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基于快速刀具伺服(FTS)系统的单点金刚石车削是加工光学自由曲面的重要方法之一.传统的直线刀具伺服系统都具有频率响应低的问题,严重限制了可以加工自由表面的复杂程度.文中介绍了麦克斯韦力驱动的快速刀具伺服系统的设计,电机采用永磁体偏置模型实现线性驱动,根据磁路设计原理推导了电机的运动公式,利用有限元分析(FEA)的方法分析了电机模型在高频信号驱动时的受力曲线、涡流损耗的大小和分布情况.根据分析的结果设计了电机的驱动系统,并进行了开环正弦驱动实验和电极频率响应曲线的测试,最终利用PID算法实现了FTS系统的闭环控制.基于麦克斯韦力驱动的FTS系统的最佳驱动频率应小于40 kHz,系统目前行程可以达到15.75μm,最大的频率响应可以达到100 kHz,系统可以跟踪500 Hz正弦波运动.
Single-point diamond turning based on FTS system is one of the most important methods for machining optical free-form surfaces. Conventional linear tool servo systems all have the problem of low frequency response and severely limit the complexity of machining free surfaces. The design of fast tool servo system driven by Maxwell force is introduced. The motor is driven linearly by the permanent magnet bias model. The motion formula of the motor is deduced according to the principle of magnetic circuit design. The finite element analysis (FEA) The driving force curve and the eddy current loss size and distribution under the high frequency signal driving.According to the result of analysis, the driving system of the motor is designed, and the open-loop sinusoidal driving experiment and the electrode frequency response curve test are carried out. Finally, the PID algorithm The closed loop control of the FTS system.The optimal drive frequency based on the Maxwell force driven FTS system should be less than 40 kHz, the system can reach the current stroke of 15.75μm, the maximum frequency response can reach 100 kHz, the system can track the 500 Hz sine wave motion.