Method For Synchronized Multi-Axis Motion Control Of Flexible Electronic Gearbox

Abstract

According to a machining principle of the CNC gear hobbing machine, a functional relation between a geometric error of a gear and a tracking error of each motion axis of the machine tool is constructed; a machining error mathematical model of tooth profile deviation, tooth pitch deviation and tooth direction deviation at each position control time point is established by tracking errors of each motion axis; a compensation quantity required for a workpiece rotation axis at the next position control time point is calculated by establishing a decoupling compensation model; average absolute values of machining errors and a total compensation quantity of the machining errors under the conditions of not adopting the synchronous control method and adopting the synchronous control method in the total position control time are obtained by calculating machining error values of each position controls time point, and the synchronized multi-axis motion control is completed.

Claims

1. A method for synchronized multi-axis motion control of a flexible electronic gearbox, wherein the method for synchronized multi-axis motion control is suitable for a CNC gear hobbing machine; the gear hobbing machine comprises an A axis, a B axis, a C axis, an X axis, a Y axis and a Z axis, the A axis serves as a reference for adjusting a hob installation angle, the B axis serves as a reference for hob rotation, the C axis serves as a reference for workpiece rotation, the X axis serves as a reference for hob radial feeding, the Y axis serves as a reference for hob tangential feeding, the Z axis serves as a reference for hob axial feeding, wherein the B axis, the X axis, the Y axis and the Z axis are main motion axes; a servo motor of each main motion axis is detected by a grating encoder and detection results are then input into a microprocessor as reference data, detections results of the B axis, Y axis and Z axis (excluding the X axis) obtained after a functional module of the flexible electronic gearbox performs calculation and transformation according to a mathematical model of a gear bobbing machining technology serve as working data of the C axis, a motion law specified by an electronic gearbox module is realized by using a control theory algorithm to realize gear bobbing machining; the flexible electronic gearbox realizes control functions based on an ARM-DSP-FPGA based hardware platform, wherein according to a machining principle of the CNC gear bobbing machine, a functional relation between a geometric error of a gear and a tracking error of each motion axis of the machine tool is constructed; the tracking errors comprise: a B axis tracking error E.sub.b (a hob rotation axis tracking error E.sub.b), a C axis tracking error E.sub.c (a workpiece rotation axis tracking error E.sub.c), a Z axis tracking error E.sub.z (a hob axial feed axis tracking error E.sub.z), a Y axis tracking error E.sub.y (a hob tangential feed axis tracking error E.sub.y), an X axis tracking error E.sub.x (a hob radial feed axis tracking error E.sub.x) and a hob installation angle error E.sub.a; a machining error mathematical model of tooth profile deviation F.sub.α, tooth pitch deviation F.sub.p and spiral deviation F.sub.β is established by tracking errors of each motion axis, and the geometric error of the gear is evaluated by using numerical results of the machining error mathematical model; through each motion axis error of each position control time point, machining error values of this time point, namely the value of the tooth profile deviation F.sub.α, the value of the tooth pitch deviation F.sub.p and the value of the spiral deviation F.sub.β, are calculated; based on a principle of cross-coupling control, a decoupling compensation model is established to calculate a compensation quantity ΔE.sub.c required for the C axis; the compensation quantity ΔE.sub.c is compensated to the C axis at the next position control time point, and the compensated machining error values, namely the compensated value of the tooth profile deviation F.sub.α, the compensated value of the tooth pitch deviation F.sub.p and the compensated value of the spiral deviation F.sub.β, are calculated through tracking errors of each motion axis at the time point; meanwhile, the synchronized multi-axis motion control of the total position control time is completed by obtaining average absolute values of the machining errors and the total compensation quantity of the machining errors under the conditions of not adopting the synchronous control method and adopting the synchronous control method in the total position control time.

