轧辊磨床是工业生产中不可缺少的一种重要设备，它用于磨削各种具有中凸度或中凹度的轧辊。普通轧辊磨床，其曲线的生成过程大部分都是通过机械结构来控制的，由于其加工的轧辊轮廓曲线类型少，加工的轧辊轮廓曲线精度低，改变加工曲线参数困难，已经不能满足目前产品生产的要求。近年来，由于冶金、造纸、橡胶、塑料以及印染业的迅速发展，对轧辊磨削的技术要求也日趋提高。随着数控技术的普及和应用，为了适应轧辊磨削精密化、高效化和自动化的发展趋势，同时也为了适应用户需求和市场的变化，开发数控轧辊磨床将很有必要。另一方面，随着计算机技术和微电子技术的发展，基于IPC机的开放式数控系统已经成为当前数控技术发展的一个重要方向。 为了解决工业生产中轧辊磨削这一难题，结合轧辊磨床的特点和当前开放式数控系统的发展趋势，本文构建了一种以IPC机为基础，以PMAC运动控制卡为核心的开放式轧辊磨床数控系统, 并对其硬件结构和软件体系进行了研究。根据轧辊磨床的特点和轧辊磨削所要实现的功能，该轧辊磨床的数控系统能够控制以下几个方向的运动：纵向的Z轴运动，横向的X轴运动，中高机构中偏心套的C轴运动，测量装置的X1和X2轴运动，工件的转动和砂轮的转动。该轧辊磨床数控系统由以下几个部分组成：一台IPC机，一套PMAC卡及其附件，五套交流伺服驱动器及交流伺服电动机，两套直流调速装置和直流电机。该数控系统是一种用PMAC卡实现前台实时运动控制，IPC机实现后台管理及人机界面接口的开放式、模块化数控系统。IPC机与PMAC卡之间通过实时、可靠的通讯来协调整个系统，共同完成加工任务。基于IPC机的控制软件主要包括四个部分：人机界面应用程序、上下位机通讯程序、运动程序和PLC程序。其中，PC机通过PMAC卡自带的动态链接库Pmac.dll建立和PMAC卡之间的通信。运动程序和PLC程序由PMAC卡自带的PEWIN软件来编写和调试，然后通过动态连接库中的函数下载到PMAC卡中去执行。人机界面应用程序采用模块化结构设计，运用高级语言Delphi7.0进行开发。通过对轧辊磨床数控系统的硬件结构和用户需求的分析，本软件包括以下八个模块：系统初始化、加工参数设置、加工过程、测量选择、测量曲线再现、砂轮补偿与修整、PLC诊断、系统帮助。 实践表明，基于PMAC的开放式数控系统可以缩短开发周期，保证了系统加工精度高度的稳定性。控制软件设计时的模块化结构使系统的通用性和可移植性大大增强，也有利于系统的功能扩展。

The roll grinder is an indispensable important equipment in the industry, which grinds all kinds of dished or convex roller. For general roll grinder, its curves are mostly made by machinery structure. Due to its contour curves are few, precision is low and changing of curve parameters is difficult, general roll grinder cannot satisfy the need of product-manufacturing at present. With the rapid development of metallurgy, paper making, latex, plastic, printing and dyeing in the recent years, the technical need for roller grinding is being increased. With the popularization and application of NC, in order to accommodate the development trend of the precision, efficiency and automatization of roller grinding and to meet consumers’ need and market change, it is necessary to develop a NC roll grinder. Moreover, with the development of computer science and micro-electronics, IPC-based open NC system has been an important direction of NC. To solve the difficult problem of roller grinding in manufacturing industry，considering the characteristics of roll grinder and the development trend of open NC system ,an open NC system of roll grinder based on IPC and PMAC is put forward, and both its hardware and software are studied. According to the characteristics and realized function of the roller grinding, the NC system of the roll grinder can control the movements of Z-axis, X-axis, C-axis, X1-axis and X2-axis, workpiece’s running and grinder wheel’s running. This NC system of roll grinder is made up of an IPC, a PMAC and its accessories, five AC servo drivers and motors, two DC transverters and DC motors. It is an open and modularization NC system, which realizes real-time movement control by PMAC, and background managing and man-machine conversation by IPC. The whole system is assorted with real-time and credible communications between IPC and PMAC in order to complete machining task. The IPC-based control software consists of man-machine interface application program, communication program between IPC and PMAC, motion programs and PLC programs. The communication between IPC and PMAC is accomplished by Pmac.dll . The motion programs and PLC programs are compiled and debugged by PEWIN, and are downloaded to PMAC and performed by functions in DLL (dynamic link library). The man-machine interface application program is designed by the modularization structure, and is developed by Delphi7.0. According to the hardware structure of NC system and consumers’ need, this software includes eight parts: system initialization, machining parameter setting, machining process, measure, curve reappearance, grinding wheel dressing and compensation, PLC diagnosis and system help. It has been proved that PMAC-based open NC system can shorten development cycle and ensure high stability of system machining precision. The modularization structure of NC software has a very well flexibility，and is in favor of the extension of system function.