学校编码：10384 分类号 密级

学号：19920081152967 UDC

硕 士 学 位 论 文

四轴数控精密研磨平台系统设计与实现

The Design and Implementation of Four-axis Numerical Control Abrasive Table System

饶睿智

指导教师姓名：郭 隐 彪 教 授 专 业 名 称：测试计量技术与仪器 论文提交日期：2011 年 5 月 论文答辩时间：2011 年 月 学位授予日期：2011 年 月

答辩委员会主席： 评 阅 人：

2011 年 5 月

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2

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厦门大学博硕士论文摘要库

厦门大学硕士论文 摘 要

I

摘 要

精密和超精密加工技术的发展，直接影响尖端技术和国防工业的发展。世

界各国在这方面都极为重视，投入很大力量进行开发研究，同时技术保密，控制

出口。由于航空航天、尖端技术、多种高精密仪器仪表、惯导平台、光学和激光

技术的迅速发展和多领域的广泛应用，各种复杂高精度零件、光学零件、高精度

平面、曲面和复杂形状的加工，成为迫切任务。

本文针对目前精密加工的现状，提出了一种四轴数控精密研磨平台设计方

案，开发了一台 200mm×200mm×150mm 的四轴加工平台，即基于 PCI-1240 运

动控制卡来研究四轴数控研磨平台的运动控制，采用了基于上位机和下位机的双

CPU 开放式数控系统。系统采用工控 PC 机和 XP 操作系统，并选用 Visual C++6.0

作为开发工具，通过研究平面磨削及非球面研磨的加工理论，完成了以下内容：

1、完成了整个数控研磨平台机械结构与硬件系统的设计与搭建。本平台采

用性能稳定的 45 号钢为主要结构材料，采用伺服电机作为驱动机构，滚珠丝杠

为传动机构，滑动导轨作为导向机构，整个系统机构稳定，性能可靠。

2、完成了整个精密研磨平台控制系统的设计与调试，控制系统采用由计算

机、控制卡、驱动器、伺服电机、传动和导向机构加工刀具等部件连接而成的控

制系统。

3、通过研究平面磨削及非球面研磨的加工理论，介绍了几种常见的加工轨

迹规划，设计及实现了控制软件。软件的主要功能模块有初始化模块、基本运动

控制模块、直线插补模块。

4、设计了四轴数控研磨平台加工试验，并对控制系统进行测试，验证了平

台系统的可行性与有效性。

关 键 字：超精密加工；运动控制卡；加工轨迹

厦门大学博硕士论文摘要库

厦门大学硕士论文 Abstract

II

Abstract

Precision and ultra precision machine’s developing is directly influencing

sophisticated technology and defense industry’s development. Countries all over the

world pay high attention to this respect,put large into developing and researching,at

the same time,technology secrecy and control export. Owing to aerospace、

sophisticated technique、various high precision instruments、 inertial navigation

platform、 optics and laser technology developed rapidly and more extensive

application in the fields , a variety of complicated high-precision parts、optics parts、

high-precision flat surface、 curved surface and complex shape processing are

becoming urgent task.

This article is armed at the precision machining,which have made a new type

design of the 200mm × 200mm × 150mm four-axis numerical control precision

abrasive table,based on PCI-1240 motion control card that used to research the motor

control of the four-axis control grinding plate,used double CPU open numerical

control system based on upper computer and lower computer .This system have

adopted IPC and XP operating system, and choose Visual C++6.0 as the

development tool,by researching flat surface grinding and aspheric surface machining

processing theory. Completing the following content：

1. Completed the whole numerical control grinding plate mechanism and

hardware system’s design and rig. This platform have used 45 steel which has steady

performance as the main structural material,and adopted servo motor as the drive

mechanism,ball screw as transmission gear,slide guide as guide mechanism, overall

system have the stable mechanism and reliable function.

2. Completed the whole precision abrasive table’s design and debug,control

system adopted control system which is held together by computer、control card、

drive、servo motor、transmission 、guide mechanism and so on.

3. By researching flat surface grinding and aspheric surface machining

厦门大学博硕士论文摘要库

厦门大学硕士论文 Abstract

III

processing theory,introduced some common machining trajectory planning,design and

realize the control software. The main functional modules of the software initializing.

bas module、basic movement control module and linear motion.

4. Designed the four-axis numerical control abrasive table machining

experiment,tested the control system,and verified the practicability and validity of this

platform system.

Key Words： ultra precision machining；motion control card；machining trajectory.