2. The method for synchronized multi-axis motion control of a flexible electronic gearbox according to claim 1, comprising the following operating steps: (1): determining the gear machining type by “a diagonal hobbing method” wherein when the “diagonal hobbing method” is used to machine a helical cylindrical gear, since a hob cutter moves along the Z axis, the C axis generates additional rotation to meet a geometrical relationship of a generated spiral; when there is a need for a hob shifting process, since the hob cutter moves along the Y axis, the C axis generates additional rotation to meet a generating relationship changing due to hob shifting; the generating and differential relationship for machining the helical cylindrical gear is shown in formula (1), $\begin{matrix} n_{c} = K_{b} \frac{Z_{b}}{Z_{r}} n_{b} + K_{z} \frac{\sin β}{π m_{n} Z_{c}} v_{z} + K_{y} \frac{\cos λ}{π m_{n} Z_{c}} & (1) \end{matrix}$ in formula (1): Z.sub.b, λ and n.sub.b are the number of threads of a hob cutter, a hob spiral angle and a hob shaft speed respectively, Z.sub.c, β, m.sub.n, and n.sub.c are the number of workpiece teeth, a spiral angle of a workpiece, a normal module of the workpiece and a rotating speed of the workpiece respectively; K.sub.b, K.sub.z and K.sub.y are a first item coefficient, a second item coefficient and a third item coefficient respectively; v.sub.z is a hob axial feed speed, and v.sub.y is a hob tangential feed speed; when the hob spiral angle is right-handed, namely when β>0, K.sub.B=1; when the hob spiral angle is left-handed, namely when β<0, K.sub.B=−1; when β>0 and V.sub.z<0, K.sub.z=1; when β<0 and V.sub.z?<0, K.sub.z=−1; when β>0 and V.sub.z>0, K.sub.z=−1; when β<0 and V.sub.z>0, K.sub.z=1; when V.sub.y>0, K.sub.y=1; when V.sub.y<0, K.sub.y=−1; when a straight tooth cylindrical gear is machined, the spiral angle of the workpiece β=0; (2): establishing a machining error mathematical model wherein the machining types of the CNC gear hobbing machine determined by step (1) are a left-handed helical cylindrical gear, a right-handed helical cylindrical gear and the straight tooth cylindrical gear; a machining error mathematical model of a workpiece at a position control time point t.sub.k is established, relevant parameters involved in the motion errors comprise: a B axis tracking error E.sub.b, a C axis tracking error E.sub.c, a Z axis tracking error E.sub.z, a Y axis tracking error E.sub.y, an X axis tracking error E.sub.x and a hob installation angle error E.sub.a; tracking errors of each motion axis at the position control time point t.sub.k are recorded as E.sub.b.sup.k, E.sub.c.sup.k, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k, wherein units of E.sub.z.sup.k, E.sub.y.sup.k and E.sub.x.sup.k are mm, units of E.sub.b.sup.k and E.sub.c.sup.k are rad, and the unit of E.sub.a.sup.k is degree, k is 0-n; three evaluation indexes of the geometric error of the gear, namely tooth profile deviation F.sub.α.sup.k, tooth pitch deviation F.sub.p.sup.k and tooth direction deviation F.sub.β.sup.k, are established according to a relative position and attitude relationship between the hob and the workpiece during hobbing, and the machining error mathematical model of the position control time point t.sub.k is as follows: $\begin{matrix} F_{a}^{k} = \frac{π m_{n} Z_{c} \cos α}{360 ° \cos β} E_{c}^{k} + \sin α E_{x}^{k} + \cos γcos E_{a}^{k} \cos α E_{y}^{k} & (2) \\ F_{p}^{k} = \frac{π m_{n} Z_{c}}{360 ° \cos β} E_{c}^{k} + \tan α E_{x}^{k} + \cos γcos E_{a}^{k} E_{y}^{k} & (3) \\ F_{β}^{k} = \frac{π m_{n} Z_{c}}{360 ° \cos β} E_{c}^{k} + \cos γcos E_{a}^{k} E_{y}^{k} + \tan β E_{z}^{k} & (4) \end{matrix}$ in formulas (2), (3) and (4), units of F.sub.α.sup.k, F.sub.p.sup.k and F.sub.