电磁阀检测系统的研发及相关流体控制技术的研究
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摘要
电磁阀是工业控制系统中重要的执行元件,其性能的好坏直接关系到整个系统的安全性及可靠性。鉴于我国目前尚没有功能完备且技术先进的电磁阀自动检测设备,本论文以某电磁阀生产企业的项目为背景研发了一套多功能和智能化的电磁阀检测系统。该检测系统的研发对推动电磁阀企业的生产及电磁阀行业的发展起着重要的作用。本文通过理论分析、计算机仿真技术及试验研究相结合的方法,对电磁阀检测系统的开发和相关流体控制技术进行了深入的研究和探讨,主要研究工作如下：
1.首先进行了电磁阀检测系统的总体方案设计,该方案可分为计算机测控系统和流体控制系统两大部分,其中对于计算机测控系统的开发涉及到硬件和软件两个方面：硬件方面着重研究上位工控机与下位机PLC组成的集成控制方案,并讨论了硬件结构和配置及硬件抗干扰技术；软件方面以虚拟仪器技术的设计思想为指导,设计了电磁阀各项性能试验的测试平台,采用Labview开发了测控软件,该软件可自动完成对电磁阀的性能测试,具有数据采集、控制、数据分析、结果数据库管理和打印输出以及用户界面等功能。
2.电磁阀试验台具有频繁使用且间歇动作的特性,管路内流体经常以非恒定流状态频繁振荡,导致管路振动继而损坏高精度传感器和流体元件。因此,本论文对电磁阀试验台主测试管路的动态特性进行研究,运用阻抗分析法分析主测试管路发生谐振的条件以及该管路在频率域内的压力传递特性。采用流体管路频域模型的近似方法对主测试管路的压力比频率特性进行了仿真研究,通过仿真研究对流体管路的几何尺寸和管路的长度等因素作出了合理的结构设计。
3.分析了诱发液压冲击和脉动产生的机理,计算了最大冲击压力和泵源脉动频率。因在实际的流体系统中根本消除压力冲击和振动源的脉动是极其困难的,采用调整系统的阻抗特性(如改变管长和元件结构等)又要受到系统合理设计的限制(如系统正常运行工况、元件安装空间方位等),因此,采用蓄能器以衰减或吸收液压冲击和脉动。通过对蓄能器的消减作用及其动态特性的分析,进而合理选择蓄能器的相关参数,使蓄能器达到最佳的减振效果。
4.设计了电磁阀试验台流体系统的压力控制方案。针对该流体系统中压力难于精确控制的问题,分析了变频泵控调压的压力控制原理,并对压力控制的关键元器件进行了合理选择。建立了流体系统压力的数学模型并根据模糊控制和PID控制各自的优点,选择模糊自适应PID控制算法为系统压力控制策略,进行了仿真研究,并将其应用于系统泄漏试验和密封试验中。
5.基于以上流体控制技术关键问题的研究,设计了流体试验台和阐述了其结构和工作原理,并在现场搭建完成所设计的试验台。遵循国家规范和行业标准研究了不同类型电磁阀产品的出厂试验和型式试验的试验方法和流程。最后对所设计和开发电磁阀检测系统进行了实际运行及进行了电磁阀的各项性能检测现场试验。现场试验不仅验证了本文对于电磁阀检测系统的研发和相关流体控制技术的研究思路和研究方法是可行的,同时也表明该电磁阀检测系统不但完全满足电磁阀产品生产的需要,而且功能完善、自动化程度高且具有极高的应用和推广价值。
本文的相关研究不仅为成功开发一个高性能的电磁阀检测系统提供了有力的理论依据和技术保障,同时对自动化测控领域和相关流体控制技术的理论研究及实际应用也具有重要的学术参考价值。
Solenoid valve is an important actuator of industry control system, which is directly related to the security and reliability of the whole system. Whereas lacking of test equipment for solenoid valve with comprehensive function and advanced technology in our country, a multifunctional and intelligent testing system of solenoid valve is developed in this paper by cooperating with a leading enterprise. The developing of this test system can promote producing of the enterprise and the development of solenoid industry. Researches on the key technologies about system developing and fluid control are conducted with the combination of theoretic analysis, computer simulation and experimental study. The main research contents are as follows:
1. The overall scheme was designed which was consisted of the computer test and control system and the fluid control system. For the developing the computer test and control system this thesis utilized the software and hardware sources. In hardware part the integrated controlling scheme about IPC and PLC was researched with great emphasis on, and the anti-interference technique was discussed. In software part with the idea based on virtual instrument technology the test platform for all performance tests of solenoid valves was designed and the test software was developed with Labview. The software could fulfill automatically the performance tests for solenoid valves, and possesses the function of data collection, controlling, analyzing, result management and printing, as well as intuitionist user interface.
