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外文翻译--越智能制造新一代柔性智能数控机 英文版.pdf

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外文翻译--越智能制造新一代柔性智能数控机 英文版.pdf

TIONANDSELFHEALINGWILLBEPRESENTEDWITHGREATFEATURESASWELLASCHALLENGESRELATEDTOZEROOFINTELLIGENTBENEFITSTHEMACHININGPROCESSMONITORINGANDCONTROLISACORECONCEPTONWHICHTOBUILDUPTHENEWGENERATIONOFFLEXIBLESELFOPTIMISINGINTELLIGENTNCMACHINESINPROCESSMEASUREMENTANDPROCESSINGOFTHEINFORMATIONPROVIDEDBYDEDICATEDSENSORSINSTALLEDINTHEMACHINE,ENABLESAUTONOMOUSDECISIONMAKINGBASEDONTHEONLINEDIAGNOSISOFTHECORRECTMACHINE,WORKPIECE,TOOLANDMACHININGPROCESSCONDITION,LEADINGTOANINCREASEDMACHINERELIABILITYTOWARDSZERODEFECTS,TOGETHERWITHHIGHERPRODUCTIVITYANDEFFICIENCYINDEED,THEMAINSENSINGANDPROCESSINGTECHNIQUESINTHELITERATURE3–5FOCUSON0094114X/SEEFRONTMATTERC2112008ELSEVIERLTDALLRIGHTSRESERVEDCORRESPONDINGAUTHORTEL441612003804EMAILADDRESSSMEKIDMANCHESTERACUKSMEKIDMECHANISMANDMACHINETHEORY442009466–476CONTENTSLISTSAVAILABLEATSCIENCEDIRECTMECHANISMANDMACHINETHEORYDOI101016/JMECHMACHTHEORY200803006UNDERVERYTIGHTCONDITIONS1,2THEMACHINETOOLINDUSTRYISRESPONDINGTOANUMBEROFREQUIREMENTS,EGE_COMMERCE,JUSTINTIMEPRODUCTIONANDMOSTIMPORTANTLYZERODEFECTCOMPONENTTHISISFACILITATEDBYINTEGRATINGNEWMATERIALS,DESIGNCONCEPTS,ANDCONTROLMECHANISMSWHICHENABLEMACHINETOOLSOPERATINGATHIGHSPEEDWITHACCURACIESBELOWTHAN5LMHOWEVERTHEINTEGRATIONOFHUMANEXPERIENCEINMANUFACTURINGTOWARDSFLEXIBLEANDSELFOPTIMISINGMACHINESISWIDELYMISSINGTHISCANBEACHIEVEDBYENHANCINGEXISTINGCOMPUTINGTECHNOLOGIESANDINTEGRATINGTHEMWITHHUMANKNOWLEDGEOFDESIGN,AUTOMATION,MACHININGANDSERVICINGINTOEMANUFACTURINGTHENEXTGENERATIONWILLBEDESCRIBEDASNEWINTELLIGENTRECONFIGURABLEMANUFACTURINGSYSTEMSWHICHREALISESADYNAMICFUSIONOFHUMANANDMACHINEINTELLIGENCE,MANUFACTURINGKNOWLEDGEANDSTATEOFTHEARTDESIGNTECHNIQUESTHISMAYLEADTOLOWCOSTSELFOPTIMISINGINTEGRATEDMACHINESITWILLENCOMPASSFAULTTOLERANTADVANCEDPREDICTIVEMAINTENANCEFACILITIESFORPRODUCINGHIGHQUALITYERRORFREEWORKPIECESUSINGCONVENTIONALANDADVANCEDMANUFACTURINGPROCESSES1INTRODUCTIONCOMPLEXCOMPONENTMACHINEDWITHLENGEREQUIREDFORTHENEWGENERATIONUCTSANDPROCESSESOFFERSSUBSTANTIALHIGHERQUALITYANDBETTERRELIABILITYVARIOUSASPECTSOFTHENEXTGENERATIONOFINTELLIGENTMACHINETOOLCENTRESC2112008ELSEVIERLTDALLRIGHTSRESERVEDDEFECTSISATOPPERFORMANCEINMASSPRODUCTIONANDITBECOMESANEWCHALMACHINETOOLSINCREASINGTHEPRECISIONANDACCURACYOFMACHINES,PRODTOAWIDERANGEOFAPPLICATIONSFROMULTRAPRECISIONTOMASSPRODUCTIONWITHRECENTDEVELOPMENTOFULTRAPRECISIONMACHINESISREACHINGNANOMETREPRECISIONBEYONDINTELLIGENTMANUFACTURINGANEWGENERATIONOFFLEXIBLEINTELLIGENTNCMACHINESSMEKIDA,,PPRUSCHEKB,JHERNANDEZCATHEUNIVERSITYOFMANCHESTER,SCHOOLOFMECHANICAL,AEROSPACEANDCIVILENGINEERING,MANCHESTERM601QD,UKBINSTITUTEFORCONTROLENGINEERINGOFMACHINETOOLSANDMANUFACTURINGUNITS,UNIVERSITYOFSTUTTGART,GERMANYCIDEKOTECHNOLOGICALCENTRE,ARRIAGAKALEA,220870ELGOIBAR–GIPUZKOA,SPAINARTICLEINFOARTICLEHISTORYRECEIVED30NOVEMBER2006RECEIVEDINREVISEDFORM3MARCH2008ACCEPTED4MARCH2008AVAILABLEONLINE29APRIL2008ABSTRACTNEWCHALLENGESFORINTELLIGENTRECONFIGURABLEMANUFACTURINGSYSTEMSAREONTHEAGENDAFORTHENEXTGENERATIONOFMACHINETOOLCENTRESZERODEFECTWORKPIECESANDJUSTINTIMEPRODUCTIONARESOMEOFTHEOBJECTIVESTOBEREACHEDFORBETTERQUALITYANDHIGHPERFORMANCEPRODUCTIONSUSTAINABILITYREQUIRESAHOLISTICAPPROACHTOCOVERNOTONLYFLEXIBLEINTELLIGENTMANUFACTUREBUTALSOPRODUCTANDSERVICESACTIVITIESNEWROUTESPHILOSOPHYOFPOSSIBLEMACHINEARCHITECTUREWITHCHARACTERISTICSSUCHASHYBRIDPROCESSESWITHINPROCESSINSPECJOURNALHOMEPAGEWWWELSEVIERCOM/LOCATE/MECHMTONTHEOTHERHAND,SPECIALATTENTIONHASTOBEPAIDTOTHELATTERPROCESSCONTROLSTRATEGIESACOCHARACTERISTICEXAMPLESSMEKIDETAL/MECHANISMANDMACHINETHEORY442009466–476467CANBEFOUNDAT15–19THEMAINFUNCTIONALITYPROVIDEDBYSUCHCONTROLSYSTEMSISTHEPOSTPROCESSSELFOPTIMISATIONOFPROCESSPARAMETERSETUPIEFEEDS,DEPTHSOFCUT,ETC,WITHTHEOBJECTIVEOFSETUPTIMEMINIMISATION,PROCESSKNOWLEDGEMANAGEMENTANDPROCESSOPTIMISATION,TOWARDSFLEXIBLEJUSTINTIMEPRODUCTIONWITHTHEINPROCESSMONITORINGOFPROCESSPERFORMANCEANDTHEPOSTPROCESSMEASUREMENTOFTHERESULTINGPARTQUALITY,AKNOWLEDGEBASEDPROCESSMODELISUSEDTODETERMINETHENEWOPTIMISEDSETOFCUTTINGPARAMETERS,ENABLINGAUTONOMOUSSELFOPTIMISATIONINTHESAMEWAY,ASAPREVIOUSSTEPTOOPTIMISATION,ACOSYSTEMSAREALSOAPPLIEDTOSELECTTHEFIRSTPROCESSSETUPFORNEWPARTQUALITYANDPROCESSREQUIREMENTSTHEREFORE,IFAFLEXIBLEINTELLIGENTNCMACHINETOOLISTOBEDEVELOPED,PROCESSKNOWLEDGEBASEDMODELSAREACOMPONENTOFPRIMARYIMPORTANCETOBEINTEGRATEDUNDERTHEMACHINETOOLCONTROLARCHITECTUREINADDITIONTOTHEADAPTATIONOFCONTROLPARAMETERSACCORDINGTOPROCESSCONDITIONS,CONTROLPARAMETERSHAVEALSOTOBEOPTIMALDURINGHANDLINGINCLUDINGCHANGINGOPERATIONSOFWORKPIECESANDTOOLSANDPOSITIONINGOPERATIONSASTHESEOPERATIONSACCOUNTTYPICALLYFORMORETHAN50OFTHEOVERALLOPERATINGTIMEEARLIERMETHODSFORPARAMETEROPTIMISATIONCONCENTRATEDONTHEREDUCTIONOFPOSITIONINGANDSETTLINGTIMESOFTHEFEEDAXISBYTUNINGONLYAFEWBASICCONTROLPARAMETERSEGGAINOFTHEPOSITIONCONTROLLOOPANDGAINANDRESETTIMEOFTHEVELOCITYCONTROLLOOPWITHINCREASEDCOMPUTATIONALPOWER,OPTIMISATIONMETHODSASDESCRIBEDIN20CANNOWBEREINVESTIGATEDFORTHEUSEWITHAWIDERPARAMETERSETINCLUDINGTHEPARAMETERSFORACCELERATIONANDJERKLIMITSWHICHAREDIRECTLYINFLUENCINGTHEVIBRATIONSOFANAXISIFTHECHARACTERISTICSOFACONTROLLEDAXISAREKNOWNBYMEANSOFTHEVIBRATIONBEHAVIOUR,ANADEQUATEGENERATIONOFTHEPROGRAMMEDTRAJECTORIESCANYIELDAFURTHEROPTIMISATIONMETHODSFORINPUTSHAPING49CANBEUSEDTODESIGNTRAJECTORIESTHATDONOTEXCITERESONANTFREQUENCIESOFAGIVENSYSTEMHENCE,SETTLINGTIMESANDTHUSPOSITIONINGTIMESCANBEFURTHERREDUCEDCONCERNINGPARAMETEROPTIMISATIONTHROUGHSELFLEARNINGPARTICULARLY,THEINTERESTOFTHESOCALLEDMACHINELEARNINGAPPROACHES21WILLBEINTRODUCEDASTHEMAINRESEARCHTRENDINPROCESSMONITORINGANDCONTROLSTRATEGIESTOWARDSTHEINTELLIGENTMANUFACTURINGSYSTEM2EXPECTEDCHARACTERISTICSOFTHENEXTGENERATIONTHEEXPECTEDCHARACTERISTICSOFTHENEXTGENERATIONOFMACHINECENTRESAREDESCRIBEDASFOLLOWSAINTEGRATIONDEVELOPMENTOFANINTEGRATEDMACHINETOOLBEINGCAPABLEOFPERFORMINGBOTHCONVENTIONALANDNONCONVENTIONALPROCESSESINONEPLATFORMBBIDIRECTIONALDATAFLOWDEFINITIONOFABIDIRECTIONALPROCESSCHAINFORUNIFIEDDATACOMMUNICATIONEXCHANGEBETWEENCAD,CAM,CNCANDDRIVESYSTEMSCPROCESSCONTROLLOOPDEVELOPMENTANDCNCINTEGRATIONOFROBUSTANDRELIABLEREALTIMESTRATEGIESFORTHEINPROCESSTOOL,PART,ANDPROCESSCONDITIONMONITORINGANDCONTROLDPREDICTIVEMAINTENANCESPECIFICATIONOFALOADANDSITUATIONDEPENDENTCONDITIONMONITORINGFORMACHINECOMPONENTSASABASISFORSELFRELIANTMACHINEOPERATIONTHISWILLBEFOLLOWEDBYTHEFORMULATIONOFASELFORGANISINGPREDICTIVEMAINTENANCESCHEDULETHATISBASEDONSELFANDREMOTEDIAGNOSTICSANDCOVERSBOTHSHORTANDLONGTERMASPECTSEAUTONOMOUSOPTIMISATIONDEVELOPMENTOFASELFCONFIGURINGSELFOPTIMISINGCONTROLSYSTEMFORAUTONOMOUSMANUFACTURING,BASEDONTHEINPROCESSMONITORING,CHARACTERISATIONANDMANAGEMENTOFPROCESSKNOWLEDGETOFACILITATESUCHCHARACTERISTICS,THEFOLLOWINGTOPICSWILLBENECESSARYTOBEIMPLEMENTEDATODEVELOPANINTEGRATEDINTELLIGENTMACHINECENTREDEDICATEDTOEMANUFACTURINGBTOINVESTIGATEANDDEVELOPFAST,STABLEANDSTIFFRECONFIGURABLEMACHINESWITHHYBRIDMACHININGPROCESSESTOPREPAREANEWPLATFORMFORFUTUREMACHINETOOLSCTOINVESTIGATEIMPLEMENTATIONOFTOTALERRORCOMPENSATIONANDINSITUINSPECTIONFACILITYMONITORINGSTRATEGIESFORPARTCONDITIONMONITORINGSURFACEROUGHNESS,SURFACEINTEGRITYANDDIMENSIONALACCURACY,TOOLCONDITIONMONITORINGTHESOCALLEDTCMFORWEARANDBREAKAGEDETECTION,PROCESSCONDITIONMONITORINGCHATTERONSETANDCOLLISIONDETECTIONANDMACHINECOMPONENTCONDITIONMONITORINGFORPREDICTIVEMAINTENANCEPURPOSESROTARYCOMPONENTSANDPARTSSUBJECTTOFRICTIONSUCHASGUIDEWAYSSINCEDIRECTANDINPROCESSMEASUREMENTISNOTGENERALLYPOSSIBLEDUETOTHEAGGRESSIVEENVIRONMENTINTHECUTTINGZONESURROUNDINGS,THEMAINRESEARCHEFFORTOVERTHELASTDECADESFORPARTANDTOOLMONITORINGHASBEENFOCUSEDONINDIRECTMEASUREMENTTECHNIQUESPROCESSCONDITIONBASED,INWHICHCUTTINGPROCESSCHARACTERISTICSIECUTTINGFORCESANDPOWER,VIBRATIONS,CUTTINGTEMPERATURE,ACOUSTICEMISSION,ETCAREMEASUREDINORDERTOINDIRECTLYINFERTHEPARTANDTOOLCONDITION6,7SENSITIVITYOFFEREDBYCNCINTERNALSERVOSIGNALSFROMOPENARCHITECTURECONTROLLERSISUNDERSTUDYASWELL8,9,SINCETHEYENABLETHEDEVELOPMENTOFMONITORINGANDCONTROLSTRATEGIESWITHOUTTHENEEDOFINSTALLINGADDITIONALSENSORSINTHEMACHINEINTHESAMEWAY,BASEDONTHEDATAPROVIDEDBYINPROCESSMONITORING,AUTONOMOUSSELFOPTIMISATIONCANBEPERFORMEDWITHTHEINTEGRATIONOFPROCESSCONTROLSTRATEGIESINTOTHEMACHINETOOLCONTROLARCHITECTUREMACHININGPROCESSCONTROLSTRATEGIESARECLASSIFIEDINTOTWOMAINGROUPS5,NAMELYADAPTIVECONTROLCONSTRAINTACCANDADAPTIVECONTROLOPTIMISATIONACOINTHEFORMERACCCONTROLSTRATEGIES,APROCESSVARIABLEIECUTTINGFORCEISKEPTCONSTANTANDUNDERCONTROLTHROUGHTHEREALTIMEINPROCESSREGULATIONOFACUTTINGPROCESSPARAMETERIECUTTINGFEED,WITHTHEAIMOFINCREASINGPROCESSPRODUCTIVITYANDREPEATABILITYMAINRESEARCHEFFORTSONACCSTRATEGIESFOCUSONCUTTINGFORCECONTROL10–12ANDCHATTERVIBRATIONSUPPRESSION13,14DRAWBACKTODEALWITH468SMEKIDETAL/MECHANISMANDMACHINETHEORY442009466–476INDEED,FLEXIBLEMONITORINGSYSTEMSAREREQUIREDUNDERTHEACTUALMARKETREQUIREMENTSANDTHUS,RELIABLEPROCESSDIAGNOSISISNECESSARYUNDERDIFFERENTCUTTINGCONDITIONSNOWADAYS,ACOMMONPROBLEMATICSHAREDBYCONVENTIONALPROCESSMONITORINGAPPROACHESFORPARTANDTOOLCONDITIONMONITORINGISTHELACKOFRELIABILITYUNDERCHANGINGCUTTINGCONDITIONSHENCELIMITINGTHEFLEXIBILITYOFSUCHAUTOMATIONSYSTEMS3ASACHARACTERISTICEXAMPLEOFTHISPROBLEMATICFORPROCESSCONDITIONBASEDTOOLCONDITIONMONITORINGTCM,THEPROCESSCONDITIONISNOTONLYINFLUENCEDBYCHANGESINTOOLCONDITION,BUTITISALSODIRECTLYAFFECTEDBYCUTTINGCONDITIONSFURTHERMORE,UNDERDIFFERENTCUTTINGCONDITIONS,DIFFERENTWEARMECHANISMSCANBEACTIVATEDONTHETOOL,EACHONEHAVINGITSPARTICULARIMPACTONPROCESSANDPARTCONDITIONTHEREFORE,WHENSETTINGUPPROCESSMONITORINGSYSTEMSFORNEWCUTTINGCONDITIONS,PREVIOUSTRIALSFORPROCESSSIGNALDATABASERETRIEVALAREREQUIRED4THESEARECOMBINEDTOGETHERWITHSKILLEDOPERATORSWITHTHENECESSARYPROCESSKNOWLEDGEINORDERTOINTERPRETCHANGESINPROCESSBEHAVIOURIEFORCES,VIBRATIONS,ETCANDSETUPSUITEDDETECTIONLIMITSADDITIONALLY,FLEXIBLEPROCESSMONITORINGEQUIPMENTSOFTENREQUIRESADDITIONALSENSORSTHATCANFAILANDRESULTINUNFORESEENDOWNTIMEASARESULT,WHENHIGHFLEXIBILITYISREQUIRED,MONITORINGSYSTEMSAREUSUALLYSWITCHEDOFFININDUSTRY,ANDDIRECTPOSTPROCESSMEASUREMENTISPERFORMED,WITHTHECORRESPONDINGRELIABILITYLACKINTHEMACHINEDPARTQUALITYDEALINGWITHSUCHAPROBLEMATIC,MODELBASEDPROCESSMONITORINGANDSENSORFUSIONAPPROACHESAREPOINTEDOUTASTHEALTERN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