The invention relates to the field of ultra-precision cutting technology, specifically a ultra-precision cutting quasi-static force measurement system based on piezoelectric ceramic sensor.
Ultra-precision cutting technology employs ultra-precision lathes with nanometer positioning accuracy and diamond tools that are sharp, hard, and wear-resistant. It achieves geometric surfaces by precisely controlling the relative motion trajectory between the tool and the workpiece, resulting in nanometer-level surface roughness and submicron-level shape precision micro-nanostructured surfaces. This technology is an important means for manufacturing optical components with micro-nano fine structures or high-precision shapes and is widely used in fields such as aerospace, national defense, information communication, life sciences, and material science. It is a significant branch in the field of ultra-precision machining.
In response to the trend towards extreme sizes of workpieces, complexities of machined surface shapes, and refinements of machined structures, as well as the market prospects for cross-scale micro-nanostructured surfaces (a type of surface with specific functions formed by large-scale distribution of micro-nano fine structures over large dimensions according to certain geometric rules), there is a need for effective online detection during the cross-scale machining process that involves ultra-long durations and high dynamic processes.
Cutting force can reflect the effective information of the machining state, hence, it is common to monitor the ultra-precision cutting process by detecting the variations in cutting force in real-time.
(1) Traditional methods for detecting ultra-precision cutting forces primarily rely on commercial dynamometers. However, existing commercial dynamometers suffer from poor structural dexterity, making it difficult to integrate them into ultra-precision cutting devices for high dynamic and sensitive cutting force detection.
(2) Piezoelectric ceramics, based on the positive piezoelectric effect, can be used as force sensors and have the advantages of being structurally nimble and highly sensitive. They are often integrated into the end of ultra-precision cutting tools/workpieces to detect the cutting forces during the machining process. Nevertheless, piezoelectric ceramics face a serious issue with charge leakage and are commonly used to detect alternating dynamic force processes (where the force variation continually charges the piezoelectric ceramic to compensate for charge leakage), making it challenging to detect static or quasi-static forces. Since the cutting process encompasses both dynamic and quasi-static components, a piezoelectric ceramic force sensor capable only of detecting dynamic forces but not quasi-static ones falls short of meeting the complete requirements for ultra-precision cutting state detection.
As shown in
The purpose of the invention is to provide a method based on dynamic compensation for charge leakage, to realize a ultra-precision cutting quasi-static force measurement system based on piezoelectric ceramic sensor.
The invention achieves its purpose in the following way:
A ultra-precision cutting quasi-static force measurement system based on piezoelectric ceramic sensor includes:
A piezoelectric ceramic force sensing unit, which is located at the machining end of the ultra-precision cutting system and is used for mounting a single-point diamond tool;
The piezoelectric ceramic force sensing unit generates a charge signal to an external post-processing module under the action of the single-point diamond tool; the post-processing module includes:
Preferably, the post-processing module also includes: a dynamic compensation module for charge leakage, which compensates the voltage output Ui of the Charge Preamplifier Circuit at the current moment based on the output voltage change |ui−Ui-1| between two adjacent moments and the circuit noise threshold uth1, as well as the voltage change |ui−ui-1| and the voltage decay threshold uth2=ui-1(1−e−T/τ) within the period T.
Preferably, the post-processing module also includes: an offset current compensation module, which dynamically compensates Ui=Ui−k1·i the voltage value Ui at a moment based on a pre-calibrated slope value i of output voltage deviation over time.
Preferably, the post-processing module also includes: a temperature compensation module, which dynamically compensates Ui=Ui−k2·ΔT; the voltage value Ui at a moment i based on a pre-calibrated slope k2 value of the correlation between output voltage variation and temperature change, where ΔTi is the change in ambient temperature relative to the moment i.
