锻造操作机主运动机构电液比例控制系统研究
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摘要
随着我国科技发展对大型锻件需求量的不断增加,锻造装备正朝着重载化、自动化的方向发展,锻造操作机是一种辅助锻造液压机工作的大型操作设备,其在大负载时的灵活性大大提升了工件的锻造效率。作为辅助设备,操作机需要密切配合压机的运动,这对操作机的控制性能提出了很高的要求,而电液系统承担着操作机所有动作的完成,其控制性能决定着操作机的整机性能,因此电液系统的设计和控制是锻造操作机的关键技术之一。环境恶劣、工况复杂及负载惯量大等特点给操作机电液系统控制带来了很大的挑战,而操作机主运动机构电液系统,包括提升系统、俯仰系统和缓冲系统,存在着运动耦合,控制难度较其他系统更高,因此如何实现操作机重载下的精确控制和保证其与压机配合过程中的良好缓冲性能,是锻造操作机主运动机构电液系统设计面临的重大挑战。
针对一种重载锻造操作机,进行了主运动机构电液系统的原理设计并建立了其数学模型,建立了锻件的弹塑性形变模型以及操作机主运动机构的运动学和动力学模型,结合电液系统数学模型,搭建了锻造操作机“锻件-机构-液压”复合仿真模型。借助该复合仿真模型,分析了电液系统的负载特性和控制特点,研究了重载和软管连接等对系统控制性能的影响,并针对比例方向阀和软管特性,设计了阀芯位移补偿算法和软管补偿算法,借助仿真和模拟试验台,验证了补偿算法的有效性。为了研究夹钳的运动控制性能,仿真分析了主运动机构电液系统之间的耦合特性,并提出了夹钳运动策略,进行了双动进给快速锻造过程仿真。为了提高操作机的缓冲性能,借助复合仿真模型对工件的拔长过程进行了仿真分析,研究发现,提高提升系统的位移跟踪精度和增加蓄能器模块都有助于提高夹钳在竖直方向上的缓冲性能,在缓冲系统中增加配置合理的蓄能器模块有助于提高夹钳在水平方向上的缓冲性能。
本论文具体研究内容如下：
第一章,概述了锻造操作机的工作原理及国内外发展历程,阐述了锻造操作机电液系统驱动与控制技术现状,并对操作机常见构型做了介绍,分析了本课题的研究背景及研究意义,介绍了课题的主要研究内容。
第二章,针对一种巨型重载锻造操作机,分析了其主运动机构结构特点,并设计了前后提升系统、俯仰系统、缓冲系统的液压原理图；在建立电液系统各元器件数学模型的基础上,借助MATLAB/Simulink软件,搭建了三个电液系统的仿真模型,采用各电液系统最常用工况为对象,初步分析了提升系统位移控制性能以及缓冲系统的缓冲性能。
第三章,以一种新构型重载操作机为对象,建立了主运动机构电液系统的负载数学模型,包括锻件塑性形变和弹性形变数学模型以及主运动机构的动力学模型,并搭建了操作机“锻件-机构-液压”复合仿真模型,并给出了电液系统初始压力设置方法。借助复合仿真模型,研究了提升、俯仰以及缓冲系统的等效重量负载和等效惯量负载,分析了三个系统的负载特性和控制性能。
第四章,针对锻造操作机电液比例系统的控制特性,研究了控制阀与液压缸之间的连接软管、比例方向阀的低频响及死区特性等对操作机提升系统控制精度的不利影响,针对大惯性负载及软管弹性导致的系统频响低、控制器参数调定困难等特点,设计了基于比例阀压力流量特性的阀芯位移补偿策略。同时研究了控制阀与执行器之间连接的软管对轨迹跟踪精度的影响,并针对性的设计了基于模型的软管补偿策略。
第五章,建立了操作机提升系统AMESim仿真模型,通过与常规PID控制的对比仿真,分析了比例方向阀阀芯位移补偿策略及软管补偿策略的作用,并研究了补偿策略对系统稳定性的影响。针对操作机系统位移跟踪的实际要求,搭建了提升系统位移跟踪负载模拟试验台,借助模拟试验台开展了补偿策略对系统闭环位移控制的影响研究,重点对比了带补偿策略的比例控制与常规PID控制的位移跟踪性能。借助仿真模型对提升系统进行线性化分析,研究了补偿策略对系统稳定性的影响。
第六章,分析了操作机主运动机构电液系统之间的耦合特性,设计了夹钳位姿观测器和夹钳运动控制策略,并仿真研究了操作机的双动进给快速锻造过程。以工件的拔长过程为分析对象,针对操作机夹钳的缓冲运动过程开展了仿真研究,分析了提升系统的控制性能对其缓冲性能的影响,研究了蓄能器在提升系统和缓冲系统中的作用。
第七章,对本文的研究工作进行了概述,给出了研究结果和主要结论,指出了本文的创新点,并展望了进一步的研究方向和内容。
With the development of the technology and economic of our country, the demand for large forgings is increasing deeply, thus the heavy load and automation are the main direction of the forging equipment. Forging manipulator, whose dexterity under heavy load increases the efficiency of the forging, is large ancillary equipment for the forging press in a free forging center. As auxiliary equipment, the manipulator has to cooperate with the movement of the forging press closely, so the control performance of the manipulator is very important. In a forging manipulator, all the movements are controlled by the electro-hydraulic system and its control performance has an impact on the property of the manipulator, thus the design and control of the electro-hydraulic system is one of the key technologies for the forging manipulator. Extreme environment, complex working condition and heavy load bring challenges to the control of the systems, especially the electro-hydraulic systems of the major-motion mechanisms, including front and rear lifting systems, pitching system and buffering system, as they are coupling together. In this condition, how to get precise control under heavy load and good buffering performance during the corporation work is the main problem for the electro-hydraulic systems of the forging manipulator.
