负载敏感平衡阀的研究
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摘要
液压平衡阀是平衡回路中的关键元件，在现代工程机械特别是起重运输机械中应用广泛。其性能的好坏直接影响整机的性能，如果设计的不合理，将使设备的作业受到限制，同时给整机的稳定性、动臂及机架的刚性带来不良影响。传统的平衡阀存在着许多缺点，如低频抖动，控制压力偏高，工作平稳性差以及系统功率损失严重等，特别是其调定背压是固定不变的，当负载产生的压力比平衡阀调定的压力高(大负载)的时候，系统的低频抖动不能完全消除，当负载产生的压力比平衡阀调定的压力低(小负载)时，存在控制压力过高，功率损耗大的问题。针对这些缺陷，本文提出了一种新型的负载敏感平衡阀。
本文中负载敏感平衡阀是在总结传统平衡阀设计经验，分析平衡阀最新发展成果的基础上设计出的一种新型的平衡阀。该平衡阀应用了负载敏感原理，将油缸下腔压力信号反馈到阀内，使阀芯的开口大小随负载变化，从而根本上解决目前平衡阀存在背压不能随负载动态变化的问题。
本文对负载敏感平衡阀的原理进行了深入阐述，对其结构进行了全面设计，特别是对该阀的关键零部件进行了详细的计算。通过对阀口的设计计算，对平衡弹簧的设计计算，提出采用双弹簧以适应非线性阀口的不同区段的负载，从而极大地改善了该阀的调节性能及控制性能。设计中将给出不同弹簧作用下阀芯位移与节流阀芯开口量的函数关系图线以及节流口实际面积与理论面积的对比图。
采用Matlab／Simulink软件对该平衡阀进行了动静态仿真分析。仿真结果表明，输入为阶跃负载信号和阶跃流量信号时，系统均在1s左右达到稳态，与其它平衡阀产品(如文献轻载1.5s，重载2.1s)相比有明显提高。
本文最后结合该阀的特点设计出了一套完整的试验方案。
本文的创新点在于提出了一种全新原理的平衡阀(该阀已申请发明专利，申请号：200610102007.X)，并对该阀进行了比较全面的分析。
Hydraulic counterbalance valve is a key element in the hydraulic balanced loop , which is applied abroad in modern engineering mechanism especially in elevating machinery. The performance of the complete appliance is influenced by the property of the counterbalance valve, so, if the design is irrational, the working of the equipment is confined, at the same time, the stability of the complete appliance and the rigidity of the movable beam and the frame are effected badly. There are many pieces of disadvantage in conventional counterbalance valves, such as whipping in Low Frequency, the high control pressure, the bad working stability, the large power loss, and especially the changeless backpressure set up. When pressure brought by load is higher (large load) than pressure set up by counterbalance valve, systemic Low Frequency whipping can't be eliminated clearly, but when lower (small load), the control pressure is very high and the power loss is very large. Aiming at the disadvantage above, a new sort of load- sensing counterbalance valve is researched in this paper.
The load-sensing counterbalance valve in this paper is a new kind of counterbalance valve which is designed on the basis of summary of the designing experience of conventional counterbalance valves and the analysis of the latest outcome. The load-sensing theory is applied in this designing, which the pressure signal from the lower cavity of hydraulic cylinder is fed back to the valve to make the size of valve plug uncork change according to the load change in order to solve the exiting problem that the backpressure can't change with the load pressure thoroughly.
In this paper, the theory of load sensing counterbalance valve is elaborated, its structure is detailed and especially, its key parts are computed in detail. According to design calculation of the valve port and compensating spring, dual spring and non-linear valve port are adopted to adapt to various section load, so as to the regulation performance and control performance of the valve are ameliorated hugely. The functional relationship graphic between spool traverse and axial relief with various springs function and the comparison diagram between real area of orifice and theoretical are given in this design.
Static state and dynamic emulation about the new counterbalance valve are carried out by the software Matlab/Simulink. The outcome of emulation proves that with the step load signal or step flow signal, system can reach steady state all the time in about ls,which is obviously improved compared with other counterbalance valve products (such as literature: at fractional load 1.5s and burden 2.1s).
A whole suite of testing program is thought out at last in this paper in view of the characteristic of this valve.
