【作者】 库祥臣；

【导师】 王润孝； 李济顺；

【作者基本信息】 西北工业大学 ， 机械电子工程， 2007， 博士

【摘要】 随着工业的发展，作为基础零部件的弹簧的应用日益广泛，对弹簧空间形状和成形精度的要求也在不断的提高。应对这种变化，适宜于加工具有复杂形状的异形弹簧的数控卷簧设备在弹簧的生产制造中发挥着越来越重要的作用。但由于各种条件的限制，我国在弹簧卷制设备制造方面与工业发达国家之间存在很大的差距，该领域主要被进口产品所占领，因此，开发具有自主知识产权的先进弹簧卷制设备对全面提升我国弹簧制造业水平显得尤为迫切和十分必要。另一方面，弹簧作为一种常见产品，人们往往忽视对其先进制造方法的研究，造成对弹簧数控卷制的研究比较薄弱。而实际上，由于弹簧卷绕成形的特点和卷绕设备工作方式的特殊性，数控卷簧设备在使用过程中存在自动化程度低、对经验的依赖性强、操作不方便等缺陷。因此，对弹簧制造过程进行深入研究具有重要的理论意义和应用价值。鉴于此，本文在教育部高等学校博士学科点专项科研基金项目和洛阳市科技攻关项目的支持下，通过对国内外的弹簧卷绕设备生产现状和发展趋势的调查与总结，概括了弹簧卷绕制造的特点和规律，分析了弹簧卷绕过程中存在的问题和制约因素，并将数字化制造、基于知识工程等先进制造技术与理念应用于弹簧卷制领域，建立了以CAD／CAPP／CAM为核心的弹簧数字化制造系统并将之应用于生产实践中，期望能在弹簧的数控制造方面有所突破。论文的主要研究内容包括：1．总结了弹簧卷绕成形的原理、过程和特点，并针对传统弹簧卷制过程中缺少精确的数学计算，主要依靠手工试制获取弹簧加工参数的缺陷，计算分析了与弹簧卷绕过程有关的工艺参数和影响因素，分解了弹簧卷制的步骤，提炼整理了典型弹簧的凸轮布局、刀具选择、参数确定等工艺过程，建立了弹簧形状与卷绕方式之间的联系。这些知识和规则可以帮助计算机方便地参与弹簧卷制过程，从而为弹簧的数字化制造作好了技术准备。2．根据弹簧的成形规律和制造特点，提出了以弹簧的CAD／CAPP／CAM为核心的弹簧数字化制造的概念，明确了系统的总体框架和功能结构，并根据面向对象的设计方法对系统的需求和功能进行分析，利用UML建立了系统静态模型和动态模型。数字化制造技术可以实现弹簧的设计、制造一体化，为弹簧的数控加工提供了新的实现方法。3．品种繁杂的异形弹簧由于具有复杂多变的末端结构，很难用一些简单的参数来完整地概括和表达其形状，造成了在弹簧的数控加工时，需要借用电机转角、送线长度等机床的动作参数来间接规定弹簧的样式，给弹簧的数控加工带来了很大的不便。本文将特征技术引入到弹簧的表达过程中，通过对弹簧类零件的形状特点和成形方式的研究，创造性地提取出了四种具有一定工程语义的基本结构特征，通过组合关系的确定和空间位置的解算，使其相互拼接组合从而构成复杂形状的异形弹簧。以形状特征为载体，利用弹簧零件的不同特征分类和层次结构，建立了弹簧零件信息表达模型，为弹簧的数字化制造提供了完整的信息源。4．弹簧的三维显示可以使操作者提前了解弹簧效果，减少试制时间，但目前的卷簧设备大多不具备这样的功能。本文以开放图形程序库OpenGL作为几何建模工具，研究了弹簧实体表面的三维离散技术和空间点的存贮方式，实现了异形弹簧的实体造型，并提出了一种替代算法对弹簧末端过渡部分进行了光滑处理。这种方式造型逼真，而且便于嵌入到集成系统中。5．弹簧卷绕成形时首先需要确定卷绕的动作顺序并完成对机床的配置，主要包括有关工装的选择、布局、调整和参数选取，这个过程耗时费力，经验性强，成为了弹簧数控加工的瓶颈。本文将人工智能应用到弹簧卷绕过程中，利用基于规则和基于实例的混合推理策略来完成弹簧卷绕工艺设计，并把形状特征编码矩阵作为判断实例相似的依据，规划了三级搜索过程来完成弹簧形状的匹配。基于知识的弹簧卷绕工艺规划方法改变了传统的调机方式，对提高弹簧加工的自动化水平和生产效率具有重要的意义。6．利用上述的有关研究成果，设计了独具特色的弹簧卷制数控指令和编程格式，开发了异形弹簧数字化制造系统，实现了弹簧卷绕过程的信息共享，完成了弹簧零件特征建模、三维造型、工艺设计、自动编程等功能，并将之应用于课题协作方的新产品开发中，较好地满足了弹簧现代化生产的需要。更多还原

