彈簧成型機之動態同步運動控制器設計

Abstract

多軸動態同動同停機制的要求，是彈簧成型機之關鍵核心架構，其動作模式需要其餘各軸跟隨一個連續運轉的主軸，在到達某一絕對位置時執行相對應跟隨運動。而彈簧成形之程序行進當中，更有可能隨時被探棒中斷。因此，彈簧成型機達成多軸動態同步互動命令之即時性處理，極為重要。 本研究透過機電整合控制技術，結合運動控制卡、驅動器、馬達，在一個非即時性作業系統平台上，建立起監視動態同步互動命令的一致性，進而分析出動態同動同停機制，突破在純軟體解決方案命令觸發不規律的瓶頸。本研究利用硬體取代需即時準確觸發命令的關鍵處，以非即時性軟體搭配即時性硬體的方法，完成多軸動態同步互動命令之即時性處理。本研究成功地將彈簧成型機動態同動同停核心機制的主軸速度，提升到1000RPM轉速，彈簧工件誤差可控制在0.04mm以內。進而，在有探棒接觸下，亦可將彈簧工件誤差控制在0.15mm以內，發展完成具競爭力的PC-Based電腦整合自動化核心模組系統。

For the spring forming machines, motions of all slave axes are required to be highly synchronized with a constant-speed master axis. Moreover, the spring forming processing may be interrupted by the probe beam and a sudden stop is required. Therefore, to achieve dynamic synchronization by applying real-time technologies becomes crucial for high-speed spring forming machines. In this study, the motion control card and the AC servo motors are integrated in a non real-time software platform. The approach by applying the Taylor’s expansion to monitor the processing speed is adopted to analyze the uniformity of the present processing. By applying the technique to trigger the processing command via as ASIC, a real-time processing control for the highly synchronized machine is then developed . This study successfully achieves high speed as 1000RPM in the master axis for the spring forming machines. Experimental results indicate that the processing error is limited to 0.04 mm for normal operations. As the probe beam is activated to interrupt the process, the present control limits the error within 0.15 mm to achieve satisfactory results.