obtain an optimized S-curve motion segment, and the motion controller performs machining control on the five-axis numerical control machine tool based on the optimized S-curve motion segment.

Description

Five-axis machining control method and system based on motion controller Technical Field The invention relates to the technical field of numerical control, in particular to a five-axis machining control method and system based on a motion controller. Background In the five-axis linkage processing process by using a five-axis numerical control machine tool, particularly in complex curved surface processing scenes such as a precision die cavity and the like, when CAM software generates a tool bit file, the CAM software is influenced by factors such as discrete sampling precision of a curved surface, and the rotating shaft inevitably generates tiny reverse motion. The micro reverse motion is ineffective noise generated in the numerical calculation process of the CAM algorithm, and can trigger the elimination of backlash of a rotating shaft and the frequent reversing of a servo system, so that the abrasion of a motor and a transmission mechanism is increased, the quality of the machined surface of a part is reduced, and the influence in a high-precision machining scene is more remarkable. In order to solve the problems, the problems are continuously existed if the processing is not performed, the track distortion is caused by a simple parameter setting dead zone, and the contour precision is affected by phase lag possibly generated by adopting low-pass filtering. Disclosure of Invention In view of the above-mentioned problems, in combination with the first aspect of the present invention, an embodiment of the present invention provides a five-axis processing control method based on a motion controller, the method including: Acquiring a continuous motion sequence of a rotating shaft, and marking a motion segment with a motion distance smaller than a first threshold value, a motion direction opposite to the adjacent forward and backward motion directions and a tool tip displacement smaller than a second threshold value in the motion sequence as a tiny reverse motion segment; Deleting a micro reverse motion segment, extracting end point parameters and start point parameters of adjacent front and back motion segments of the micro reverse motion segment, and reconnecting based on the end point parameters and the start point parameters to generate an S-curve motion segment; acquiring an updated tool tip point track corresponding to the S-curve motion section based on a forward kinematics mechanism, and comparing the updated tool tip point track with the original tool tip point track to acquire track deviation; based on the track deviation, carrying out validity judgment on the S-curve motion segment by combining a third threshold value, and obtaining a judgment result; And carrying out local smooth optimization based on the judgment result, obtaining an optimized S-curve motion segment, and carrying out processing control on the five-axis numerical control machine tool based on the optimized S-curve motion segment by a motion controller. As a further scheme of the invention, a continuous motion sequence of a rotating shaft is obtained, a motion segment with a motion distance smaller than a first threshold value, a motion direction opposite to an adjacent forward and backward motion direction and a knife point displacement smaller than a second threshold value in the motion sequence is marked as a tiny reverse motion segment, and the method comprises the following steps: Acquiring a CAM tool bit file, analyzing the CAM tool bit file through a motion controller, and extracting a continuous motion sequence of a rotating shaft, wherein the continuous motion sequence comprises a plurality of continuously connected motion segments; Respectively extracting a movement distance, a movement direction and a corresponding tool tip displacement of the movement sections in the movement sequence; Comparing the extracted movement distance with a first threshold value, comparing the movement direction with the movement direction of the adjacent front-back movement section, and comparing the knife point displacement with a second threshold value; When any motion segment simultaneously meets the condition that the motion distance is smaller than a first threshold value, the motion direction is opposite to the motion direction of the adjacent front-back motion segment, and the knife point displacement is smaller than a second threshold value, the micro reverse motion segment is marked. As a further scheme of the invention, deleting the micro reverse motion segment, extracting the end point parameter and the start point parameter of the adjacent front and back motion segments of the micro reverse motion segment, reconnecting based on the end point parameter and the start point parameter, and generating the S-curve motion segment, wherein the method comprises the following steps: deleting a tiny reverse motion segment based on a motion controller, and extracting an end point parameter of a motion segment adjacent to a previous segment of