β.sup.k are mm, m.sub.n is a normal module of the workpiece, Z.sub.c is the number of workpiece teeth, α is a workpiece pressure with a unit of degree, β is a spiral angle of the workpiece with a unit of degree, γ is a hob installation angle with a unit of degree; when the hob is right-handed, β is greater than 0; when the hob is left-handed, β is less than 0; (3): establishing a decoupling compensation model wherein according to the machining error mathematical model, a decoupling compensation model based on the principle of cross-coupling control is proposed to reduce the synchronized multi-axis motion error so as to realize accurate control of synchronized multi-axis motion; an item E.sub.c.sup.k in formula (3) is set to E.sub.c.sup.k−ΔE.sub.c.sup.k+1 to obtain formula (5), and a tooth pitch error F.sub.p.sup.k is set to 0; $\begin{matrix} F_{p}^{k} = \frac{π m_{n} Z_{c}}{360 ° \cos β} (E_{c}^{k} - Δ E_{c}^{k + 1}) + \tan α E_{x}^{k} + \cos γcos E_{a}^{k} E_{y}^{k} = 0 & (5) \end{matrix}$ according to formula (5), a relationship between a compensation object and multiple parameters affecting the geometric error of the gear is obtained, namely a relationship between the C axis compensation quantity ΔE.sub.c.sup.k+1 at the position control time point t.sub.k+1 and the tracking error E.sub.c, E.sub.x and E.sub.y of each motion axis at the position control time point t.sub.k, is obtained, and the decoupling compensation model is obtained as follows: $\begin{matrix} Δ E_{c}^{k + 1} = E_{c}^{k} + \frac{360 ° \tan αcosβ}{π m_{n} z_{c}} E_{x}^{k} + \frac{360 ° \cos γcos E_{a}^{k} \cos β}{π m_{n} z_{c}} E_{y}^{k} & (6) \end{matrix}$ in formula (6): ΔE.sub.c.sup.k+1 is a C axis compensation quantity with a unit of mm, m.sub.n is gear normal module, Z.sub.c is the number of gear teeth, α is a gear pressure angle with a unit of degree, β is a spiral angle of a gear with a unit of degree, and γ is a hob installation angle with a unit of degree;
E.sub.c.sup.(k+1)′=E.sub.c.sup.k+1−ΔE.sub.c.sup.k+1 (7) in formula (7): E.sub.c.sup.(k+1)′ is the C axis tracking error when synchronous motion control is adopted at the position control time point t.sub.k+1, and the unit is rad; in formulas (5), (6) and (7), k is 0-n; (4): calculating the average absolute value of the machining errors and the total compensation quantity of the machining errors wherein under the condition of not adopting the synchronous control method, average absolute values of three items of the machining errors of the total position control time t are respectively as follows: $M_{a} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{a}^{k} .Math.; M_{p} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{p}^{k} .Math.; M_{β} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{β}^{k} .Math.$ M.sub.α is an average absolute value of tooth profile errors with a unit of mm, M.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-n; under the condition of adopting the synchronous control method, E.sub.b.sup.k, E.sub.c.sup.k′, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k are taken into formulas (2), (3) and (4) to obtain F.sub.α.sup.k′, F.sub.p.sup.k′ and F.sub.β.sup.k′ of the position control time point t.sub.k, and average absolute values of three items of the machining errors of the total position control time t are respectively as follows: $M_{a}^{'} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{a}^{k^{'}} .Math.; M_{p}^{'} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{p}^{k^{'}} .Math.; M_{β}^{'} = \frac{1}{n} {.Math.}_{k = 1}^{n} .Math. F_{β}^{k^{'}} .Math.$ M′.sub.α is an average absolute value of tooth profile errors with a unit of mm, M′.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M′.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-n: the total compensation quantity for the total position control time t is:
S=n(M.sub.α+M.sub.p+M.sub.β−M′.sub.α−M′.sub.p−M′.sub.β) (8) in formula (8), S is the total compensation quantity for the total position control time t with a unit of mm, and the synchronized multi-axis motion control of the total position control time t is completed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] FIG. 1 is a schematic diagram of distribution of each motion axis of a gear hobbing machine tool; and

