微能耗变压边力系统研究
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摘要
压边是板材拉深成形的重要工艺手段;压边力是压边的最基本、最重要参数之一。与恒压边力和不可控变压边力压边相比,可控变压边力压边可进一步提高拉深成形极限和工件几何精度,其中的液压可控变压边力压边,不但可以提供较大的压边力,而且易于借助计算机实现变压边力的高性能控制,已成为变压边力压边发展的主要方向。压边的能量消耗问题尚未引起足够重视,能源的持续紧张使节能压边具有重要意义。为此,本文提出了一种微能耗变压边力系统,并通过理论分析、数值模拟和实验,对其节能机理及控制方法进行了系统的研究,以实现节能、液压可控变压边力的高性能控制。
应用能量法对微能耗变压边力系统的能量损失进行了解析,以此为基础,分析和对比了微能耗变压边力系统和液压垫压边系统的压边能量损失,由此阐明了微能耗变压边力系统的节能机理。
对于微能耗变压边力系统的两种封闭容腔压力控制方式,即伺服阀直接控制方式和伺服阀—伺服液压缸控制方式,针对系统的高度非线性建立了非线性数学模型和PID控制的闭环系统基础仿真模型,研究了系统的响应特性及主要参数的影响规律,考察了系统对多种典型变压边压力加载曲线的跟踪性能,并验证了压边能量损失的理论分析结果,从而确定了系统节能变压边力控制的可行性。
针对微能耗变压边力系统的参数不确定性,应用模糊智能控制理论设计了模糊控制器、模糊PID开关切换控制器、模糊PID混合控制器和模糊PID自适应控制器;分别建立了对应上述控制器的系统仿真模型,通过对比系统在不同控制器下的控制性能,优选了系统的控制方法。
为实现系统的节能、高性能变压边力控制,建立了微能耗变压边力系统的仿射非线性数学模型,利用微分几何理论对模型进行了全维精确线性化,设计了线性二次型状态调节器,最终建立了系统的线性二次型最优控制仿真模型,获得了兼顾最少能量和最佳性能的系统优化控制方法。
研制了微能耗变压边力系统物理模拟装置,应用LabVIEW软件编制了实时测控程序,并与其它相关控制硬件集成,建立了微能耗变压边力实验系统;实验结果与仿真结果吻合,验证了仿真研究的有效性。
研究结果表明,微能耗变压边力系统节能效果显著,静动态特性符合应用要求,具有工程应用价值;研究工作从原理,方法及其物理实现几方面为微能耗变压边力系统的工程应用奠定了基础。
Blank holder force(BHF) is one of most fundamental and predominant parameters of blank holding which is an important technologic measure for deep drawing in sheet metal forming processes. Blank holding with controlled variable blank holder force(CVBHF) is can further improve deep drawing forming limits and geometrical precision of sheet metal parts,compared with blank holding with constant and uncontrolled BHF. Hydraulic CVBHF has become major development direction of blank holding with VBHF, because it can not only provide greater BHF, but also achieve high performance when controlled by computer. The energy consumption in providing BHF is not taken into enough consideration, and the energy saving blank holding will have great significance for the increasingly severe condition of energy sources. In this paper, a low energy consumption VBHF system is proposed, and the energy saving mechanism and the control strategy for the system are researched into by methods of theoretical analysis, numerical simulation and experiment, aiming at achieving energy saving blank holding and high performance Hydraulic CVBHF control.
The energy consumption of the low energy consumption VBHF system is analyzed theoretically using the energy method, and the blank holding energy consumption is compared between the low energy consumption VBHF system and hydraulic cushion blank holding system, clarifying the energy saving mechanism of low energy consumption VBHF system.
Base on two control modes, the closed chamber controlled by a servo valve and the closed chamber controlled by a servo valve through servo cylinder of low energy consumption VBHF system, for high nonlinearity of the system, the nonlinear mathematical models and the PID controlled fundamental simulation models of closed-loop system are built, and a series of researches including the response characteristics, the main parameters and its influence, the tracking performance to typical VBHF loading curves, and the blank holding energy consumption of the system are carried out to confirm the energy saving and VBHF control feasibility of the system.
Because the low energy consumption VBHF system includes uncertain parameters, the Fuzzy controller, Fuzzy-PID switch controller, Fuzzy-PID hybrid controller and Fuzzy-PID adaptive controller are designed by using the fuzzy intelligent control theory, and corresponding simulation models are established. The relative best control strategy is determined by comparing the control effects of them.
In order to realize energy saving and high performance VBHF control of the low energy consumption VBHF system, an Affine Nonlinear mathematical model for this system is established, a exact linearization of the model is made by using the differential geometry theory, and the linear quadratic state regulator is presented, finally simulation model of the system base on LQR optimal control is set up to gain the system optimal control method considering both minimum energy and optimal performance.
A low energy consumption VBHF experiment system is built by integrating physical simulation equipment, a real-time data acquisition and control program on LabVIEW and other correlative control hardware. The results from experiments and the simulations are in a reasonable agreement, and the validity of simulation research is confirmed.