2. For the solenoid valve test-bed has the characteristic of being used frequently and acting intermittently, liquid in pipeline is always in the state of unsteady flow and it makes the pipeline vibrating which would damaged the delicate sensors and fluid components. So the dynamic characteristic of main test pipeline in solenoid valve test-bed was studied, and the impedance was applied to research the conduction of resonance and the characteristic of pressure dissemination in frequency domain. Furthermore, the simulation research was carried on with approximation method about frequency domain characteristic for pipeline. From the results of simulation we made the reasonable structure design about the diameter and length of the pipeline.
3. In this thesis mechanism of inducing hydraulic impact and pressure fluctuation were analyzed, and the maximum value of impact pressure and the fluctuation frequency of pump were calculated. At the same time it is difficult to remove the impact and fluctuation essentially, but to adjust the impedance, for example changing the length of pipeline or the structure of components, etc, is constricted by the reasonable system design including the normal running state of system and special location of components. Consequently, accumulators were installed to attenuate or absorb impact and fluctuation. Furthermore, its related parameters were chosen rationally to achieve the best effect of eliminating vibration based on the research on the working principle and dynamic characteristic of accumulators.
4. Pressure control scheme for solenoid test-bed was designed. In view of the problem about pressure precisely control the pressure control principle was analyzed, and relative components are introduced. A mathematical model of system pressure is created, and the intelligent algorithms which are fuzzy adaptive PID control were proposed by combining advantages of fuzzy control and PID control as the best control strategy for system pressure control. The pressure simulation experiments were carried out in leakage and sealing experiments.
5. Based on the analysis of the key problems of fluid control, the test-bed for solenoid valve was designed of which structure and principle were explained, and built it in the workshop. Furthermore, according the principle of the performance tests analyzed above, test methods were conducted on different types of solenoid valve products about delivery inspection and type tests followed the national standards and industry standards. At last the test system for solenoid valve which was designed and developed was operated actually, and solenoid valves were tested in all performance tests. The tests prove that the feasibility of the method about the design for solenoid valve test-bed and researches on fluid control technique in this thesis, and also prove that not only fully meet the needs of actual batch production, but also have a perfect function and high automation in wide applications.
The related research results not only provide theoretical foundation and technical support for successful development of a high performance solenoid valve test system, but also have some value in academic reference for theoretical research and practical applications in the automated measurement and control fields.
1.首先进行了电磁阀检测系统的总体方案设计,该方案可分为计算机测控系统和流体控制系统两大部分,其中对于计算机测控系统的开发涉及到硬件和软件两个方面：硬件方面着重研究上位工控机与下位机PLC组成的集成控制方案,并讨论了硬件结构和配置及硬件抗干扰技术；软件方面以虚拟仪器技术的设计思想为指导,设计了电磁阀各项性能试验的测试平台,采用Labview开发了测控软件,该软件可自动完成对电磁阀的性能测试,具有数据采集、控制、数据分析、结果数据库管理和打印输出以及用户界面等功能。
2.电磁阀试验台具有频繁使用且间歇动作的特性,管路内流体经常以非恒定流状态频繁振荡,导致管路振动继而损坏高精度传感器和流体元件。因此,本论文对电磁阀试验台主测试管路的动态特性进行研究,运用阻抗分析法分析主测试管路发生谐振的条件以及该管路在频率域内的压力传递特性。采用流体管路频域模型的近似方法对主测试管路的压力比频率特性进行了仿真研究,通过仿真研究对流体管路的几何尺寸和管路的长度等因素作出了合理的结构设计。
3.分析了诱发液压冲击和脉动产生的机理,计算了最大冲击压力和泵源脉动频率。因在实际的流体系统中根本消除压力冲击和振动源的脉动是极其困难的,采用调整系统的阻抗特性(如改变管长和元件结构等)又要受到系统合理设计的限制(如系统正常运行工况、元件安装空间方位等),因此,采用蓄能器以衰减或吸收液压冲击和脉动。通过对蓄能器的消减作用及其动态特性的分析,进而合理选择蓄能器的相关参数,使蓄能器达到最佳的减振效果。
4.设计了电磁阀试验台流体系统的压力控制方案。针对该流体系统中压力难于精确控制的问题,分析了变频泵控调压的压力控制原理,并对压力控制的关键元器件进行了合理选择。建立了流体系统压力的数学模型并根据模糊控制和PID控制各自的优点,选择模糊自适应PID控制算法为系统压力控制策略,进行了仿真研究,并将其应用于系统泄漏试验和密封试验中。
5.基于以上流体控制技术关键问题的研究,设计了流体试验台和阐述了其结构和工作原理,并在现场搭建完成所设计的试验台。遵循国家规范和行业标准研究了不同类型电磁阀产品的出厂试验和型式试验的试验方法和流程。最后对所设计和开发电磁阀检测系统进行了实际运行及进行了电磁阀的各项性能检测现场试验。现场试验不仅验证了本文对于电磁阀检测系统的研发和相关流体控制技术的研究思路和研究方法是可行的,同时也表明该电磁阀检测系统不但完全满足电磁阀产品生产的需要,而且功能完善、自动化程度高且具有极高的应用和推广价值。
本文的相关研究不仅为成功开发一个高性能的电磁阀检测系统提供了有力的理论依据和技术保障,同时对自动化测控领域和相关流体控制技术的理论研究及实际应用也具有重要的学术参考价值。