A ultra-precision cutting quasi-static force measurement method based on piezoelectric ceramic sensor includes the following steps:
Step one, continuously monitor the voltage signal on the piezoelectric ceramic force sensor and record the output value Ui of the charge amplifier at that moment; at the start of cutting, the first detected output value U of the charge amplifier is the actual output voltage U1 of the charge amplifier at that moment, and calculate the actual force
acting on the piezoelectric ceramic force sensor for the first time;
Step two, use the observed voltage Ui at the current moment and the voltage Ui-1 from the previous moment to calculate the dynamic variation voltage ΔUi generated by dynamic forces, that is,
Step three, calculate the dynamic force fi at the current moment,
c represents the linear coefficient between the output voltage of the charge amplifier and the force applied to the piezoelectric ceramic.
Step four, based on the calculation of the dynamic variation fi of force at each moment, by accumulating the dynamic variations of force from previous moments, the actual force Fi acting on the piezoelectric ceramic force sensor at the current moment can be obtained, that is
Preferably, in step one, the voltage signal on the piezoelectric ceramic force sensor is filtered as follows:
When the change |ui−ui-1| in output voltage between two adjacent moments is less than or equal to the circuit noise threshold uth1, and the voltage change is also less than or equal to the decay threshold uth2, the result ui-1e−T/τ of the voltage ui-1 decay from the previous moment is used as the calculated value Ui for the current moment and is substituted into step three.
Preferably, in step one, offset current compensation is performed: a pre-calibrated slope value k1 of the deviation of the output voltage over time is used to dynamically compensate Ui the voltage value Ui at a moment i,
Preferably, in step one, temperature compensation is performed: a pre-calibrated slope value k2 of the correlation between changes in output voltage and temperature changes is used to dynamically compensate Ui the voltage value Ui at moment i,
ΔTi is the change in ambient temperature of moment i relative to the initial moment's ambient temperature.
The invention exhibits prominent and beneficial technical effects compared to existing technologies:
This invention amplifies the weak charge signals generated by the piezoelectric ceramic force sensor integrated into the ultra-precision cutting device during the force application process through a Charge Preamplifier Circuit. Following the initial amplification, the signal sequentially passes through a low-pass filter circuit and ADC data acquisition, and then undergoes real-time processing in the DSP signal processor. Starting from the principle of charge leakage effect in piezoelectric ceramics, the invention realizes the quasi-static force detection function based on dynamic compensation for charge leakage in the piezoelectric ceramic force sensor. The results obtained from the quasi-static force compensation algorithm described by the invention show that it is not only sensitive to instantaneous changes in applied force but also maintains this sensitivity consistently, thus enabling the measurement of quasi-static forces, meaning it can reflect the actual force acting on the piezoelectric ceramic force sensor at any given moment.
The structure of the invention is ingenious and has good integration performance. Compared to commercial dynamometers with fixed structures that lack flexibility, the method described by this invention is based on ordinary piezoelectric ceramic force sensors. Piezoelectric force sensors are small in size and have an ingenious structure, which makes them convenient to integrate at the tool end of ultra-precision cutting devices as a tool holder, allowing for the perception of ultra-low cutting forces close to the site of the ultra-precision cutting process.
This invention has broad measurable types of forces. The method described is not only capable of performing traditional dynamic force detection functions based on piezoelectric force sensors but also breaks through the limitations caused by charge leakage issues that make it difficult to detect static and quasi-static forces. It achieves comprehensive measurement coverage of dynamic, quasi-static, and static forces based on highly integrated, rigid, and sensitive piezoelectric ceramic force sensors.
Below, in conjunction with the accompanying figures, provides a further detailed explanation of the specific embodiments of the present invention.
As shown in
A ultra-precision cutting quasi-static force measurement system based on piezoelectric ceramic sensor includes:
A piezoelectric ceramic force sensing unit 1, located at the machining end of the ultra-precision cutting system 14, and used for mounting the single-point diamond tool 13; The piezoelectric ceramic force sensing unit 1 is a piezoelectric ceramic force sensor integrated into the ultra-precision cutting device, which produces weak charge signals during the application of force;
The piezoelectric ceramic force sensing unit 1, when subjected to the force exerted by the single-point diamond tool 13, generates a charge signal that is transmitted to an external post-processing module. This post-processing module includes:
where
The time interval T depends on the computational power of the processor, which affects the frequency of real-time processing. The processor used in this invention has an interval of about 1 ms, corresponding to 1 kHz. Theoretically, the stronger the computational power of the processor, the shorter the time interval T and the higher the precision.
