电液流量、方向连续控制新原理及其应用研究
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摘要
电液控制技术在航空、航天,海洋工程、冶金,矿山、重型机械等体现一个国家综合国力和国防现代化的许多工业领域,起着非常关键的作用。这一技术的核心是控制执行器工作速度、方向、位置和输出力的流量、方向连续控制元件,目前主要有比例方向阀和伺服比例阀。这一领域,我国虽然在系统集成技术方面已取得了许多成就,但在核心元件技术方面同国外发达国家仍有较大差距,制约了我国装备制造业的发展,许多国家需求的重大装备,如全断面掘进机、板坯连铸连扎设备、大型成型设备等,所用电液控制元件,特别是高性能比例方向阀、伺服比例阀只能高价从国外进口,造成国外在技术和价格上对我国的垄断。国家也充分认识到这一问题的严重性,2009年5月国务院出台的装备制造业调整和振兴规划,在原有振兴装备制造业16个优先发展重大专项基础上,补充了基础部件,这其中就包含电液伺服和比例元件。在我国制定的国家中长期科学和技术发展规划纲要(2006—2020年),优先主题第26项之基础件和通用部件：“重点研究开发重大装备所需的关键基础件和通用部件的设计、制造和批量生产的关键技术”,更是将电液控制技术所需的核心元器件列为重点研发内容。正是在这样的背景下,在国家自然科学基金“有源、流量闭环先导级为驱动的电液流量控制理论与方法、51175362”和国家2011年重大科技成果转化项目“高响应、大流量伺服比例阀关键技术、系列产品开发及应用”的资助下,提出本课题的研究内容,通过对新的电液流量控制方法相关基础问题的研究,为我国自主研发高精度、高动态响应、模块化、易集成的比例流量控制元件提供理论和试验依据。
首先,对国内外的相关研究工作作了较为详细的分析和论证,找出了现有技术存在的不足,提出解决问题的创新思想,研究工作对发展具有我国自主知识产权的低能耗电液流量控制元件,突破国外在这一领域对我国技术和经济上的垄断及制约,带动我国液压工业发展,推动相关主机行业的技术进步具有重要的理论和现实意义。
对影响电液伺服比例阀特性的关键技术和基础理论开展了研究,采用流体动力学仿真方法CFD,对影响阀特性的动静态液动力及其补偿方法作了研究,给出了新的减小液压动力影响的补偿方法；对制约阀动态响应快速性的电机械转换器及其控制方法作了研究,提出采用动圈式电机械转换器做驱动的改进思路。
提出创新的比例方向阀控制方案,对新型比例方向阀的工作机理进行阐述,对关键的结构参数进行设计、计算,应用AutoCAD软件和Pro/E软件详细建立了阀的二维工程图和三维实体模型,验证了结构参数的合理性,为后续仿真优化设计、工作特性分析以及生产物理样机奠定了基础。
根据新型比例方向阀的结构及工作原理,建立阀的完整数学模型。根据线性化理论,对阀的动静态特性进行理论计算和分析,对影响稳态控制特性及零位阀系数的主要几何参数展开讨论；根据合理假设,进一步将阀的非线性状态空间模型简化,推导出系统方框图和传递函数,并对系统稳定性进行分析,得出了新型比例方向阀的系统稳定性条件。研究结果表明,阀的动态特性为一阶滞后环节,其转折频率随节流槽面积梯度的增大而增大,随阀芯面积比的增大而减小。为保证阀的稳定性,节流槽应留有一定的预开口量。
将阀的CAD实体导入SimulationX仿真平台,创建出新型比例方向阀的多学科仿真模型,分别在时域和频域中对阀的稳态特性和动态特性进行仿真研究,讨论了将先导阀回油直接引油箱以及节流槽面积梯度的改变对阀的动态性能影响。研究结果表明,新型比例方向阀的稳态特性和等位移特性良好,主阀芯位移控制曲线的线性度也较好,但有一定的中位控制死区。阀的动态阶跃响应时间较长,阀芯位移的响应速度与系统压力和给定信号有关。阀的工作频宽约7Hz,频响曲线没有出现谐振峰值,具有典型一阶滞后环节的特征,仿真结果验证了理论分析的正确性。
为进一步提高阀的控制精度和动态性能,提出采用主阀芯位移-电闭环、先导阀芯位移-电闭环和双电闭环三种控制方案,分析了三种阀的结构特点及工作机理,分别对其进行多领域建模和仿真研究。结果表明,主阀芯位移-电闭环控制阀能够明显抑制液动力、摩擦力等干扰,提高了阀的稳态控制精度和动态响应速度,将阀的频带拓宽到18Hz,阀的综合性能获得大幅度提升；采用先导阀芯位移-电闭环控制,由于系统闭环包括的范围太小,无法消除功率级干扰,因此对阀的性能影响不大；加入双电闭环控制则可以结合前两种电闭环控制的优势,合理调节控制器参数,就可使阀获得最佳的工作特性。引入电闭环控制方案,不仅改善了阀的动静态性能,也使阀具有了在闭环控制通道发生故障的情况下,仍可开环工作的容错控制功能。
Proportional directional valve of high performance with servo function is the key element of electro-hydraulic control technology. Because of the long-term gap in these key components, the technology of equipment manufacturing industry in our country falls behind that of developed countries, and the development of many important technical equipments for national demands is restricted. Therefore, developing the proportional control elements of low cost, high performance and high reliability is of great significance for promoting the international competitiveness of proportional valve products in China and driving the technological progress of the hydraulic industry and related host industry in our country. As a part of the research content of National Natural Science Foundation "Theories and Methods of Electro-hydraulic Flow Rate Control With Active, Flow Closed-loop and Pilot-Operated"(51175362), this thesis focuses on the comprehensive discussion, analysis and simulation research of the novel electro-hydraulic proportional direction valve based on displacement-flow feedback control principle.