【Abstract】 With the development of industry, the increasing interest in quality control andproduction efficiency is also having impact in the spring production field. Copingwith this situation, the CNC spring coiler that suited for coiling special-shape spring isplaying more and more important role in the spring manufacturing process. Butbecause of various restricting factors, there is big gap between China and otherdeveloped countries in the spring manufacturing technologies. Therefore, the researchon spring coiler will have important significance for promoting the development ofour country’s spring manufacturing industry.On the other hand, as a kind of common mechanical product, the research ofadvanced manufacture method for spring is often neglected. But in fact, there aresome problems of spring coiler, such as lower automation and inconvenient operation.So, it has important theory significance and application value to deeply study thespring coiling process.For the reasons mentioned above, the main problems and restriction factors ofspring coiling process are analyzed and the spring digital manufacturing system isestablished in this dissertation. The main contents and achievements of thedissertation are as follows:1. The spring coiling process and principle are illuminated, some parameterswhich influence the coiling are analyzed, the coiling step of spring with typical shapefeature are decomposed, the corresponding relations between the spring spatial shapeand coiling method are established, the knowledge and rule about spring coiling areconstructed. All these works provide the important foundation for the digitalmanufacturing of spring.2. Based on the problems of the spring coiling, the concept of spring digitalmanufacturing which in core of CAD/CAPP/CAM is put forward. Several mainsupporting technologies of the spring digital coiling system are defined and studied.According to the viewpoint of object-oriented, the requirement and function of thesystem are analyzed. Using UML, the detailed static and dynamic model of the systemare established. The general frame and function structure for spring digitalmanufacturing is also constructed. The digital manufacture system help implement theintegration of design and manufacture of spring and provide the new realization method for the spring CNC coiling.3. The shapes of spring is quite different, thus there are various special-shapespring with complex spatial shape. It is difficult to use simple and commonparameters to generalize and express various special-shape spring comprehensively,especially for their complicated and diverse end structure. Using the feature-basedtechnology, four kinds of elementary shape features are extracted and their datastructures also are defined respectively in this dissertation. Many different elementaryshape features are linked and formed the whole spring. Through classifying differentfeatures, the whole part information of spring is created. This representation methodprovide entire information source for spring digital manufacturing.4. The 3D solid modeling of spring can facility the operator to watch the springshape earlier and reduce the production time. So, the 3D modeling technology ofspecial-shape spring using OpenGL is studied in this dissertation. The emphasis is onhow to disperse the spring solid surface and store the coordinates of these discreetpoints. In order to avoid the gap between the helix and spring end, a solution tosubstitute this transition part with cylinder and torus is presented. The high realitysolid modeling is created using this method.5. In most present-day coiling machines, all the setup jobs, including toolselection, cam layout, program, are achieved by manual work using a trial-and-errormethod. This method seriously affects the spring production efficiency. It is obviousthat the machine adjustment is the toughest part of the production process and themost time-consuming phase. In order to solve this problem, the artificial intelligenceis applied to the spring coiling process and the knowledge-based computer-aidedprocess planning for spring coiling is proposed. According to the formingcharacteristic of the special-shape spring, the hybrid reasoning techniques whichintegrating case-based and rule-based reasoning are proposed and used to plan thesetup of the coiler.6. The integrated system for spring digital manufacturing is developed andapplied in practice on the foundation of study work above. The information sharing ofspring coiling process is realized in system, including spring spatial shaperepresentation, 3D modeling, coiling process planning and automatic programming.更多还原