[0037] FIG. 2 is a schematic diagram of synchronized multi-axis motion control of a flexible electronic gearbox.

DETAILED DESCRIPTION OF THE DRAWINGS

[0038] In order to more specifically describe the implementation technical means and innovative features of the present invention, the technical solution of the present invention is described in further detail below through examples with reference to the accompanying drawings.

[0039] A method for synchronized multi-axis motion control of a flexible electronic gearbox is suitable for a CNC gear bobbing machine. The gear bobbing machine includes an A axis, a B axis, a C axis, an X axis, a Y axis and a Z axis, the A axis serves as a reference for adjusting a hob installation angle, the B axis serves as a reference for hob rotation, the C axis serves as a reference for workpiece rotation, the X axis serves as a reference for hob radial feeding, the Y axis serves as a reference for hob tangential feeding, the Z axis serves as a reference for hob axial feeding.

Example 1

[0040] Hob parameters are as follows: with respect to a right-handed hob, a normal module m.sub.n is 1, the number Z.sub.b of hob heads is 1, a hob pressure angle α is 20°, a hob spiral angle λ is 1.93°, an installation angle γ is 23.07°, hob axial feed V.sub.2 is less than 0, and hob tangential feed V.sub.y is greater than 0. Workpiece parameters are as follows: a gear normal module m.sub.n is 1, the number Z.sub.c of gear teeth is 49, a gear pressure angle α is 20°, the gear is right-handed, a spiral angle β is 25°, and the total position control time is 11 ms and is divided into 11 position control time points.

[0041] The method for synchronized multi-axis motion control based on a flexible electronic gearbox includes the following operating steps:

[0042] (1): Determine the Gear Machining Type by “a Diagonal Hobbing Method”.

[0043] When the “diagonal bobbing method” is used to machine a helical cylindrical gear, since a hob cutter moves along the Z axis, the C axis generates additional rotation to meet a geometrical relationship of a generated spiral; when there is a need for a hob shifting process, since the hob cutter moves along the Y axis, the C axis generates additional rotation to meet a generating relationship changing due to hob shifting;

[0044] the generating and differential relationship for machining the helical cylindrical gear is shown in formula (1),

n.sub.c=0.0204×n.sub.b+0.0027×v.sub.z+0.0064×v.sub.y (1)

In the formula, n.sub.b is a hob shaft speed, n.sub.c is a rotating speed of a workpiece, v.sub.z is a hob axial feed speed, and v.sub.y is a hob tangential feed speed.

[0045] (2): Establish a Machining Error Mathematical Model.

[0046] After the machining types of the CNC gear hobbing machine determined by step (1) are a right-handed helical cylindrical gear, a machining error mathematical model of a workpiece at a position control time point t.sub.k is established, relevant parameters involved in the motion errors include: a B axis tracking error E.sub.b, a C axis tracking error E.sub.c, a Z axis tracking error E.sub.z, a Y axis tracking error E.sub.y, an X axis tracking error E.sub.x and a hob installation angle error E.sub.a; tracking errors of each motion axis at the position control time point t.sub.k are recorded as E.sub.b.sup.k, E.sub.c.sup.k, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k, where units of E.sub.z.sup.k, E.sub.y.sup.k and E.sub.x.sup.k are mm, units of E.sub.b.sup.k and E.sub.c.sup.k are rad, and the unit of E.sub.a.sup.k is degree, k is 0-10; and tracking error data of each motion axis for the position control time points t.sub.0 to t.sub.10 is shown in Table 1.

TABLE-US-00001 TABLE 1 E.sub.a.sup.k E.sub.c.sup.k E.sub.z.sup.k E.sub.y.sup.k E.sub.x.sup.k t.sub.0 0 0.0031 0.00012 −0.00032 −0.0008 t.sub.1 0 0.0052 0.00016 −0.00024 −0.00068 t.sub.2 0.0003 −0.0011 0.00008 −0.00017 −0.00021 t.sub.3 0.0001 −0.0023 0.00013 0.00003 −0.00019 t.sub.4 0.0003 0.0033 0.00011 0.00012 −0.00054 t.sub.5 −0.0001 0.0025 0.00013 −0.00021 0.00001 t.sub.6 −0.0001 0.0024 0.0001 −0.00025 −0.00015 t.sub.7 0.0001 0.0039 0.00006 −0.0003 −0.00041 t.sub.8 −0.0002 0.0034 0.00012 0.00011 −0.00027 t.sub.9 0 −0.0014 0.00003 −0.00041 −0.00011 t.sub.10 0.0001 −0.0051 0.00014 −0.00034 −0.00051

[0047] Three evaluation indexes of the geometric error of the gear, namely tooth profile deviation F.sub.α.sup.k, tooth pitch deviation F.sub.p.sup.k and tooth direction deviation F.sub.β.sup.k, are established according to a relative position and attitude relationship between the hob and the workpiece during hobbing, and the machining error mathematical model of the position control time point t.sub.k is as follows:

F.sub.α.sup.k=0.4434×E.sub.c.sup.k+0.3420×E.sub.x.sup.k+0.8645×cos E.sub.a.sup.kE.sub.y.sup.k (2)