The innovation points of this paper are that a kind of counterbalance valve (it has been declared patent of invention and the application number of patent is 200610102007.X) with completely new theory is brought forward and complete analyses are carried out it.
本文中负载敏感平衡阀是在总结传统平衡阀设计经验，分析平衡阀最新发展成果的基础上设计出的一种新型的平衡阀。该平衡阀应用了负载敏感原理，将油缸下腔压力信号反馈到阀内，使阀芯的开口大小随负载变化，从而根本上解决目前平衡阀存在背压不能随负载动态变化的问题。
本文对负载敏感平衡阀的原理进行了深入阐述，对其结构进行了全面设计，特别是对该阀的关键零部件进行了详细的计算。通过对阀口的设计计算，对平衡弹簧的设计计算，提出采用双弹簧以适应非线性阀口的不同区段的负载，从而极大地改善了该阀的调节性能及控制性能。设计中将给出不同弹簧作用下阀芯位移与节流阀芯开口量的函数关系图线以及节流口实际面积与理论面积的对比图。
采用Matlab／Simulink软件对该平衡阀进行了动静态仿真分析。仿真结果表明，输入为阶跃负载信号和阶跃流量信号时，系统均在1s左右达到稳态，与其它平衡阀产品(如文献轻载1.5s，重载2.1s)相比有明显提高。
本文最后结合该阀的特点设计出了一套完整的试验方案。
本文的创新点在于提出了一种全新原理的平衡阀(该阀已申请发明专利，申请号：200610102007.X)，并对该阀进行了比较全面的分析。
Hydraulic counterbalance valve is a key element in the hydraulic balanced loop , which is applied abroad in modern engineering mechanism especially in elevating machinery. The performance of the complete appliance is influenced by the property of the counterbalance valve, so, if the design is irrational, the working of the equipment is confined, at the same time, the stability of the complete appliance and the rigidity of the movable beam and the frame are effected badly. There are many pieces of disadvantage in conventional counterbalance valves, such as whipping in Low Frequency, the high control pressure, the bad working stability, the large power loss, and especially the changeless backpressure set up. When pressure brought by load is higher (large load) than pressure set up by counterbalance valve, systemic Low Frequency whipping can't be eliminated clearly, but when lower (small load), the control pressure is very high and the power loss is very large. Aiming at the disadvantage above, a new sort of load- sensing counterbalance valve is researched in this paper.
The load-sensing counterbalance valve in this paper is a new kind of counterbalance valve which is designed on the basis of summary of the designing experience of conventional counterbalance valves and the analysis of the latest outcome. The load-sensing theory is applied in this designing, which the pressure signal from the lower cavity of hydraulic cylinder is fed back to the valve to make the size of valve plug uncork change according to the load change in order to solve the exiting problem that the backpressure can't change with the load pressure thoroughly.
In this paper, the theory of load sensing counterbalance valve is elaborated, its structure is detailed and especially, its key parts are computed in detail. According to design calculation of the valve port and compensating spring, dual spring and non-linear valve port are adopted to adapt to various section load, so as to the regulation performance and control performance of the valve are ameliorated hugely. The functional relationship graphic between spool traverse and axial relief with various springs function and the comparison diagram between real area of orifice and theoretical are given in this design.
Static state and dynamic emulation about the new counterbalance valve are carried out by the software Matlab/Simulink. The outcome of emulation proves that with the step load signal or step flow signal, system can reach steady state all the time in about ls,which is obviously improved compared with other counterbalance valve products (such as literature: at fractional load 1.5s and burden 2.1s).
A whole suite of testing program is thought out at last in this paper in view of the characteristic of this valve.
The innovation points of this paper are that a kind of counterbalance valve (it has been declared patent of invention and the application number of patent is 200610102007.X) with completely new theory is brought forward and complete analyses are carried out it.