First of all, it is stated the work principle of the new kind of three-position four-way proportional direction valve by adopting the hydraulic transistor technology theory. According to the proposal of the innovative structure scheme by the research group, the structure of the core components is designed and the geometric parameters of the key parts are calculated. With the detailed establishment of the valve's2D engineering drawings and3D entity models by using AutoCAD and Pro/E software, the rationality of the structure parameters is verified, laying a foundation for the subsequent simulation optimization design、performance analysis and physical prototype production.
The mathematic model is set up based on the structure and working principle of the novel proportional direction valve. The theoretical calculation and analysis on the static properties and dynamic properties of the new valve are conducted with the help of linearization theory. Main geometric parameters that affect the steady state control characteristics and neutral position valve coefficients are discussed. Based on reasonable hypothesis, the nonlinear state space model of the valve is simplified further, and the systematic block diagram and transfer function are derived. Then with analysis of the system stability, the stability criterion of the new type of proportional direction valve is obtained. The research shows that the dynamic characteristics of the valve is of a first-order lag link whose break frequency increases with the throttle slot area gradient and decreases with the spool area ratio. To guarantee the stability of the valve, the throttle slot always has to maintain a certain underlap.
By importing the CAD entities of the valve into simulation platform ——SimulationX, the multi-domain model of new type of proportional direction valve is created. Thus the simulation research on the valve's steady state and dynamic performances is carried out separately in time domain and frequency domain. This thesis also includes a further discussion about the influence on valve's dynamic characteristics by sending the pilot flow directly to the tank, or changing the throttle slot area gradient. The results show that the new type of proportional direction valve is of good steady state control characteristics and equal displacement characteristics. The linearity of the control curve of the main spool displacement is well. However, there exists a certain neutral position control dead zone. The dynamic step response time of the valve is comparatively long. The response speed of the spool displacement is related to the system pressure and given signals. The valve's working bandwidth is about7Hz, and its frequency response curve doesn't appear resonance peak and has the feature of a typical first-order lag link. The simulation results prove the validity of the theoretical analysis.