F.sub.p.sup.k=0.4718×E.sub.c.sup.k+0.3640×E.sub.x.sup.k+0.9200 cos E.sub.a.sup.kE.sub.y.sup.k (3)

F.sub.β.sup.k=0.4718×E.sub.c.sup.k+0.9200×cos E.sub.a.sup.kE.sub.y.sup.k+0.4663×E.sub.z.sup.k (4)

[0048] In formulas (2), (3) and (4), units of F.sub.α.sup.k, F.sub.p.sup.k and F.sub.β.sup.k are mm, units of E.sub.z.sup.k, E.sub.y.sup.k and E.sub.x.sup.k are mm, units of E.sub.b.sup.k and E.sub.c.sup.k are rad, and the unit of E.sub.a.sup.k is degree.

[0049] (3): Establish a Decoupling Compensation Model.

[0050] According to the machining error mathematical model, a decoupling compensation model based on the principle of cross-coupling control is proposed, as shown in FIG. 2, to reduce the synchronized multi-axis motion error so as to realize accurate control of synchronized multi-axis motion; an item E.sub.c.sup.k in formula (3) is set to E.sub.c.sup.k−ΔE.sub.c.sup.k+1 to obtain formula (5), and a tooth pitch error F.sub.p.sup.k is set to 0;

F.sub.p.sup.k=0.4718×(E.sub.c.sup.k−ΔE.sub.c.sup.k+1)+0.3640×E.sub.x.sup.k+0.9200×cos E.sub.a.sup.kE.sub.y.sup.k (5)

according to formula (5), a relationship between a compensation object and multiple parameters affecting the geometric error of the gear is obtained, namely a relationship between the C axis compensation quantity ΔE.sub.c.sup.k+1 at the position control time point t.sub.k+1 and the tracking error E.sub.c, E.sub.x and E.sub.y of each motion axis at the position control time point t.sub.k, is obtained, and the decoupling compensation model is obtained as follows:

ΔE.sub.c.sup.k+1==E.sub.c.sup.k+0.7714×E.sub.x.sup.k+1.9500×cos E.sub.a.sup.kE.sub.y.sup.k (6)

[0051] in formula (6): ΔE.sub.c.sup.k+1 is a C axis compensation quantity with a unit of mm.

E.sub.c.sup.(k+1)′=E.sub.c.sup.k+1−ΔE.sub.c.sup.k+1 (7)

In formula (7): E.sub.c.sup.(k+1)′ is the C axis tracking error when synchronous motion control is adopted at the position control time point t.sub.k+1, and the unit is rad.

[0052] (4): Calculate the Average Absolute Value and the Total Compensation Quantity of the Machining Errors.

[0053] Under the condition of not adopting the synchronous control method, average absolute values of three items of the machining errors of the total position control time t are respectively as follows:

[00008] $M_{a} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{a}^{k} .Math. = 0.001327; M_{p} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{p}^{k} .Math. = 0.001413; M_{β} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{β}^{k} .Math. = 0.001470$

[0054] M.sub.α is an average absolute value of tooth profile errors with a unit of mm, M.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-10.

[0055] Under the condition of adopting the synchronous control method, E.sub.b.sup.k, E.sub.c.sup.k′, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k are taken into formulas (2), (3) and (4) to obtain F.sub.α.sup.k′, F.sub.p.sup.k′ and F.sub.β.sup.k′ of the position control time point t.sub.k, and average absolute values of three items of the machining errors of the total position control time t are respectively as follows:

[00009] $M_{a}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{a}^{k^{'}} .Math. = 0.001190; M_{p}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{p}^{k^{'}} .Math. = 0.001266; M_{β}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{β}^{k^{'}} .Math. = 0.001300$

[0056] M′.sub.α is an average absolute value of tooth profile errors with a unit of mm, M′.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M′.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-10.

[0057] The total compensation quantity for the total position control time t is:

S=10×(M.sub.α+M.sub.p+M.sub.β−M′.sub.α−M′.sub.p−M′.sub.β)=0.004542 (8)

in formula (8), S is the total compensation quantity for the total position control time t with a unit of mm, and the synchronized multi-axis motion control of the total position control time t is completed.

[0058] The effect of synchronized multi-axis motion control is shown in Table 2.

