2D阀控制电液激振器及在疲劳试验系统中的应用研究
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摘要
疲劳试验是现代工程技术领域中的一项基本试验,也是工业产品研发的重要手段,工业生产中的各种材料、零部件、构件以至整机都需要经过疲劳试验才能确定它们的力学性能和预期的寿命周期。
电液疲劳试验机是进行重载疲劳试验的关键设备。随着现代工业和航天航空技术的发展,对电液疲劳试验机的试验频率提出了更高的要求,但现有的电液疲劳试验机的激振频率受激振器中电液伺服阀频率特性的限制难以提高,为此提出了双自由度阀(简称2D阀)控制液压缸驱动活塞实现电液高频激振的新方案。在2D阀中,阀芯具有周向旋转和轴向滑动双自由度。当2D阀阀芯连续转动时,阀芯台肩上沟槽和阀套上窗口的特殊几何结构布置使得液压缸两腔内的油液压力发生交替变化,驱动液压缸活塞来回往复运动,对试验对象实施交变载荷的疲劳试验。液压缸活塞的振动频率和幅值分别由2D阀阀芯的转速和轴向滑动控制,同时还并联了一个伺服阀对活塞位移的偏置进行控制,实现对频率、幅值和偏置的独立控制。由于2D阀阀芯为惯性很小的细长结构,又处于油液很好的润滑环境中,因此很容易通过提高阀芯转速来实现高频激振。论文的主要研究工作和成果如下:
1、针对传统的电液激振器的激振频率受电液伺服阀频响限制难以提高的现状,提出了2D阀控制电液激振器的方案,以实现在5~200Hz的频率范围内对试验对象实施疲劳加载,并保持频率、幅值和偏载能独立地进行闭环或开环控制。
2、在分析2D阀控电液激振器工作原理的基础上,建立2D阀控电液激振器的数学模型,应用四阶龙格-库塔法编制数值仿真程序求解活塞位移波形和偏离正弦波的失真度曲线,结合2D阀对液压动力机构的运动过程进行讨论。
3、针对2D阀控电液激振器的频率、幅值和偏置独立控制并相互耦合的特性,提出采用解耦控制方法对其进行解耦控制研究。在分析2D阀控电液激振器的解耦控制原理的基础上,应用数值仿真程序,求解出不同激振频率下,2D阀阀芯轴向滑动与活塞位移幅值之间的变化曲线、并联伺服阀阀芯轴向滑动与活塞位移偏置之间的变化曲线以及幅值和偏置间的耦合特性,并给出系统的幅频特性曲线以研究幅值随激振频率的变化规律。
4、针对多轴疲劳试验系统中加载载荷的相位同步要求,对2D阀控电液激振器的相频特性进行研究。介绍电液四轴高频结构强度疲劳试验系统的结构组成;在分析2D阀结构的基础上,提出了2D阀控电液激振器的同步控制策略和初始相位同步控制方法,求解出2D阀控电液激振器的相频特性曲线,研究表明当激振频率在固有频率的0.048~0.870倍时,激振频率和2D阀阀芯轴向滑动对相位的影响可以忽略不计,为2D阀控电液激振器在开环控制应用于同步加载的多轴疲劳试验系统提供理论依据。
5、搭建了基于2D阀控电液激振器的单轴电液疲劳试验系统和多轴电液结构强度疲劳试验系统进行实验研究。通过位移和载荷传感器测取5~200Hz频率范围内的活塞位移和输出力波形,对仿真结果进行验证。
Fatigue test is not only an essential test in the field of modern engineering technology, but also an important method in industrial product development, a variety of materials, parts, components in industrial production have to make fatigue testing in order to determine their mechanical properties and expected life cycle.
Electro-hydraulic fatigue testing machine was the key equipment in fatigue test. With the development of modern industrial and aerospace technology, the higher test frequency is put forward to electro-hydraulic fatigue testing machine; but the vibration frequency is difficult to improve which is restricted by the frequency characteristics of electro-hydraulic servo valve. A novel scheme for an electro-hydraulic vibrator controlled by a two-dimensional valve (called 2D valve) is therefore proposed to achieve higher frequency. The spool of 2D valve has two degrees of freedom including circumferential rotation and axial sliding. When the spool of 2D valve rotates continuously, the special geometry layout between grooves in spools and windows in sleeves makes the oil pressure change alternately to drive the piston of hydraulic cylinder go back-and-forth reciprocating motion which is making fatigue testing to test object. Vibration frequency and amplitude of piston of cylinder is controlled by the rotary speed and axial sliding, and a parallel servo valve is also used to realize the offset control of the displacement of piston in cylinder. So the frequency, amplitude and offset of displacement of piston in cylinder can be contolled independently. The spool of 2D valve is small and slender with few inertial, and in oil environment with a good lubricating, it is easy to achieve higer frequency by increasing rotary speed of the spool of 2D valve. The main research of this paper as follows:
1. The working frequency of the conventional electrohydraulic vibration exciters is limited to fairly narrow range by the frequency response capability of the servo valve. A scheme of electrohydraulic vibration exciter using a 2D valve is therefore proposed to carry out fatigue test in 5 ~ 200Hz, and maintain the the frequency, amplitude and offset of piston disaplacement be controlled independently in closed or open loop.