Solenoid valve is an important actuator of industry control system, which is directly related to the security and reliability of the whole system. Whereas lacking of test equipment for solenoid valve with comprehensive function and advanced technology in our country, a multifunctional and intelligent testing system of solenoid valve is developed in this paper by cooperating with a leading enterprise. The developing of this test system can promote producing of the enterprise and the development of solenoid industry. Researches on the key technologies about system developing and fluid control are conducted with the combination of theoretic analysis, computer simulation and experimental study. The main research contents are as follows:
1. The overall scheme was designed which was consisted of the computer test and control system and the fluid control system. For the developing the computer test and control system this thesis utilized the software and hardware sources. In hardware part the integrated controlling scheme about IPC and PLC was researched with great emphasis on, and the anti-interference technique was discussed. In software part with the idea based on virtual instrument technology the test platform for all performance tests of solenoid valves was designed and the test software was developed with Labview. The software could fulfill automatically the performance tests for solenoid valves, and possesses the function of data collection, controlling, analyzing, result management and printing, as well as intuitionist user interface.
2. For the solenoid valve test-bed has the characteristic of being used frequently and acting intermittently, liquid in pipeline is always in the state of unsteady flow and it makes the pipeline vibrating which would damaged the delicate sensors and fluid components. So the dynamic characteristic of main test pipeline in solenoid valve test-bed was studied, and the impedance was applied to research the conduction of resonance and the characteristic of pressure dissemination in frequency domain. Furthermore, the simulation research was carried on with approximation method about frequency domain characteristic for pipeline. From the results of simulation we made the reasonable structure design about the diameter and length of the pipeline.
3. In this thesis mechanism of inducing hydraulic impact and pressure fluctuation were analyzed, and the maximum value of impact pressure and the fluctuation frequency of pump were calculated. At the same time it is difficult to remove the impact and fluctuation essentially, but to adjust the impedance, for example changing the length of pipeline or the structure of components, etc, is constricted by the reasonable system design including the normal running state of system and special location of components. Consequently, accumulators were installed to attenuate or absorb impact and fluctuation. Furthermore, its related parameters were chosen rationally to achieve the best effect of eliminating vibration based on the research on the working principle and dynamic characteristic of accumulators.
4. Pressure control scheme for solenoid test-bed was designed. In view of the problem about pressure precisely control the pressure control principle was analyzed, and relative components are introduced. A mathematical model of system pressure is created, and the intelligent algorithms which are fuzzy adaptive PID control were proposed by combining advantages of fuzzy control and PID control as the best control strategy for system pressure control. The pressure simulation experiments were carried out in leakage and sealing experiments.
5. Based on the analysis of the key problems of fluid control, the test-bed for solenoid valve was designed of which structure and principle were explained, and built it in the workshop. Furthermore, according the principle of the performance tests analyzed above, test methods were conducted on different types of solenoid valve products about delivery inspection and type tests followed the national standards and industry standards. At last the test system for solenoid valve which was designed and developed was operated actually, and solenoid valves were tested in all performance tests. The tests prove that the feasibility of the method about the design for solenoid valve test-bed and researches on fluid control technique in this thesis, and also prove that not only fully meet the needs of actual batch production, but also have a perfect function and high automation in wide applications.
The related research results not only provide theoretical foundation and technical support for successful development of a high performance solenoid valve test system, but also have some value in academic reference for theoretical research and practical applications in the automated measurement and control fields.
引文
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