In this dissertation, the electro-hydraulic systems of the major-motion mechanism for a heavy duty forging manipulator are designed and mathematic models are built accordingly. The plastic deformation and elastic deformation models of the forging, and the kinematics and dynamics of the major-motion mechanism are built in the dissertation, combined with the mathematic models of the electro-hydraulic systems, the co-simulation model of the major-motion mechanism is built in MATLAB/Simulink. With the co-simulation model, the characteristic of the loads for the hydraulic systems is studied, and the control characteristic of the lifting system is analyzed. In order to improve the control performance of the lifting system, the influence of heavy load and hose of the system are studied, then spool displacement compensation is designed based on the characteristics of the proportional valve and hose compensation is designed based on the mathematical model of the rubber hose. Both simulation and experiment results show that the compensation strategies are effective in improving the displacement tracking precision of the lifting system. With the digital prototype, the coupling characteristic of the major-motion mechanism is analyzed and control strategy for the pose of the clamp is designed. In order to improve the buffering performance of the clamp, a stretching process of a flat-tool is simulated and it is shown that the vertical buffering performance of the clamp will be improved by increasing the tracking precision of the lifting system and the horizontal buffering performance of the clamp will be improved by arranging well-adjusted accumulators to the buffering system.
The main contents of the dissertation are presented as follows:
In chapter1, the working principle and the developing history of the forging manipulator in our country and abroad were outlined, the drive and control technology of the electro-hydraulic system and the common structure of the forging manipulator were summarized, the researching background and significance were also analyzed and the main contents of the subject were introduced.
In chapter2, the characteristic of major-motion mechanism was analyzed according to a heavy duty forging manipulator and the schematic diagram of the lifting systems, the pitching system and the buffering system were designed. Simulation models of the hydraulic systems were built in MATLAB/Simulink based on the mathematic models of the components in the hydraulic circuits. Aiming at the fundamental motion, the control performance of the lifting system and the buffering performance of the buffering system were preliminarily studied.
In chapter3, one new type heavy load forging manipulator was introduced and the loads of the hydraulic systems, including the plastic deformation and elastic deformation of the work piece and the dynamic model of the major-motion mechanisms. The co-simulation model of the work piece, the mechanism and the hydraulic system was built. Then equivalent gravity loads and equivalent inertia loads of the hydraulic systems were calculated with the co-simulation model, the characteristic of the load was analyzed.
In chapter4, the lifting system of the forging manipulator was studied, and it was shown that the rubber hose connected from the control valve to the cylinder, the dead zone and low natural frequency of the proportional valve make it difficult to get good tracking precision. Aiming at these disadvantages of the lifting system, spool displacement compensation and hose compensation strategies were designed based on the mathematical model of the system.
In chapter5, simulation model of the lifting system was built in the environment of AMESim and the compensation strategies were tested in comparing with traditional PID control. Displacement tracking test rig of the lifting system was built according to the lifting system of the forging manipulator. Comparative experiments were carried out between the optimal traditional PID control and P control with the compensation strategies. Besides, the simulation model of the lifting system was linearized in AMESim, and the stability was studied and results showed that it is independent of the compensation strategies.