Preferably, the post-processing module also includes: a charge leakage dynamic compensation module 10, which compensates the voltage output Ui of the preamplifier circuit at the current moment based on the change |ui−ui-1| in output voltage between adjacent moments and the circuit noise threshold uth1, as well as the change |ui−ui-1| in voltage and the voltage decay threshold uth2=Ui-1(1−e−T/τ) within the cycle time T.
Preferably, the post-processing module also includes: an offset current compensation module 11, which performs dynamic compensation Ui=Ui−k1·i on the voltage value Ui at the moment i based on a pre-calibrated slope value k1 of the deviation of the output voltage over time.
Preferably, the post-processing module also includes: a temperature compensation module 12, which performs dynamic compensation Ui=Ui−k2·ΔT; on the voltage value Ui at the moment i based on a pre-calibrated slope value k2 of the correlation between changes in output voltage and temperature changes, where ΔTi is the change in ambient temperature relative to the moment i's ambient temperature.
A ultra-precision cutting quasi-static force measurement method based on piezoelectric ceramic sensor includes the following steps:
Step 1, continuously detect the voltage signal on the piezoelectric ceramic force sensor and record the output value Ui of the charge amplifier at that moment; if the dynamic varying force acting on the piezoelectric ceramic force sensor at any moment is fi, then the contribution of this dynamic force to the output of the charge amplifier at that moment is ΔUi,
At the start of cutting, the initially detected output value Ui of the charge amplifier is the actual output voltage U1 of the charge amplifier at that moment, and the initial dynamic varying force f1 is the actual force F1 initially applied to the piezoelectric ceramic force sensor,
Step 2, use the current moment's charge amplifier output value Ui and the previous moment's charge amplifier output value Ui-1 to calculate the dynamic varying voltage ΔUi generated due to the dynamic force,
Step 3, calculate the dynamic varying force fi at the current moment,
c represents the linear coefficient between the output voltage of the charge amplifier and the force applied to the piezoelectric ceramic;
Step 4, based on the solution fi of the dynamic varying force at each moment, the actual force Fi acting on the piezoelectric ceramic force sensor at the current moment can be obtained by accumulating the dynamic varying forces from previous moment i, that is
Preferably, in Step 1, as shown in
Preferably, in Step 1, as shown in
Preferably, in Step 1, as shown in
ΔTi represents the change in ambient temperature relative to the moment i's ambient temperature.
In summary, the function of measuring quasi-static forces with the piezoelectric ceramic force sensor is realized based on charge leakage dynamic compensation, and the precision of quasi-static force detection is achieved through the offset current compensation module and temperature compensation module.
To further verify the effectiveness of the method described in this invention, a comparison was made with a commercial dynamometer, and the results are shown in
In the upper part of
The middle part of
The lower part of
The actual detection process of this system: Each detection starts from zero. At the beginning of cutting, the first detected output value Ui of the charge amplifier is the actual output voltage U1 of the charge amplifier at that moment, and the first actual force F1=U1/c is obtained through the formula. During the second detection, the current output voltage U2 is used as a basis, and is subtracted the residual charge U1e−T/τ from U1 due to charge leakage to obtain the actual increased voltage ΔU2 for the second detection. Then based on the actual increased voltage ΔU2, the actual dynamic changing force f2 is calculated. By accumulating the dynamic changing force f2 based on the F1, the actual force F2 acting on the single-point diamond tool 13 at the current moment can be obtained, and so forth.
The above embodiments and descriptions in the specification are only to illustrate the principles of the invention. Under the premise of not departing from the spirit and scope of the invention, there may be various modifications and improvements, which fall within the scope of the invention as claimed. The scope of protection sought by the invention is defined by the attached claims and their equivalents.
The present application is a continuation of International Application No. PCT/CN2021/139402, with an international filing date of Dec. 18, 2021, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/CN2021/139402 | Dec 2021 | WO |
Child | 18746110 | US |