高速转塔冲床电液控制系统研究
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摘要
冲压成形是现代制造业中高速发展的重要技术,是广泛应用于汽车、电子、仪表、电器等行业的先进金属加工方法之一。高速数控转塔冲床(高速数控冲模回转头压力机)是应用于高端压力加工的设备。目前我国的高速数控转塔冲床的核心部分高速液压驱动系统是从国外进口。
采用电液伺服阀控制的压力机驱动系统具有响应快、控制精度高的优点,但它也具有成本高、能耗大、抗污染能力差的缺点。
本课题所研究的液压系统采用高速开关阀作为先导阀控制二通插装阀构成复合十二位四通阀,选取其四种机能位置进行冲压油缸控制,具有成本低、控制输出速度高、油路相对简单的特点,为高速转塔冲床液压控制开辟了一条新路。此复合阀应用于数控转塔冲床控制,目前未检索到相关文献报道。
本文的主要研究工作包括:根据系统性能的要求,在分析和比较多种方案的基础上,确定了复合阀的控制方案;建立了所选方案系统回路数学模型,使用Matlab的Simulink仿真软件包建立系统仿真模型;进一步对系统各阶段的位移、速度和油缸上、下油腔压力进行了仿真实验;根据仿真结果,分析了冲压周期中的各阶段工况工作特性,初步确定了影响系统冲压速度的关键因素给出相应的设计、参数确定原则。
最后参考国外成熟实用化系统提出了系统的改进意见。
论文为高速转塔冲床的液压控制提出了新方法,具有较好的实用前景。
Press formation is one of the most advanced sheet metal processing methods in modern manufacture. Rapid NC turret punch press was used as advanced press process equipment. For the time being, the high speed hydraulic control system, as the key component still relies on importation, which is not suit for our economic situation because of shortcoming of high cost.Punch press driver system with electro-hydraulic servo valve employed has good characters of fast respond, high control precision. On the other hand, it has disadvantages of high cost, the huge energy waste and sensitive to oil pollution. High speed on/off solenoid valve is inexpensive, simple in structure and not sensitive to oil pollution compare with servo valve, although it has shortcoming of small flow rate. Cartridge valve use 2 way single directional components as main valve and use pilot control and plug in connection, which has advantages of small leakiness, small flow resistance, fast respond, mass flow rate, easy to control by pilot valve and easy to integrate. These features compensate shortcoming of high speed on/off solenoid valve.The complex 4 way 12 port valves which used in this project take on/off solenoid valve as pilot valve and cartridge valve as main valve, which have priority of low cost, high output speed and simple in circuit.4 functional ports of complex valve were employed in punch press circuit. A new way in field of turret punch press hydraulic control was found by this way and no related report found on this kind of complex valve using in rapid turret punch press to update.The static analysis and two schemes on system are presented first, then the system model is built and simulation is completed by using Simulink tools of Matlab. As a result, system position curve, velocity curve, and pressure curve are gotten.The last part of this article analysis the simulation results and gave explanation for features of every stage in a punch cycle. Then related design and parameter decision roles are given from the key factors which affect the punch speed. At the end, by referencing well used system, improve advices were given for the system.
采用电液伺服阀控制的压力机驱动系统具有响应快、控制精度高的优点,但它也具有成本高、能耗大、抗污染能力差的缺点。
本课题所研究的液压系统采用高速开关阀作为先导阀控制二通插装阀构成复合十二位四通阀,选取其四种机能位置进行冲压油缸控制,具有成本低、控制输出速度高、油路相对简单的特点,为高速转塔冲床液压控制开辟了一条新路。此复合阀应用于数控转塔冲床控制,目前未检索到相关文献报道。
本文的主要研究工作包括:根据系统性能的要求,在分析和比较多种方案的基础上,确定了复合阀的控制方案;建立了所选方案系统回路数学模型,使用Matlab的Simulink仿真软件包建立系统仿真模型;进一步对系统各阶段的位移、速度和油缸上、下油腔压力进行了仿真实验;根据仿真结果,分析了冲压周期中的各阶段工况工作特性,初步确定了影响系统冲压速度的关键因素给出相应的设计、参数确定原则。
最后参考国外成熟实用化系统提出了系统的改进意见。
论文为高速转塔冲床的液压控制提出了新方法,具有较好的实用前景。
Press formation is one of the most advanced sheet metal processing methods in modern manufacture. Rapid NC turret punch press was used as advanced press process equipment. For the time being, the high speed hydraulic control system, as the key component still relies on importation, which is not suit for our economic situation because of shortcoming of high cost.Punch press driver system with electro-hydraulic servo valve employed has good characters of fast respond, high control precision. On the other hand, it has disadvantages of high cost, the huge energy waste and sensitive to oil pollution. High speed on/off solenoid valve is inexpensive, simple in structure and not sensitive to oil pollution compare with servo valve, although it has shortcoming of small flow rate. Cartridge valve use 2 way single directional components as main valve and use pilot control and plug in connection, which has advantages of small leakiness, small flow resistance, fast respond, mass flow rate, easy to control by pilot valve and easy to integrate. These features compensate shortcoming of high speed on/off solenoid valve.The complex 4 way 12 port valves which used in this project take on/off solenoid valve as pilot valve and cartridge valve as main valve, which have priority of low cost, high output speed and simple in circuit.4 functional ports of complex valve were employed in punch press circuit. A new way in field of turret punch press hydraulic control was found by this way and no related report found on this kind of complex valve using in rapid turret punch press to update.The static analysis and two schemes on system are presented first, then the system model is built and simulation is completed by using Simulink tools of Matlab. As a result, system position curve, velocity curve, and pressure curve are gotten.The last part of this article analysis the simulation results and gave explanation for features of every stage in a punch cycle. Then related design and parameter decision roles are given from the key factors which affect the punch speed. At the end, by referencing well used system, improve advices were given for the system.