In chapter6, the coupling characteristic of the major-motion mechanism and the motion control property of the clamp were analyzed, the motion control strategy of the clamp was designed, and the quick forging mode of the manipulator was studied with the control strategy. Aiming at the stretching process of a plat-tool, the buffering behavior of the clamp was simulated with the co-simulation model. The effect of the displacement tracking performance and the accumulator were studied based on the optimization of the lifting and the buffering systems.
In chapter7, the main results and conclusions were summarized, the achievements were concluded, and suggestions were provided for the future work.
针对一种重载锻造操作机,进行了主运动机构电液系统的原理设计并建立了其数学模型,建立了锻件的弹塑性形变模型以及操作机主运动机构的运动学和动力学模型,结合电液系统数学模型,搭建了锻造操作机“锻件-机构-液压”复合仿真模型。借助该复合仿真模型,分析了电液系统的负载特性和控制特点,研究了重载和软管连接等对系统控制性能的影响,并针对比例方向阀和软管特性,设计了阀芯位移补偿算法和软管补偿算法,借助仿真和模拟试验台,验证了补偿算法的有效性。为了研究夹钳的运动控制性能,仿真分析了主运动机构电液系统之间的耦合特性,并提出了夹钳运动策略,进行了双动进给快速锻造过程仿真。为了提高操作机的缓冲性能,借助复合仿真模型对工件的拔长过程进行了仿真分析,研究发现,提高提升系统的位移跟踪精度和增加蓄能器模块都有助于提高夹钳在竖直方向上的缓冲性能,在缓冲系统中增加配置合理的蓄能器模块有助于提高夹钳在水平方向上的缓冲性能。
本论文具体研究内容如下：
第一章,概述了锻造操作机的工作原理及国内外发展历程,阐述了锻造操作机电液系统驱动与控制技术现状,并对操作机常见构型做了介绍,分析了本课题的研究背景及研究意义,介绍了课题的主要研究内容。
第二章,针对一种巨型重载锻造操作机,分析了其主运动机构结构特点,并设计了前后提升系统、俯仰系统、缓冲系统的液压原理图；在建立电液系统各元器件数学模型的基础上,借助MATLAB/Simulink软件,搭建了三个电液系统的仿真模型,采用各电液系统最常用工况为对象,初步分析了提升系统位移控制性能以及缓冲系统的缓冲性能。
第三章,以一种新构型重载操作机为对象,建立了主运动机构电液系统的负载数学模型,包括锻件塑性形变和弹性形变数学模型以及主运动机构的动力学模型,并搭建了操作机“锻件-机构-液压”复合仿真模型,并给出了电液系统初始压力设置方法。借助复合仿真模型,研究了提升、俯仰以及缓冲系统的等效重量负载和等效惯量负载,分析了三个系统的负载特性和控制性能。
第四章,针对锻造操作机电液比例系统的控制特性,研究了控制阀与液压缸之间的连接软管、比例方向阀的低频响及死区特性等对操作机提升系统控制精度的不利影响,针对大惯性负载及软管弹性导致的系统频响低、控制器参数调定困难等特点,设计了基于比例阀压力流量特性的阀芯位移补偿策略。同时研究了控制阀与执行器之间连接的软管对轨迹跟踪精度的影响,并针对性的设计了基于模型的软管补偿策略。
第五章,建立了操作机提升系统AMESim仿真模型,通过与常规PID控制的对比仿真,分析了比例方向阀阀芯位移补偿策略及软管补偿策略的作用,并研究了补偿策略对系统稳定性的影响。针对操作机系统位移跟踪的实际要求,搭建了提升系统位移跟踪负载模拟试验台,借助模拟试验台开展了补偿策略对系统闭环位移控制的影响研究,重点对比了带补偿策略的比例控制与常规PID控制的位移跟踪性能。借助仿真模型对提升系统进行线性化分析,研究了补偿策略对系统稳定性的影响。
第六章,分析了操作机主运动机构电液系统之间的耦合特性,设计了夹钳位姿观测器和夹钳运动控制策略,并仿真研究了操作机的双动进给快速锻造过程。以工件的拔长过程为分析对象,针对操作机夹钳的缓冲运动过程开展了仿真研究,分析了提升系统的控制性能对其缓冲性能的影响,研究了蓄能器在提升系统和缓冲系统中的作用。
第七章,对本文的研究工作进行了概述,给出了研究结果和主要结论,指出了本文的创新点,并展望了进一步的研究方向和内容。
With the development of the technology and economic of our country, the demand for large forgings is increasing deeply, thus the heavy load and automation are the main direction of the forging equipment. Forging manipulator, whose dexterity under heavy load increases the efficiency of the forging, is large ancillary equipment for the forging press in a free forging center. As auxiliary equipment, the manipulator has to cooperate with the movement of the forging press closely, so the control performance of the manipulator is very important. In a forging manipulator, all the movements are controlled by the electro-hydraulic system and its control performance has an impact on the property of the manipulator, thus the design and control of the electro-hydraulic system is one of the key technologies for the forging manipulator. Extreme environment, complex working condition and heavy load bring challenges to the control of the systems, especially the electro-hydraulic systems of the major-motion mechanisms, including front and rear lifting systems, pitching system and buffering system, as they are coupling together. In this condition, how to get precise control under heavy load and good buffering performance during the corporation work is the main problem for the electro-hydraulic systems of the forging manipulator.