In order to improve the valve's control accuracy and dynamic property, the thesis presents three control schemes:main spool displacement-electronic closed-loop control, pilot spool displacement-electronic closed-loop control and double electronic closed-loop control. The structure features and working principles of the three valves are introduced and the multi-domain modeling and simulation research are included respectively at last. Results show that the valve under the main spool displacement-electronic closed-loop control can effectively restrain the interference of the flow force and viscous force. Accordingly it can improve both the steady state control accuracy and dynamic response speed of the valve with broadening the bandwidth of the valve to18Hz. As a result, the overall performance of the valve is promoted by a large margin. The adoption of pilot spool displacement-electronic closed-loop control cannot remove the interference from the power stage because the system closed-loop range is too limited. Therefore there is little influence on the valve's performance. Relatively, the valve under double electronic closed-loop control can combine the advantages of the former two valves, and by adjusting the control parameter reasonably, the valve will obtain optimal working characteristics. In addition, after introducing the electronic closed-loop control strategy, it can not only improve the dynamic and static properties of the valve but also make the valve possess the ability of fault tolerance by means of working in open-loop control once the closed-loop channel is in trouble.
首先,对国内外的相关研究工作作了较为详细的分析和论证,找出了现有技术存在的不足,提出解决问题的创新思想,研究工作对发展具有我国自主知识产权的低能耗电液流量控制元件,突破国外在这一领域对我国技术和经济上的垄断及制约,带动我国液压工业发展,推动相关主机行业的技术进步具有重要的理论和现实意义。
对影响电液伺服比例阀特性的关键技术和基础理论开展了研究,采用流体动力学仿真方法CFD,对影响阀特性的动静态液动力及其补偿方法作了研究,给出了新的减小液压动力影响的补偿方法；对制约阀动态响应快速性的电机械转换器及其控制方法作了研究,提出采用动圈式电机械转换器做驱动的改进思路。
提出创新的比例方向阀控制方案,对新型比例方向阀的工作机理进行阐述,对关键的结构参数进行设计、计算,应用AutoCAD软件和Pro/E软件详细建立了阀的二维工程图和三维实体模型,验证了结构参数的合理性,为后续仿真优化设计、工作特性分析以及生产物理样机奠定了基础。
根据新型比例方向阀的结构及工作原理,建立阀的完整数学模型。根据线性化理论,对阀的动静态特性进行理论计算和分析,对影响稳态控制特性及零位阀系数的主要几何参数展开讨论；根据合理假设,进一步将阀的非线性状态空间模型简化,推导出系统方框图和传递函数,并对系统稳定性进行分析,得出了新型比例方向阀的系统稳定性条件。研究结果表明,阀的动态特性为一阶滞后环节,其转折频率随节流槽面积梯度的增大而增大,随阀芯面积比的增大而减小。为保证阀的稳定性,节流槽应留有一定的预开口量。
将阀的CAD实体导入SimulationX仿真平台,创建出新型比例方向阀的多学科仿真模型,分别在时域和频域中对阀的稳态特性和动态特性进行仿真研究,讨论了将先导阀回油直接引油箱以及节流槽面积梯度的改变对阀的动态性能影响。研究结果表明,新型比例方向阀的稳态特性和等位移特性良好,主阀芯位移控制曲线的线性度也较好,但有一定的中位控制死区。阀的动态阶跃响应时间较长,阀芯位移的响应速度与系统压力和给定信号有关。阀的工作频宽约7Hz,频响曲线没有出现谐振峰值,具有典型一阶滞后环节的特征,仿真结果验证了理论分析的正确性。
为进一步提高阀的控制精度和动态性能,提出采用主阀芯位移-电闭环、先导阀芯位移-电闭环和双电闭环三种控制方案,分析了三种阀的结构特点及工作机理,分别对其进行多领域建模和仿真研究。结果表明,主阀芯位移-电闭环控制阀能够明显抑制液动力、摩擦力等干扰,提高了阀的稳态控制精度和动态响应速度,将阀的频带拓宽到18Hz,阀的综合性能获得大幅度提升；采用先导阀芯位移-电闭环控制,由于系统闭环包括的范围太小,无法消除功率级干扰,因此对阀的性能影响不大；加入双电闭环控制则可以结合前两种电闭环控制的优势,合理调节控制器参数,就可使阀获得最佳的工作特性。引入电闭环控制方案,不仅改善了阀的动静态性能,也使阀具有了在闭环控制通道发生故障的情况下,仍可开环工作的容错控制功能。
Proportional directional valve of high performance with servo function is the key element of electro-hydraulic control technology. Because of the long-term gap in these key components, the technology of equipment manufacturing industry in our country falls behind that of developed countries, and the development of many important technical equipments for national demands is restricted. Therefore, developing the proportional control elements of low cost, high performance and high reliability is of great significance for promoting the international competitiveness of proportional valve products in China and driving the technological progress of the hydraulic industry and related host industry in our country. As a part of the research content of National Natural Science Foundation "Theories and Methods of Electro-hydraulic Flow Rate Control With Active, Flow Closed-loop and Pilot-Operated"(51175362), this thesis focuses on the comprehensive discussion, analysis and simulation research of the novel electro-hydraulic proportional direction valve based on displacement-flow feedback control principle.