TABLE-US-00002 TABLE 2 F.sub.α.sup.k F.sub.p.sup.k F.sub.β.sup.k F.sub.α.sup.k′ F.sub.p.sup.k′ F.sub.β.sup.k′ t.sub.1 0.001865 0.001985 0.002307 0.001041 0.001108 0.00143 t.sub.2 −0.00071 −0.00075 −0.00064 −0.00257 −0.00274 −0.00262 t.sub.3 −0.00106 −0.00113 −0.00105 −0.00035 −0.00037 −0.0003 t.sub.4 0.001382 0.001471 0.001719 0.002441 0.002598 0.002845 t.sub.5 0.00093 0.00099 0.001047 −0.00045 −0.00048 −0.00042 t.sub.6 0.000797 0.000848 0.000907 −0.00013 −0.00014 −0.00008 t.sub.7 0.00133 0.001415 0.001592 0.000533 0.000567 0.000744 t.sub.8 0.00151 0.001607 0.001761 0.000181 0.000192 0.000346 t.sub.9 −0.00101 −0.00108 −0.00102 −0.00252 −0.00268 −0.00263 t.sub.10 −0.00268 −0.00285 −0.00265 −0.00167 −0.00178 −0.00158

[0059] Due to abrupt changes in motion error values of each axis, at a few position control time points, the values F.sub.α.sup.k′, F.sub.p.sup.k′ and F.sub.β.sup.k′ a after compensation by synchronous motion control are greater than the values F.sub.α.sup.k, F.sub.p.sup.k and F.sub.β.sup.k without compensation by synchronous motion control, such as position control time points t.sub.2, t.sub.4 and t.sub.9 in Table 2. However, this does not affect the effectiveness of synchronous motion control for the total position control time.

[0060] It can be seen that under the condition of adopting the synchronous control method, average absolute values of three items of the machining error are smaller than the average absolute values of the corresponding items without the adoption of the synchronous control method. The total compensation quantity of the machining error was 0.004542 mm within the total position control duration of 11 mm.

Example 2

[0061] Hob parameters are as follows: with respect to a left-handed hob, a normal module m.sub.n is 2, the number Z.sub.b of hob heads is 1, a hob pressure angle α is 20°, a hob spiral angle λ is 2.01°, an installation angle γ is 22.99°, hob axial feed V.sub.2 is greater than 0, and hob tangential feed V.sub.y is less than 0. Workpiece parameters are as follows: a gear normal module m.sub.n is 2, the number Z.sub.c of gear teeth is 27, a gear pressure angle α is 20°, the gear is left-handed, a spiral angle β is −25°, and the total position control time is 11 ms and is divided into 11 position control time points.

[0062] The method for synchronized multi-axis motion control based on a flexible electronic gearbox includes the following operating steps:

[0063] (1): Determine the Gear Machining Type by “a Diagonal Hobbing Method”.

[0064] When the “diagonal hobbing method” is used to machine a helical cylindrical gear, since a hob cutter moves along the Z axis, the C axis generates additional rotation to meet a geometrical relationship of a generated spiral; when them is a need for a hob shifting process, since the hob cutter moves along the Y axis, the C axis generates additional rotation to meet a generating relationship changing due to hob shifting;

[0065] the generating and differential relationship for machining the helical cylindrical gear is shown in formula (1),

n.sub.c=−0.0370×n.sub.b+0.0025×v.sub.z−0.0058×v.sub.y (1).

[0066] In the formula, n.sub.b is a hob shaft speed, n.sub.c is a rotating speed of a workpiece, v.sub.z is a hob axial feed speed, and v.sub.y is a hob tangential feed speed.

[0067] (2): Establish a Machining Error Mathematical Model.

[0068] After the machining types of the CNC gear hobbing machine determined by step (1) are a right-handed helical cylindrical gear, a machining error mathematical model of a workpiece at a position control time point t.sub.k is established, relevant parameters involved in the motion errors include: a B axis tracking error E.sub.b, a C axis tracking error E.sub.c, a Z axis tracking error E.sub.z, a Y axis tracking error E.sub.y, an X axis tracking error E.sub.x and a hob installation angle error E.sub.a; tracking errors of each motion axis at the position control time point t.sub.k are recorded as E.sub.b.sup.k, E.sub.c.sup.k, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k, where k is 0-10; and tracking error data of each motion axis for the position control time points t.sub.0 to t.sub.10 is shown in Table 3.