2. The mathematical model of the electro-hydraulic valve controlled by 2D valve is established based on the analysis of principle of the electro-hydraulic valve controlled by 2D valve, the displacement curve of piston and distortion curve deviated from sine wave are solved using the numerical simulation program based on the fourth-order Runge - Kutta method, the movement of the hydraulic power mechanism is discussed combined with 2D valve.
3. The decoupling control method is proposed to contol the exciter frequency, amplitude and offset of displacement of electro-hydraulic exciter controlled by 2D valve which are controlled indenpendently and coupled each other. The curve between the amplitude and the axial sliding of 2D valve’spool, the curve between the offset and the axial sliding of bias valve’s spool and the coupling laws between amplitude and offset in different frequency are drived using the numerical simulation program based on the introduce of decoupling control principle of electro-hydraulic exciter controlled by 2D valve, and the amplitude-frequency curves are also given to study the laws between amplitude and vibratin frequency.
4. The phae-frequency characteristic of electro-hydraulic exciter controlled by 2D valve is studied according to the requirement of phase synchronization of load in multiaxial fatigure test system. The structural of electro-hydraulic four-axis high-frequency structural strength fatigue testing system is described. The synchronous control strategy and the initial phase synchronization control method of electro-hydraulic exciter controlled by 2D valve are proposed bason in the analysis of structure of 2D valve and the phase-frequency characteristic curve of electro-hydraulic exciter controlled by 2D valve is derived; Research shows that when the excitation frequency among 0.048 ~ 0.870 times of natural frequency, the impact to the phase from the excitation frequency and the 2D axial sliding spool valve is negligible, which can provide the theoretical basis for the electro-hydraulic exciter used in synchronous multi-axis fatigue test system under the open loop control.
5. The single-axis fagitue test system and multi-axial structural strength fatigue test system based on the electro-hydraulic exciter controlled by 2D valve are established to carry out experimental study. The test displacement wavrform of pistion in 5~200Hz is measured by force and displacement sensors to verify the simuliation results.
电液疲劳试验机是进行重载疲劳试验的关键设备。随着现代工业和航天航空技术的发展,对电液疲劳试验机的试验频率提出了更高的要求,但现有的电液疲劳试验机的激振频率受激振器中电液伺服阀频率特性的限制难以提高,为此提出了双自由度阀(简称2D阀)控制液压缸驱动活塞实现电液高频激振的新方案。在2D阀中,阀芯具有周向旋转和轴向滑动双自由度。当2D阀阀芯连续转动时,阀芯台肩上沟槽和阀套上窗口的特殊几何结构布置使得液压缸两腔内的油液压力发生交替变化,驱动液压缸活塞来回往复运动,对试验对象实施交变载荷的疲劳试验。液压缸活塞的振动频率和幅值分别由2D阀阀芯的转速和轴向滑动控制,同时还并联了一个伺服阀对活塞位移的偏置进行控制,实现对频率、幅值和偏置的独立控制。由于2D阀阀芯为惯性很小的细长结构,又处于油液很好的润滑环境中,因此很容易通过提高阀芯转速来实现高频激振。论文的主要研究工作和成果如下:
1、针对传统的电液激振器的激振频率受电液伺服阀频响限制难以提高的现状,提出了2D阀控制电液激振器的方案,以实现在5~200Hz的频率范围内对试验对象实施疲劳加载,并保持频率、幅值和偏载能独立地进行闭环或开环控制。
2、在分析2D阀控电液激振器工作原理的基础上,建立2D阀控电液激振器的数学模型,应用四阶龙格-库塔法编制数值仿真程序求解活塞位移波形和偏离正弦波的失真度曲线,结合2D阀对液压动力机构的运动过程进行讨论。
3、针对2D阀控电液激振器的频率、幅值和偏置独立控制并相互耦合的特性,提出采用解耦控制方法对其进行解耦控制研究。在分析2D阀控电液激振器的解耦控制原理的基础上,应用数值仿真程序,求解出不同激振频率下,2D阀阀芯轴向滑动与活塞位移幅值之间的变化曲线、并联伺服阀阀芯轴向滑动与活塞位移偏置之间的变化曲线以及幅值和偏置间的耦合特性,并给出系统的幅频特性曲线以研究幅值随激振频率的变化规律。
4、针对多轴疲劳试验系统中加载载荷的相位同步要求,对2D阀控电液激振器的相频特性进行研究。介绍电液四轴高频结构强度疲劳试验系统的结构组成;在分析2D阀结构的基础上,提出了2D阀控电液激振器的同步控制策略和初始相位同步控制方法,求解出2D阀控电液激振器的相频特性曲线,研究表明当激振频率在固有频率的0.048~0.870倍时,激振频率和2D阀阀芯轴向滑动对相位的影响可以忽略不计,为2D阀控电液激振器在开环控制应用于同步加载的多轴疲劳试验系统提供理论依据。
5、搭建了基于2D阀控电液激振器的单轴电液疲劳试验系统和多轴电液结构强度疲劳试验系统进行实验研究。通过位移和载荷传感器测取5~200Hz频率范围内的活塞位移和输出力波形,对仿真结果进行验证。
Fatigue test is not only an essential test in the field of modern engineering technology, but also an important method in industrial product development, a variety of materials, parts, components in industrial production have to make fatigue testing in order to determine their mechanical properties and expected life cycle.