引文
[1] 姚平喜，张晓俊，液压平衡回路辨析，液压与气动，2005(1)，74-76
[2] 陈奎生，液压与气压传动，湖北武汉，武汉理工大学出版社，2001．8
[3] 贺劲，液压步履式桩架起架机构平衡回路的改进设计，建设机械技术与管理，1995(4)，26-27
[4] 金平海，张平，汽车起重机平衡阀原理及故障排除，山东交通科技，2003(2)，59、83
[5] 赵春红，起重机液压平衡回路的改进，起重运输机械，2000(8)，33-35
[6] 刘国臣，新型双作用缓冲平衡阀，液压与气动，2000(3)，45
[7] 彭勇，FD型平衡阀的工作原理，建设机械技术与管理，2002(7)，31
[8] 廖义德，李壮云，带压力补偿平衡阀的设计及性能研究，锻压装备与制造技术2003(3)，22-24
[9] 杨国平，贺尚红，李自光，新型平衡阀数字仿真研究，长沙交通学院学报 1995(3)，23-30
[10 ]黄宗益，李兴华，陈明，液压传动的负载敏感和压力补偿
[11] 宋鸿尧，丁忠尧，液压阀设计与计算，北京，机械工业出版社，1979．12
[12] B eyerle, Richard, Low power actuates balanced valve, Machine Design; Apt 18, 1996; 68, 8; ABI/INFORM Global, pg. 72
[13] 李峰，马长林，平衡阀动态特性仿真与参数优化研究，机床与液压，2003(4)，232-234
[14] Joe Scott, Balancing valves a key to reliable recirculation, Contractor; Feb 1999; 46, 2; ABI/INFORM Global, pg. 40
[15] Tom Sato, Kenzo Tonoki, Takuro Yoshikawa, Yoshihiro Tsuchiya, Numerical and hydraulic simulations of the effect of Density Current Generator in a semi-enclosed tidal bay, T. Sato et al. / Coastal Engineering 53 (2006) 49-64
[16] 赵敏，南志华，王红光，平衡阀模拟工况试验研究，机械管理开发，2001(11)，35-37
[17] C Kosarzecki, A counterbalance valve's biggest enemy, Hydraulics & Pneumatics; Mar 2003; 56, 3; ABI/INFORM Trade & Industry pg. 47
[18] Richard T Schneider, Hysteresis-a counterbalance valve's worst enemy, Hydraulics & Pneumatics; Mar 2000; 53, 3; ABI/INFORM Trade & Industry pg. 37
[19] 郝贵成，韩进，负载传感液压系统的设计，液压与气动，1993(1)，12-15
[20] Anonymous, Basics ofdesignengineering: Pressure valves, Machine Design; Jun 15, 1995; 67, 11; ABI/INFORM Global pg. 162
[21] Muhammad M. Rahman and Jose L. F. Porteiro, Numerical simulation and animation of oscillating turbulent flow in a counterbalance valve
[22] Jill E. Krutz, Design of a hydraulic actuator test stand for non-linear analysis of hydraulic actuator systems,2001
[23] 贺辉，新型工程机械液压平衡阀的设计与实验研究，湖南大学硕士学位论文，2002
[24] 陈奎生，液压与气压传动，湖北，武汉理工大学出版社，2001
[25] 王起龙，机械工程手册(第二版)·传动设计卷·第四篇，北京，机械工业出版社，1996
[26] 胡长胜，赵伟民，李瑰贤，一种新型压差负反馈平衡阀，液压与气动，2005(3)，52-53
[27] William L Geers, Hank Litchfield, Circuit balancing valves, PM Engineer; Sep 2001; 7, 9; Academic Research Library, pg. 32
[28] 查小春，李定华，先导式液压平衡阀动态性能及育关参数设计与分析，机床与液压，1994(3)，161-166
[29] 杨伟洪，新型的插件式双向平衡阀特性初探，机电设备，1994(5)，45-48
[30] Won-Pyo Chang, Young-MiffKwon, Yong-Bum Lee, Dohee Hahn, Model development for analysis of the Korea advanced liquid metal reactor, W.-P. Chang et al. / Nuclear Engineering and Design 217 (2002) 64 63-80
[31] 李自光，颜国平，杨荣庆，新型平衡阀系统计算机仿真及参数优化研究．中国公路学报，1998(7)，121-126
[32] Anonymous, Power Modulation and Control, Machine Design; Jun 1990; 62, 11; ABI/INFORM Global pg. 588
[33] 伍艳芳，葛思华，王佑民，史维祥，负载敏感系统的稳定性分析，西安交通大学学报，1992(2)，23-28