厦门大学博硕士论文摘要库

厦门大学硕士论文 目录

IV

目 录

第一章 绪论 ..............................................................................................1

1.1 课题研究背景 ................................................1

1.1.1 非球面与球面的区别 .......................................1

1.1.2 非球面的种类及其优点 .....................................2

1.1.3 非球面的应用领域 .........................................3

1.1.4 非球面光学零件加工方法 ...................................3

1.2 精密研磨加工技术国内外发展现状 ..............................6

1.2.1 国外非球面光学零件加工设备及生产现状 .....................6

1.2.2 我国非球面光学零件加工设备及生产现状 ....................10

1.3 本文主要研究内容.............................................12

第二章 四轴数控研磨平台结构设计 ................................................. 13

2.1 四轴数控精密研磨平台原理 ...................................13

2.2 四轴数控精密研磨平台结构 ...................................14

2.2.1 总体结构 ................................................14

2.2.2 运动机构 ................................................16

2.3 四轴数控精密研磨平台研磨工具的选用 .........................17

2.3.1 砂轮磨削的特点 ..........................................17

2.3.2 砂轮的特性和选择 ........................................18

2.4 小结 .......................................................21

第三章 四轴数控精密研磨平台控制系统硬件设计 ......................... 22

3.1 控制系统硬件选型 ...........................................22

3.2 控制系统控制方案 ...........................................23

3.3 平台控制系统硬件 ...........................................25

3.3.1 运动控制卡 ..............................................25

3.2.2 伺服驱动器 ..............................................29

3.4 平台控制系统的连接 .........................................31

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3.5 小结 .......................................................32

第四章 四轴数控精密研磨平台控制系统软件设计 ......................... 33

4.1 系统软件开发平台选择 .......................................33

4.2 系统软件总体框架 ...........................................34

4.3 系统软件的主要实现模块 .....................................37

4.3.1 系统主界面 ..............................................37

4.3.2 初始化模块 ..............................................37

4.3.3 基本运动控制子界面 ......................................38

4.3.4 轨迹规划模块 ............................................40

4.3.5 直线插补子界面 ..........................................40

4.4 小结 .......................................................44

第五章 四轴数控精密研磨平台仿真与实验 ..................................... 45

5.1 加工实验总体规划 ...........................................45

5.2 几种常见的加工轨迹设计 .....................................45

5.2.1 轴对称光学元件加工轨迹规划 ..............................46

5.2.2 平面/斜面光学元件加工轨迹规划 ...........................49

5.2.3 非轴对称非球面加工轨迹规划 ..............................51

5.3 几种加工轨迹的仿真实验 .....................................54

5.3.1 螺旋线形轨迹加工仿真实验 ................................54

5.3.2 同心圆轨迹加工仿真实验 ..................................55

5.3.3 光栅式轨迹加工仿真实验 ..................................56

5.4 小结 .......................................................57

第六章 结论与展望 ............................................................................. 58

6.1 结论 .......................................................58

6.2 展望 .......................................................58

附 录........................................................................................................ 60

参 考 文 献 ........................................................................................... 65

致 谢........................................................................................................ 69

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硕士期间科研成果 ................................................................................. 70

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VII

Table of Contents

Chapter 1 Introduction ············································································1

1.1 Background ·····································································································1

1.1.1 The Distinguish Between Aspheric Surface and Sphere ·························· 1

1.1.2 The Kinds and Advantage of Aspheric Surface········································ 2

1.1.3 The Application Fields of Aspheric Surface ············································ 2

1.1.4 The Process Methods of Aspheric Surface Optics Part ···························· 3

1.2 Development of Precision Measurement Oversea and Domestic···············6

1.2.1 Aspheric Surface Optics Part’s Processing Equipment and Manufacturing Statusoversea······································································································· 6

1.2.2 Aspheric Surface Optics Part’s Processing Equipment and Manufacturing Status Domestic ······························································································· 10

1.3 Main Research Areas·······················································································12

Chapter 2 Four-axis Numerical Control Abrasive Table System ·····13

2.1 The Principle of Four-axis Numerical Control Abrasive Table ···············13

2.2 Mechanical Structure of Precision Measuring Platform ··························14

2.2.1 Framework Design ················································································ 14

2.2.2 Motion Mechanism················································································ 16

2.3 Abrasive Tool of Precision Measuring Platform········································17

2.3.1 Characteristics of Grinding Wheel Grinding·········································· 17

2.3.2 The Characteristics and Choose Wheel·················································· 18

2.4 Conclusion········································································································21

Chapter 3 The hardware design of four-axis numerical control

abrasive table control system ································································22

3.1 The Choose of Control System’s Hardware···············································22

3.2 The Control Scheme of Control System’s Hardware ································23

3.3 The Hardware of Platform’s Control System············································25

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VIII

3.3.1 Motion Control Card ············································································· 25

3.2.2 Servo Drivers························································································· 29

3.4 Connection of Control System·····································································31

3.5 Conclusion·····································································································32

Chapter 4 The Software Design of Four-axis Numerical Control

Abrasive Table Control System·····························································33

4.1 The Choose of System Software’s Development Platform························33

4.2 Software Architecture ··················································································34

4.3 The Main Modules Sac of System Software···············································37

4.3.1 The Main Interface of System ······························································· 37

4.3.2 Initialize. as Module ·············································································· 37

4.3.3 Basic Motion Control Sub-interface ······················································ 38

4.3.4 Trajectory Planning Sub-interface ························································· 40

4.3.5 Linear Interpolation Sub-interface ························································· 40

4.4 Conclusion·····································································································40

Chapter 5 Four-axis numerical control abrasive table machining

experiment ·······························································································45

