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高精度、高效率硬支承平衡机测量系统若干关键技术研究
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摘要
论文基于对硬支承平衡机测量技术发展现状的分析,从完善平衡机振动系统的动力学分析、高效不平衡测量的数据处理方法以及平衡机振动信号模拟生成这三个方面展开研究。
     平衡机的测量方程通常从振动微分方程得到,但若将基座振动的影响考虑在内,振动系统微分方程将十分复杂。本文将多体模型方法引入到不平衡振动系统分析中,与微分方程方法相比,同样具有高精度下具有较小的计算量,同时能够详细得到各部分的状态量。
     现有各种不平衡振动信号处理方法的不平衡提取精度非常依赖于样本数据的长度,影响平衡效率尤其是低速动平衡的效率,针对这一问题本文提出了基于残差MUSIC谱分析的不平衡信号处理方法。MUSIC谱内含对信号组成成分和结构特征的建模和预测,具有很高的频率分辨率。通过遍历匹配信号的幅值和相位求取残差的MUSIC谱极小值的方法,利用较少的数据样本即可以得到满足精度要求的不平衡信号的幅值和相位。采用该方法对现场采样振动信号进行了提取,并与相关滤波法的提取结果进行了对比,结果表明该方法具有较高提取的精度和良好的重复性。
     探索了采用AR预测模型对采样振动信号进行预测和延拓,增加有效数据样本的方法。将其应用到基于残差MUSIC谱分析法提取不平衡信号的方法中,可以进一步缩短对信号长度的要求。数据仿真验证了该处理方法的有效性。同时也对现场平衡机信号进行了提取,能够在有限长度内准确提取出不平衡信号的幅值和相位。
     针对一直以来无法独立评估平衡机测量系统性能、无法有效评价各种不平衡振动信号处理方法的问题,探索了对不平衡振动信号进行数字模拟建立不平衡振动信号库的可能性。在分析干扰源并对其进行频域分析和功率谱分析的基础上,建立了用于估计平衡机振动信号功率谱的AR模型,给出了阶数选取的依据并进行了实验对比。采用改进的协方差法求解了该功率谱模型的参数。由Ziggurat方法生成的高斯白噪声信号通过该AR功率谱模型完成对传感器输出信号的数字仿真。实验对比了仿真信号与实际振动传感器输出信号的功率谱,结果表明仿真信号与传感器信号具有很强的相似性。
     研制了高精度通用硬支承动平衡机测量系统。系统采用嵌入式结构,基于linux系统的人机交互编程,用户界面友好,系统稳定性强,具有较好的扩展能力。系统的最小可达剩余不平衡量为0.1μm,一次不平衡降低率为95%,满足高精度机床主轴等旋转机械的动平衡试验要求。
Considering the high efficacy and general feature, hard-bearingbalancing machine has advantages over soft-bearing one in unbalancingmeasurement. These advantages are from its vibration responseequivalent to static force when ignoring the rotor’s inertia. In the presentresearch, vibration response is analyzed by the establishment of dynamicdifferential equation. To obtain distinct physical-mathematical equation,these analyses do not involve the influence of the base. In the thesis, themulti-body dynamic model, comprising the mass and rigidity of the base,is introduced to comprehensively analyze vibration response ofunbalancing machine. Besides lower computational complexity, thismethod can get more vibration information of unbalancing machine andprovide theoretical evidences for designing the base of the balancingmachine。
     The extraction efficacy and precision of unbalancing signal is limitedby the length of the sampling data. MUSIC spectrum based on residualerror, which can predict the element and structure of the unknown signal,is presented to improve this problem. The amplitude and phase of theunbalancing signal can be determined after matching signal retrieval. Theexperiment results validate this proposed method could improve theextraction precision of unbalancing signal from the limited lengthsampling signal.
     To further improve extraction precision of unbalancing signal fromshorter data, AR model is adopted to predict and extend the shorter signal,with the result of expanding useful information of the specimen. Then the above MUSIC spectrum is used to separate unbalancing signal from thepredicted signal. The final experiment results show the effectiveness ofthis method in terms of shorter sampling data.
     There are various processing methods to extract unbalancing signal,but lacking of a criterion to evaluate their effectiveness. Especially, thereis short evaluation method of performance of the measurement system ofbalancing machine. A new method is proposed to simulate the vibrationsignal of the balancing machine. Based on analyzing the disturbancesources, the AR power model of vibration signal is built, and the principleof AR order is proposed. Then the improved covariance method isapplied to estimate the parameters of power model. Vibration signal canbe obtained after the built Gauss white noise goes through this AR powermodel. Experiments results show the effectiveness of this simulatedvibration signal.
     Finally, a hard-bearing balancing prototype machine is realized. Thisdesigned unbalancing machine has excellent properties, includinguser-friendly interface, robust stability, great extensibility and highmeasurement precision with0.1μm minimum achievable residual and95%unbalance reduction ratio.
引文
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