[2] 陈奎生，液压与气压传动，湖北武汉，武汉理工大学出版社，2001．8
[3] 贺劲，液压步履式桩架起架机构平衡回路的改进设计，建设机械技术与管理，1995(4)，26-27
[4] 金平海，张平，汽车起重机平衡阀原理及故障排除，山东交通科技，2003(2)，59、83
[5] 赵春红，起重机液压平衡回路的改进，起重运输机械，2000(8)，33-35
[6] 刘国臣，新型双作用缓冲平衡阀，液压与气动，2000(3)，45
[7] 彭勇，FD型平衡阀的工作原理，建设机械技术与管理，2002(7)，31
[8] 廖义德，李壮云，带压力补偿平衡阀的设计及性能研究，锻压装备与制造技术2003(3)，22-24
[9] 杨国平，贺尚红，李自光，新型平衡阀数字仿真研究，长沙交通学院学报 1995(3)，23-30
[10 ]黄宗益，李兴华，陈明，液压传动的负载敏感和压力补偿
[11] 宋鸿尧，丁忠尧，液压阀设计与计算，北京，机械工业出版社，1979．12
[12] B eyerle, Richard, Low power actuates balanced valve, Machine Design; Apt 18, 1996; 68, 8; ABI/INFORM Global, pg. 72
[13] 李峰，马长林，平衡阀动态特性仿真与参数优化研究，机床与液压，2003(4)，232-234
[14] Joe Scott, Balancing valves a key to reliable recirculation, Contractor; Feb 1999; 46, 2; ABI/INFORM Global, pg. 40
[15] Tom Sato, Kenzo Tonoki, Takuro Yoshikawa, Yoshihiro Tsuchiya, Numerical and hydraulic simulations of the effect of Density Current Generator in a semi-enclosed tidal bay, T. Sato et al. / Coastal Engineering 53 (2006) 49-64
[16] 赵敏，南志华，王红光，平衡阀模拟工况试验研究，机械管理开发，2001(11)，35-37
[17] C Kosarzecki, A counterbalance valve's biggest enemy, Hydraulics & Pneumatics; Mar 2003; 56, 3; ABI/INFORM Trade & Industry pg. 47
[18] Richard T Schneider, Hysteresis-a counterbalance valve's worst enemy, Hydraulics & Pneumatics; Mar 2000; 53, 3; ABI/INFORM Trade & Industry pg. 37
[19] 郝贵成，韩进，负载传感液压系统的设计，液压与气动，1993(1)，12-15
[20] Anonymous, Basics ofdesignengineering: Pressure valves, Machine Design; Jun 15, 1995; 67, 11; ABI/INFORM Global pg. 162
[21] Muhammad M. Rahman and Jose L. F. Porteiro, Numerical simulation and animation of oscillating turbulent flow in a counterbalance valve
[22] Jill E. Krutz, Design of a hydraulic actuator test stand for non-linear analysis of hydraulic actuator systems,2001
[23] 贺辉，新型工程机械液压平衡阀的设计与实验研究，湖南大学硕士学位论文，2002
[24] 陈奎生，液压与气压传动，湖北，武汉理工大学出版社，2001
[25] 王起龙，机械工程手册(第二版)·传动设计卷·第四篇，北京，机械工业出版社，1996
[26] 胡长胜，赵伟民，李瑰贤，一种新型压差负反馈平衡阀，液压与气动，2005(3)，52-53
[27] William L Geers, Hank Litchfield, Circuit balancing valves, PM Engineer; Sep 2001; 7, 9; Academic Research Library, pg. 32
[28] 查小春，李定华，先导式液压平衡阀动态性能及育关参数设计与分析，机床与液压，1994(3)，161-166
[29] 杨伟洪，新型的插件式双向平衡阀特性初探，机电设备，1994(5)，45-48
[30] Won-Pyo Chang, Young-MiffKwon, Yong-Bum Lee, Dohee Hahn, Model development for analysis of the Korea advanced liquid metal reactor, W.-P. Chang et al. / Nuclear Engineering and Design 217 (2002) 64 63-80
[31] 李自光，颜国平，杨荣庆，新型平衡阀系统计算机仿真及参数优化研究．中国公路学报，1998(7)，121-126
[32] Anonymous, Power Modulation and Control, Machine Design; Jun 1990; 62, 11; ABI/INFORM Global pg. 588
[33] 伍艳芳，葛思华，王佑民，史维祥，负载敏感系统的稳定性分析，西安交通大学学报，1992(2)，23-28