TABLE-US-00003 TABLE 3 E.sub.a.sup.k E.sub.c.sup.k E.sub.z.sup.k E.sub.y.sup.k E.sub.x.sup.k t.sub.0 0 0.0013 0.00021 −0.00019 −0.00017 t.sub.1 0.0001 0.0022 0.00009 −0.00037 0.00024 t.sub.2 0 0.0052 0.00017 −0.00021 −0.00009 t.sub.3 0.0001 0.0041 0.00014 −0.00034 −0.00021 t.sub.4 −0.0002 0.0027 0.00018 0.00013 −0.00012 t.sub.5 0.0001 −0.0019 0.00021 −0.00034 0.00035 t.sub.6 0 −0.0037 0.00034 0.00028 0.00003 t.sub.7 0 −0.0018 0.00012 −0.00053 −0.00029 t.sub.8 0 0.0011 0.00004 −0.00038 0.00025 t.sub.9 0.0001 0.0027 0.00022 −0.00043 0.00021 t.sub.10 −0.0002 0.0013 0.00029 0.00021 −0.00019

[0069] Three evaluation indexes of the geometric error of the gear, namely tooth profile deviation F.sub.α.sup.k, tooth pitch deviation F.sub.p.sup.k and tooth direction deviation F.sub.β.sup.k, are established according to a relative position and attitude relationship between the hob and the workpiece during hobbing, and the machining error mathematical model of the position control time point t.sub.k is as follows:

F.sub.α.sup.k=0.4886×E.sub.c.sup.k+0.3420×E.sub.x.sup.k+0.8651×cos E.sub.a.sup.kE.sub.y.sup.k (2)

F.sub.p.sup.k=0.5200×E.sub.c.sup.k+0.3640×E.sub.x.sup.k+0.9206 cos E.sub.a.sup.kE.sub.y.sup.k (3)

F.sub.β.sup.k=0.5200×E.sub.c.sup.k+0.9206×cos E.sub.a.sup.kE.sub.y.sup.k−0.4663×E.sub.z.sup.k (4)

[0070] In formulas (2), (3) and (4), units of F.sub.α.sup.k, F.sub.p.sup.k and F.sub.β.sup.k are mm, units of E.sub.z.sup.k, E.sub.y.sup.k and E.sub.x.sup.k are mm, units of E.sub.b.sup.k and E.sub.c.sup.k are rad, and the unit of E.sub.a.sup.k is degree.

[0071] (3): Establish a Decoupling Compensation Model.

[0072] According to the machining error mathematical model, a decoupling compensation model based on the principle of cross-coupling control is proposed, as shown in FIG. 2, to reduce the synchronized multi-axis motion error so as to realize accurate control of synchronized multi-axis motion; an item E.sub.c.sup.k in formula (3) is set to E.sub.c.sup.k−ΔE.sub.c.sup.k+1 to obtain formula (5), and a tooth pitch error F.sub.p.sup.k is set to 0;

F.sub.p.sup.k=0.5200×(E.sub.c.sup.k−ΔE.sub.c.sup.k+1)+0.3640×E.sub.x.sup.k+0.9206×cos E.sub.a.sup.kE.sub.y.sup.k=0 (5)

[0073] according to formula (5), a relationship between a compensation object and multiple parameters affecting the geometric error of the gear is obtained, namely a relationship between the C axis compensation quantity ΔE.sub.c.sup.k+1 at the position control time point t.sub.k+1 and the tracking error E.sub.c, E.sub.x and E.sub.y of each motion axis at the position control time point t.sub.k, is obtained, and the decoupling compensation model is obtained as follows:

ΔE.sub.c.sup.k+1=E.sub.c.sup.k+0.7000×E.sub.x.sup.k+1.7705×cos E.sub.a.sup.kE.sub.y.sup.k (6)

[0074] in formula (6): ΔE.sub.c.sup.k+1 is a C axis compensation quantity with a unit of mm.

E.sub.c.sup.(k+1)′=E.sub.c.sup.k+1−ΔE.sub.c.sup.k+1 (7)

in formula (7): E.sub.c.sup.(k+1)′ is the C axis tracking error when synchronous motion control is adopted at the position control time point t.sub.k+1, and the unit is rad;

[0075] (4): Calculate the Average Absolute Value and the Total Compensation Quantity of the Machining Errors.

