基于数字孪生的五轴机床复合轮廓误差控制方法

Combined contour error control method for five-axis machine tools based on digital twin.

作者信息

Wang Liuquan, Yang Ruijie, Lv Shisheng, Yang Zhiqi, Xin Shuwei, Liu Yanqiang, Liu Qiang

机构信息

School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, China.

Jiangxi Research Institute of Beihang University, Nanchang, 330096, China.

出版信息

Sci Rep. 2025 May 22;15(1):17809. doi: 10.1038/s41598-025-02047-2.

DOI:10.1038/s41598-025-02047-2

PMID:40404807

原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC12098878/

Abstract

Contour error is a critical factor influencing machining quality. This paper proposes a combined contour error control method for five-axis machine tools based on digital twin. The proposed method combines pre-compensation implemented in digital twin with feedback control in the real-time controller. After obtaining the tool path input, the digital twin performs interpolation and applies model predictive pre-compensation control to the interpolated commands to control modeled errors. The pre-compensated commands and interpolation data are sent to the real-time controller where contour error is estimated and controlled in each control cycle through feedback control to control unmodeled errors. Using the S-shaped curve as the test case, the maximum tool tip position contour error is reduced by 77.78%, with an average reduction of 83.90%. The maximum tool orientation contour error decreased by 79.05%, with an average reduction of 86.66%. The experimental results demonstrate that the proposed method significantly reduces tool contour error.

摘要

轮廓误差是影响加工质量的关键因素。本文提出了一种基于数字孪生的五轴机床组合轮廓误差控制方法。该方法将数字孪生中实现的预补偿与实时控制器中的反馈控制相结合。在获得刀具路径输入后，数字孪生进行插补，并对插补命令应用模型预测预补偿控制以控制建模误差。预补偿命令和插补数据被发送到实时控制器，在实时控制器中，通过反馈控制在每个控制周期估计和控制轮廓误差，以控制未建模误差。以S形曲线为例进行测试，刀具尖端位置的最大轮廓误差降低了77.78%，平均降低了83.90%。刀具方向的最大轮廓误差降低了79.05%，平均降低了86.66%。实验结果表明，所提出的方法显著降低了刀具轮廓误差。