5.1 The Master Plan of the Processing experiment ·········································45

5.2 Introduction of Some Common Machining Trajectory Designs ··············45

5.2.1 Axial Symmetry Optical Element’s Machining Trajectory Designs······· 46

5.2.2 Flat Surface/bevel Optical Element’s Machining Trajectory Designs ···· 49

5.2.3 Nonaxisymmetry Optical Element’s Machining Trajectory Designs ····· 51

5.3 The experiment of some machining trajectory designs································53

5.3.1 The Tracing of the Spiral line Machining ·············································· 53

5.3.2 The Tracing of the Concentric Circles Machining ································· 54

5.3.3 The Tracing of the Raster Machining ···················································· 55

5.4 Conclution ·····································································································56

Chapter 6 Summarize and Outlook···················································57

6.1 Summarize································································································ 58

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6.2 Outlook····································································································· 59

Appendix ··································································································60

References ································································································65

Acknowledgement ···················································································69

Published papers ·····················································································70

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厦门大学博硕士论文摘要库

厦门大学硕士论文 第一章 绪论

1

第一章 绪论

1.1 课题研究背景

近年来，随着光电子学的发展，非球面光学零件在军用和民用产品上的应

用也越来越普及，如在电视摄像管、卫星红外望远镜、录像机镜头、激光视盘装

置、光纤通信的接头、医疗仪器等中有广泛的应用。非球面加工已经发展成为一

个研究热点，我们有必要对非球面的特点及其加工技术等相关现状做以了解[1]。

一些主要的光学非球面器件的材料及应用领域如表 1.1 所示

表1.1 主要的光学元件器件的材料及应用领域

Table 1.1 The main optical component materials and applications

器材类型 材料 应用领域

普通镜头

红外线镜头

普通反射镜

折射模具

椭圆体反射镜

光学玻璃

单晶锗、单晶硅

铝合金、铜、磷青铜

陶瓷、镍合金

石英玻璃、碳化硅

显微镜、CD/DVD、投影仪

夜视镜、医用内视镜、激光加工

激光加工机、大型显示器

激光打印机

X射线系统

1.1.1 非球面与球面的区别

所谓球面和非球面，主要是针对各种光学仪器的镜头或者眼镜的镜片几何

形状而言，即球面镜片与非球面镜片[2]。球面是一种旋转曲面，球面上每一点的

曲面半径是相同的，球面镜片，其镜片程球面的弧度，其横切面亦程弧状。当不

同波长的光线，以平行于光轴的方向入射到镜片上不同的位置时，通过球面镜片

的折射作用，在菲林平面（与镜片中心和镜片焦点联机相垂直的、通过焦点的平

面）上不能聚焦成一点，而形成像差的问题，影响影响的质素，例如出现清晰度

下降和变形等现象。一般普通镜头基本都是采用球面镜组成的，而非球面可以说

是没有一点曲率半径的曲面，非球面镜片，其镜片并非呈球面的弧度，而是镜片

边缘部分被“削去”少许，其横切面呈平面状。当光线入射到非球面镜面时，光线

厦门大学博硕士论文摘要库

四轴数控精密研磨平台系统设计与实现

2

能够聚焦于一点，亦即菲林平面上，以消除各种像差。例如耀光现象，在球面镜

作用下，使用大光圈会比细光圈下拍摄来得严重，但若然加入非球面镜便可将耀

光情况大大降低；又例如影像呈现变形（枕装或桶状），是因为镜头内的光线没

有适当折射而产生，以变焦镜为例，短焦距时通常是桶状变形，而变焦至长焦时

则为枕状变形，若采用非球面镜，则可以改善这方面的像差。如图一所示，展示

了球面与非球面的光学特性。

图 1.1 球面与非球面的光学特性

Fig1.1 Optical characteristics of spherical surface and aspheric surface

1.1.2 非球面的种类及其优点

非球面主要应用于光学零件，非球面光学曲面包括有回转轴的回转非球面，

如抛物面、椭球面、渐开面、双曲面等二次曲面以及高次曲面，和没有任何对称

轴的非回转球面，如离轴非球面以及自由光学曲面[3]。相对于球面而言。它具有

许多优点，可以消除球面镜片在光学传递过程中产生的球差、慧差、像散、场曲

及畸变等诸多不利因素，减少光能损失，从而获得高质量的图像效果和高品质的

光学特征。一般来说，在光学仪器上，一块非球面透镜的作用相对于三块球面镜，

因此，光学仪器设备采用非球面镜片具有重量轻、透光性能好、成本低、且使光

学系统设计更具有灵活性的优点。图 1.2 显示了应用球面和非球面透镜的新旧电

视摄像管的比较。

厦门大学博硕士论文摘要库

Degree papers are in the “Xiamen University Electronic Theses and Dissertations Database”. Fulltexts are available in the following ways: 1. If your library is a CALIS member libraries, please log on http://etd.calis.edu.cn/ and submitrequests online, or consult the interlibrary loan department in your library. 2. For users of non-CALIS member libraries, please mail to etd@xmu.edu.cn for delivery details.

厦门大学博硕士论文摘要库