In this dissertation, the electro-hydraulic systems of the major-motion mechanism for a heavy duty forging manipulator are designed and mathematic models are built accordingly. The plastic deformation and elastic deformation models of the forging, and the kinematics and dynamics of the major-motion mechanism are built in the dissertation, combined with the mathematic models of the electro-hydraulic systems, the co-simulation model of the major-motion mechanism is built in MATLAB/Simulink. With the co-simulation model, the characteristic of the loads for the hydraulic systems is studied, and the control characteristic of the lifting system is analyzed. In order to improve the control performance of the lifting system, the influence of heavy load and hose of the system are studied, then spool displacement compensation is designed based on the characteristics of the proportional valve and hose compensation is designed based on the mathematical model of the rubber hose. Both simulation and experiment results show that the compensation strategies are effective in improving the displacement tracking precision of the lifting system. With the digital prototype, the coupling characteristic of the major-motion mechanism is analyzed and control strategy for the pose of the clamp is designed. In order to improve the buffering performance of the clamp, a stretching process of a flat-tool is simulated and it is shown that the vertical buffering performance of the clamp will be improved by increasing the tracking precision of the lifting system and the horizontal buffering performance of the clamp will be improved by arranging well-adjusted accumulators to the buffering system.
The main contents of the dissertation are presented as follows:
In chapter1, the working principle and the developing history of the forging manipulator in our country and abroad were outlined, the drive and control technology of the electro-hydraulic system and the common structure of the forging manipulator were summarized, the researching background and significance were also analyzed and the main contents of the subject were introduced.
In chapter2, the characteristic of major-motion mechanism was analyzed according to a heavy duty forging manipulator and the schematic diagram of the lifting systems, the pitching system and the buffering system were designed. Simulation models of the hydraulic systems were built in MATLAB/Simulink based on the mathematic models of the components in the hydraulic circuits. Aiming at the fundamental motion, the control performance of the lifting system and the buffering performance of the buffering system were preliminarily studied.
In chapter3, one new type heavy load forging manipulator was introduced and the loads of the hydraulic systems, including the plastic deformation and elastic deformation of the work piece and the dynamic model of the major-motion mechanisms. The co-simulation model of the work piece, the mechanism and the hydraulic system was built. Then equivalent gravity loads and equivalent inertia loads of the hydraulic systems were calculated with the co-simulation model, the characteristic of the load was analyzed.
In chapter4, the lifting system of the forging manipulator was studied, and it was shown that the rubber hose connected from the control valve to the cylinder, the dead zone and low natural frequency of the proportional valve make it difficult to get good tracking precision. Aiming at these disadvantages of the lifting system, spool displacement compensation and hose compensation strategies were designed based on the mathematical model of the system.
In chapter5, simulation model of the lifting system was built in the environment of AMESim and the compensation strategies were tested in comparing with traditional PID control. Displacement tracking test rig of the lifting system was built according to the lifting system of the forging manipulator. Comparative experiments were carried out between the optimal traditional PID control and P control with the compensation strategies. Besides, the simulation model of the lifting system was linearized in AMESim, and the stability was studied and results showed that it is independent of the compensation strategies.
In chapter6, the coupling characteristic of the major-motion mechanism and the motion control property of the clamp were analyzed, the motion control strategy of the clamp was designed, and the quick forging mode of the manipulator was studied with the control strategy. Aiming at the stretching process of a plat-tool, the buffering behavior of the clamp was simulated with the co-simulation model. The effect of the displacement tracking performance and the accumulator were studied based on the optimization of the lifting and the buffering systems.
In chapter7, the main results and conclusions were summarized, the achievements were concluded, and suggestions were provided for the future work.
引文
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