How does the five-axis repeater reduce vibration and interference?

Mechanical structure design

The use of high-rigidity materials and structure: the fuselage, bracket and other key components of the five-axis repeator are usually made of high-strength cast iron or aluminum alloy materials. These materials have high rigidity, which can effectively reduce their own deformation and thus vibration. For example, cast iron materials can provide good vibration absorption properties, and the damping characteristics of its structure can convert vibration energy into heat dissipation. In the overall structural design of the machine, the use of reasonable reinforcement layout, increase the strength and stiffness of the structure, such as the design of cross reinforcement bars on the gantry of the gantry five-axis reloader, can enhance the anti-vibration ability of the gantry in the process of movement.

Optimization of shafting layout and connection mode: Reasonable design of the layout between the five axes, so that the motion inertia distribution of each axis is uniform, reduce the vibration caused by migration. For the connection between the shaft and the shaft, such as the coupling, choose a coupling with good elastic and damping characteristics, which can buffer and absorb the vibration and shock generated during the movement of the shaft. For example, the use of elastic coupling can effectively isolate the vibration transmission between the motor output shaft and the screw and other transmission components, so that the movement of each shaft is more stable.

Precision guide rail and slider design: Guide rail and slider are the key components of the movement of the five-axis repeater. The high precision linear guide rail and the matching low friction coefficient slider can ensure the straightness and smoothness of the shaft in the process of moving. The surface accuracy of the guide rail and the adjustment of the preload force of the slide are important for reducing vibration. For example, by setting the appropriate preload force, close contact can be maintained between the slider and the guide rail, reducing the gap and preventing shaking and vibration during movement. Some high-end five-axis retractor will also use advanced technology such as air cushion guide or magnetic levitation guide to further improve the smoothness of the movement.

Control system aspect

Advanced control algorithm: vibration suppression algorithm is used in the control system, such as adaptive filtering algorithm, feedforward compensation algorithm, etc. The adaptive filter algorithm can monitor the vibration signal in the process of machine movement in real time, and suppress the vibration of specific frequency by adjusting the filter parameters. The feedforward compensation algorithm is based on the known characteristics of the interference source, and the compensation amount is added to the control signal in advance to offset the possible vibration. For example, when the five-axis repeater is in high-speed reciprocating motion, the control system can adjust the torque output of the motor in advance according to the speed and load changes of the motor through these algorithms to reduce the vibration caused by speed changes and load fluctuations.

Real-time monitoring and feedback adjustment: acceleration sensors, displacement sensors and other sensors are installed on the five-axis reciprocating machine to monitor the motion of each axis in real time. These sensors will be collected vibration, displacement, speed and other information feedback to the control system, the control system according to the feedback data to the motor speed, torque and other parameters for real-time adjustment. For example, when the sensor detects that vibration intensifies during the movement of a certain axis, the control system will quickly speed up the movement of the axis or adjust its movement trajectory to control the vibration in time.

Reasonable speed and acceleration planning: When programming the motion trajectory of the five-axis repeater, reasonably plan the motion speed and acceleration curves of each axis. Avoid abrupt changes in the speed of motion and excessive changes in acceleration, because these situations are easy to cause vibration and shock of the machine. By using smooth speed and acceleration planning methods such as S-shaped curve and parabola, the shaft can transition smoothly in the process of starting, stopping and reversing. For example, when performing complex surface machining tasks, accurate planning of the speed and acceleration of the five axes can ensure that the tool contacts the workpiece surface in a smooth state during the cutting process, reducing the impact of vibration on machining accuracy.

Installation environment and external protection

Vibration isolation foundation installation: the five-axis repeater is installed on a special vibration isolation foundation, such as rubber vibration isolation pad, air spring vibration isolation device, etc. These vibration isolation devices can effectively isolate the vibration transmission between the machine and the ground, and reduce the vibration interference from the ground. For example, in the factory floor, the ground may vibrate due to the operation of other large equipment, and by installing rubber vibration pads on the bottom of the five-axis reloader, these external vibrations can be prevented from affecting the normal operation of the machine.

Protective measures around the machine: The installation of protective guardrail or soundproof cover around the five-axis repeater can not only protect personnel, but also reduce the interference of external factors (such as airflow, noise, etc.) to the machine to a certain extent. The sound enclosure can play a role in reducing noise and blocking impurities such as dust into the inside of the machine, but also the influence of external air flow on the movement of the machine, thereby reducing the vibration of the machine.