引文
[1] 朱钒 等.国内外液压机技术现状及发展趋势.机床与液压,2000,(1):6～7
[2] 范宏才.现代锻压机械.北京:机械工业出版社,1994.231～277
[3] 刘振堂.国外数控冲床的现状和发展趋势.锻压机械,2002,(1):7～10
[4] 赵恩林.液压驱动数控转塔冲床.高压电器,1998,(2):55～56
[5] 刘振堂.数控转塔冲床的新进展.锻压装备与制造技术,2003,(3):13～15
[6] 丁小艺,孙友松.数控回转头压力机及其液压驱动系统.制造业自动化,2003,(2):39～40
[7] 杨襄壁等.高速开关阀的电液控制系统的研究.凿岩机械气动工具,2001,(2):43～45
[8] 施光林,钟廷修.高速电磁开关阀的研究与应用.机床与液压,2001,(2):7～9
[9] 罗艳蕾,胡应曦.用二通插装式控制阀实现液压传动系统的集成.煤矿机械,2004,(3):90～91
[10] 周福章 等.高速开关阀的设计与研究.机械工程学报,1998,34(5):101～105.
[11] 石延平,刘成文.一种大流量高速开关阀的研究与设计.机械工程学报,2004,40(5):195～198
[12] 张敬国 等.电控柴油机用大流量高速开关阀性能试验研究.内燃机学报,2003,21(3):252～256
[13] 陈海泉 等.基于流体逻辑理论的船用插装阀机能研究.大连海事大学学报,2004,30(3):34～37
[14] 雷天觉 主编.液压工程手册.北京:机械工业出版社,1990.1722～1730
[15] 冯长印 等.二通插装阀方向油路设计中的几个问题.佛山陶瓷,2004,(6):29～32
[16] 刘建国,戴红梅.逻辑插装技术在水轮机调速器中的应用.小水电,2005,(1):26～28
[17] 石红雁 等.基于SIMULINK的液压系统动态仿真.农业机械学报,2000,(31)5:94～96
[18] 郜立焕 等.阀控液压缸开关系统的模糊控制及SIMULINK仿真.甘肃工业大学学报,2000,29(3):65～67
[19] 张力钧 等,二通插装阀统一建模方法的研究.液压气动与密封,2003,(3):1～4
[20] 罗艳蕾 等.插装式二通方向控制动态仿真模型的建立.贵州工业大学学报,2004,33(1):39～42
[21] W. Backe, Design Systematic and Performance of Cartridge Valve Controls, International conference on Fluid Power, 1987.
[2] 范宏才.现代锻压机械.北京:机械工业出版社,1994.231～277
[3] 刘振堂.国外数控冲床的现状和发展趋势.锻压机械,2002,(1):7～10
[4] 赵恩林.液压驱动数控转塔冲床.高压电器,1998,(2):55～56
[5] 刘振堂.数控转塔冲床的新进展.锻压装备与制造技术,2003,(3):13～15
[6] 丁小艺,孙友松.数控回转头压力机及其液压驱动系统.制造业自动化,2003,(2):39～40
[7] 杨襄壁等.高速开关阀的电液控制系统的研究.凿岩机械气动工具,2001,(2):43～45
[8] 施光林,钟廷修.高速电磁开关阀的研究与应用.机床与液压,2001,(2):7～9
[9] 罗艳蕾,胡应曦.用二通插装式控制阀实现液压传动系统的集成.煤矿机械,2004,(3):90～91
[10] 周福章 等.高速开关阀的设计与研究.机械工程学报,1998,34(5):101～105.
[11] 石延平,刘成文.一种大流量高速开关阀的研究与设计.机械工程学报,2004,40(5):195～198
[12] 张敬国 等.电控柴油机用大流量高速开关阀性能试验研究.内燃机学报,2003,21(3):252～256
[13] 陈海泉 等.基于流体逻辑理论的船用插装阀机能研究.大连海事大学学报,2004,30(3):34～37
[14] 雷天觉 主编.液压工程手册.北京:机械工业出版社,1990.1722～1730
[15] 冯长印 等.二通插装阀方向油路设计中的几个问题.佛山陶瓷,2004,(6):29～32
[16] 刘建国,戴红梅.逻辑插装技术在水轮机调速器中的应用.小水电,2005,(1):26～28
[17] 石红雁 等.基于SIMULINK的液压系统动态仿真.农业机械学报,2000,(31)5:94～96
[18] 郜立焕 等.阀控液压缸开关系统的模糊控制及SIMULINK仿真.甘肃工业大学学报,2000,29(3):65～67
[19] 张力钧 等,二通插装阀统一建模方法的研究.液压气动与密封,2003,(3):1～4
[20] 罗艳蕾 等.插装式二通方向控制动态仿真模型的建立.贵州工业大学学报,2004,33(1):39～42
[21] W. Backe, Design Systematic and Performance of Cartridge Valve Controls, International conference on Fluid Power, 1987.