Electro-hydraulic fatigue testing machine was the key equipment in fatigue test. With the development of modern industrial and aerospace technology, the higher test frequency is put forward to electro-hydraulic fatigue testing machine; but the vibration frequency is difficult to improve which is restricted by the frequency characteristics of electro-hydraulic servo valve. A novel scheme for an electro-hydraulic vibrator controlled by a two-dimensional valve (called 2D valve) is therefore proposed to achieve higher frequency. The spool of 2D valve has two degrees of freedom including circumferential rotation and axial sliding. When the spool of 2D valve rotates continuously, the special geometry layout between grooves in spools and windows in sleeves makes the oil pressure change alternately to drive the piston of hydraulic cylinder go back-and-forth reciprocating motion which is making fatigue testing to test object. Vibration frequency and amplitude of piston of cylinder is controlled by the rotary speed and axial sliding, and a parallel servo valve is also used to realize the offset control of the displacement of piston in cylinder. So the frequency, amplitude and offset of displacement of piston in cylinder can be contolled independently. The spool of 2D valve is small and slender with few inertial, and in oil environment with a good lubricating, it is easy to achieve higer frequency by increasing rotary speed of the spool of 2D valve. The main research of this paper as follows:
1. The working frequency of the conventional electrohydraulic vibration exciters is limited to fairly narrow range by the frequency response capability of the servo valve. A scheme of electrohydraulic vibration exciter using a 2D valve is therefore proposed to carry out fatigue test in 5 ~ 200Hz, and maintain the the frequency, amplitude and offset of piston disaplacement be controlled independently in closed or open loop.
2. The mathematical model of the electro-hydraulic valve controlled by 2D valve is established based on the analysis of principle of the electro-hydraulic valve controlled by 2D valve, the displacement curve of piston and distortion curve deviated from sine wave are solved using the numerical simulation program based on the fourth-order Runge - Kutta method, the movement of the hydraulic power mechanism is discussed combined with 2D valve.
3. The decoupling control method is proposed to contol the exciter frequency, amplitude and offset of displacement of electro-hydraulic exciter controlled by 2D valve which are controlled indenpendently and coupled each other. The curve between the amplitude and the axial sliding of 2D valve’spool, the curve between the offset and the axial sliding of bias valve’s spool and the coupling laws between amplitude and offset in different frequency are drived using the numerical simulation program based on the introduce of decoupling control principle of electro-hydraulic exciter controlled by 2D valve, and the amplitude-frequency curves are also given to study the laws between amplitude and vibratin frequency.
4. The phae-frequency characteristic of electro-hydraulic exciter controlled by 2D valve is studied according to the requirement of phase synchronization of load in multiaxial fatigure test system. The structural of electro-hydraulic four-axis high-frequency structural strength fatigue testing system is described. The synchronous control strategy and the initial phase synchronization control method of electro-hydraulic exciter controlled by 2D valve are proposed bason in the analysis of structure of 2D valve and the phase-frequency characteristic curve of electro-hydraulic exciter controlled by 2D valve is derived; Research shows that when the excitation frequency among 0.048 ~ 0.870 times of natural frequency, the impact to the phase from the excitation frequency and the 2D axial sliding spool valve is negligible, which can provide the theoretical basis for the electro-hydraulic exciter used in synchronous multi-axis fatigue test system under the open loop control.
5. The single-axis fagitue test system and multi-axial structural strength fatigue test system based on the electro-hydraulic exciter controlled by 2D valve are established to carry out experimental study. The test displacement wavrform of pistion in 5~200Hz is measured by force and displacement sensors to verify the simuliation results.
引文
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