The research results demonstrate that the low energy consumption VBHF system has remarkable energy saving effect, static and dynamic characteristics conforming to the application requirements, and a high value for engineering application. The works lay a foundation for the engineering application of low energy consumption VBHF system in some aspects of principle, method and physical realization.
应用能量法对微能耗变压边力系统的能量损失进行了解析,以此为基础,分析和对比了微能耗变压边力系统和液压垫压边系统的压边能量损失,由此阐明了微能耗变压边力系统的节能机理。
对于微能耗变压边力系统的两种封闭容腔压力控制方式,即伺服阀直接控制方式和伺服阀—伺服液压缸控制方式,针对系统的高度非线性建立了非线性数学模型和PID控制的闭环系统基础仿真模型,研究了系统的响应特性及主要参数的影响规律,考察了系统对多种典型变压边压力加载曲线的跟踪性能,并验证了压边能量损失的理论分析结果,从而确定了系统节能变压边力控制的可行性。
针对微能耗变压边力系统的参数不确定性,应用模糊智能控制理论设计了模糊控制器、模糊PID开关切换控制器、模糊PID混合控制器和模糊PID自适应控制器;分别建立了对应上述控制器的系统仿真模型,通过对比系统在不同控制器下的控制性能,优选了系统的控制方法。
为实现系统的节能、高性能变压边力控制,建立了微能耗变压边力系统的仿射非线性数学模型,利用微分几何理论对模型进行了全维精确线性化,设计了线性二次型状态调节器,最终建立了系统的线性二次型最优控制仿真模型,获得了兼顾最少能量和最佳性能的系统优化控制方法。
研制了微能耗变压边力系统物理模拟装置,应用LabVIEW软件编制了实时测控程序,并与其它相关控制硬件集成,建立了微能耗变压边力实验系统;实验结果与仿真结果吻合,验证了仿真研究的有效性。
研究结果表明,微能耗变压边力系统节能效果显著,静动态特性符合应用要求,具有工程应用价值;研究工作从原理,方法及其物理实现几方面为微能耗变压边力系统的工程应用奠定了基础。
Blank holder force(BHF) is one of most fundamental and predominant parameters of blank holding which is an important technologic measure for deep drawing in sheet metal forming processes. Blank holding with controlled variable blank holder force(CVBHF) is can further improve deep drawing forming limits and geometrical precision of sheet metal parts,compared with blank holding with constant and uncontrolled BHF. Hydraulic CVBHF has become major development direction of blank holding with VBHF, because it can not only provide greater BHF, but also achieve high performance when controlled by computer. The energy consumption in providing BHF is not taken into enough consideration, and the energy saving blank holding will have great significance for the increasingly severe condition of energy sources. In this paper, a low energy consumption VBHF system is proposed, and the energy saving mechanism and the control strategy for the system are researched into by methods of theoretical analysis, numerical simulation and experiment, aiming at achieving energy saving blank holding and high performance Hydraulic CVBHF control.
The energy consumption of the low energy consumption VBHF system is analyzed theoretically using the energy method, and the blank holding energy consumption is compared between the low energy consumption VBHF system and hydraulic cushion blank holding system, clarifying the energy saving mechanism of low energy consumption VBHF system.
Base on two control modes, the closed chamber controlled by a servo valve and the closed chamber controlled by a servo valve through servo cylinder of low energy consumption VBHF system, for high nonlinearity of the system, the nonlinear mathematical models and the PID controlled fundamental simulation models of closed-loop system are built, and a series of researches including the response characteristics, the main parameters and its influence, the tracking performance to typical VBHF loading curves, and the blank holding energy consumption of the system are carried out to confirm the energy saving and VBHF control feasibility of the system.
Because the low energy consumption VBHF system includes uncertain parameters, the Fuzzy controller, Fuzzy-PID switch controller, Fuzzy-PID hybrid controller and Fuzzy-PID adaptive controller are designed by using the fuzzy intelligent control theory, and corresponding simulation models are established. The relative best control strategy is determined by comparing the control effects of them.
In order to realize energy saving and high performance VBHF control of the low energy consumption VBHF system, an Affine Nonlinear mathematical model for this system is established, a exact linearization of the model is made by using the differential geometry theory, and the linear quadratic state regulator is presented, finally simulation model of the system base on LQR optimal control is set up to gain the system optimal control method considering both minimum energy and optimal performance.
A low energy consumption VBHF experiment system is built by integrating physical simulation equipment, a real-time data acquisition and control program on LabVIEW and other correlative control hardware. The results from experiments and the simulations are in a reasonable agreement, and the validity of simulation research is confirmed.
The research results demonstrate that the low energy consumption VBHF system has remarkable energy saving effect, static and dynamic characteristics conforming to the application requirements, and a high value for engineering application. The works lay a foundation for the engineering application of low energy consumption VBHF system in some aspects of principle, method and physical realization.
引文
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