[0076] Under the condition of not adopting the synchronous control method, average absolute values of three items of the machining errors of the total position control time t are respectively as follows:

[00010] $M_{a} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{a}^{k} .Math. = 0.001235; M_{p} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{p}^{k} .Math. = 0.001315; M_{β} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{β}^{k} .Math. = 0.001293$

[0077] M.sub.α is an average absolute value of tooth profile errors with a unit of mm, M.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-10.

[0078] Under the condition of adopting the synchronous control method, E.sub.b.sup.k, E.sub.c.sup.k′, E.sub.z.sup.k, E.sub.y.sup.k, E.sub.x.sup.k and E.sub.a.sup.k are taken into formulas (2), (3) and (4) to obtain F.sub.α.sup.k′, F.sub.p.sup.k′ and F.sub.β.sup.k′ of the position control time point t.sub.k, and average absolute values of three items of the machining errors of the total position control time t are respectively as follows:

[00011] $M_{a}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{a}^{k^{'}} .Math. = 0.000864; M_{p}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{p}^{k^{'}} .Math. = 0.000920; M_{β}^{'} = 0.1 \times {.Math.}_{k = 1}^{10} .Math. F_{β}^{k^{'}} .Math. = 0.000927$

[0079] M′.sub.α is an average absolute value of tooth profile errors with a unit of mm, M′.sub.p is an average absolute value of tooth pitch errors with a unit of mm, M′.sub.β is an average absolute value of tooth shape errors with a unit of mm, and k is 0-10.

[0080] The total compensation quantity for the total position control time t is:

S=10×(M.sub.α+M.sub.p+M.sub.β−M′.sub.α−M′.sub.p−M′.sub.β)=0.011325 (8)

[0081] in formula (8), S is the total compensation quantity for the total position control time t with a unit of mm, and the synchronized multi-axis motion control of the total position control time t is completed.

[0082] The effect of synchronized multi-axis motion control is shown in Table 4.

TABLE-US-00004 TABLE 4 F.sub.α.sup.k F.sub.p.sup.k F.sub.β.sup.k F.sub.α.sup.k′ F.sub.p.sup.k′ F.sub.β.sup.k′ t.sub.1 0.000837 0.000891 0.000761 0.000424 0.000451 0.000322 t.sub.2 0.002328 0.002478 0.002431 0.001491 0.001587 0.001541 t.sub.3 0.001637 0.001742 0.001754 −0.00069 −0.00074 −0.00072 t.sub.4 0.001391 0.00148 0.00144 −0.00025 −0.00026 −0.0003 t.sub.5 −0.0011 −0.00117 −0.0014 −0.00249 −0.00265 −0.00288 t.sub.6 −0.00156 −0.00166 −0.00182 −0.00045 −0.00048 −0.00065 t.sub.7 −0.00144 −0.00153 −0.00148 0.000118 0.000126 0.000175 t.sub.8 0.000294 0.000313 0.000203 0.001731 0.001842 0.001733 t.sub.9 0.001019 0.001084 0.000905 0.000725 0.000771 0.000592 t.sub.10 0.000752 0.0008 0.000734 −0.00027 −0.00028 −0.00035

[0083] Due to abrupt changes in motion error values of each axis, at a few position control time points, the values F.sub.α.sup.k′, F.sub.p.sup.k′ and F.sub.β.sup.k′ after compensation by synchronous motion control are greater than the values F.sub.α.sup.k, F.sub.p.sup.k and F.sub.β.sup.k without compensation by synchronous motion control, such as position control time points, t.sub.5 and t.sub.8 in Table 4. However, this does not affect the effectiveness of synchronous motion control for the total position control time.

[0084] It can be seen that under the condition of adopting the synchronous control method, average absolute values of three items of the machining error are smaller than the average absolute values of the corresponding items without the adoption of the synchronous control method. The total compensation quantity of the machining error was 0.011325 mm within the total position control duration of 11 mm.

Method For Synchronized Multi-Axis Motion Control Of Flexible Electronic Gearbox

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G05B19/402

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G05B19/404

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G05B19/416

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G06F17/18

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G06N7/00

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G05B2219/41359

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B23F23/006

PERFORMING OPERATIONS; TRANSPORTING

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G05B19/402

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G05B19/404

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G05B19/416

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G06F17/18

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G06N7/00

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