First of all, it is stated the work principle of the new kind of three-position four-way proportional direction valve by adopting the hydraulic transistor technology theory. According to the proposal of the innovative structure scheme by the research group, the structure of the core components is designed and the geometric parameters of the key parts are calculated. With the detailed establishment of the valve's2D engineering drawings and3D entity models by using AutoCAD and Pro/E software, the rationality of the structure parameters is verified, laying a foundation for the subsequent simulation optimization design、performance analysis and physical prototype production.
The mathematic model is set up based on the structure and working principle of the novel proportional direction valve. The theoretical calculation and analysis on the static properties and dynamic properties of the new valve are conducted with the help of linearization theory. Main geometric parameters that affect the steady state control characteristics and neutral position valve coefficients are discussed. Based on reasonable hypothesis, the nonlinear state space model of the valve is simplified further, and the systematic block diagram and transfer function are derived. Then with analysis of the system stability, the stability criterion of the new type of proportional direction valve is obtained. The research shows that the dynamic characteristics of the valve is of a first-order lag link whose break frequency increases with the throttle slot area gradient and decreases with the spool area ratio. To guarantee the stability of the valve, the throttle slot always has to maintain a certain underlap.
By importing the CAD entities of the valve into simulation platform ——SimulationX, the multi-domain model of new type of proportional direction valve is created. Thus the simulation research on the valve's steady state and dynamic performances is carried out separately in time domain and frequency domain. This thesis also includes a further discussion about the influence on valve's dynamic characteristics by sending the pilot flow directly to the tank, or changing the throttle slot area gradient. The results show that the new type of proportional direction valve is of good steady state control characteristics and equal displacement characteristics. The linearity of the control curve of the main spool displacement is well. However, there exists a certain neutral position control dead zone. The dynamic step response time of the valve is comparatively long. The response speed of the spool displacement is related to the system pressure and given signals. The valve's working bandwidth is about7Hz, and its frequency response curve doesn't appear resonance peak and has the feature of a typical first-order lag link. The simulation results prove the validity of the theoretical analysis.
In order to improve the valve's control accuracy and dynamic property, the thesis presents three control schemes:main spool displacement-electronic closed-loop control, pilot spool displacement-electronic closed-loop control and double electronic closed-loop control. The structure features and working principles of the three valves are introduced and the multi-domain modeling and simulation research are included respectively at last. Results show that the valve under the main spool displacement-electronic closed-loop control can effectively restrain the interference of the flow force and viscous force. Accordingly it can improve both the steady state control accuracy and dynamic response speed of the valve with broadening the bandwidth of the valve to18Hz. As a result, the overall performance of the valve is promoted by a large margin. The adoption of pilot spool displacement-electronic closed-loop control cannot remove the interference from the power stage because the system closed-loop range is too limited. Therefore there is little influence on the valve's performance. Relatively, the valve under double electronic closed-loop control can combine the advantages of the former two valves, and by adjusting the control parameter reasonably, the valve will obtain optimal working characteristics. In addition, after introducing the electronic closed-loop control strategy, it can not only improve the dynamic and static properties of the valve but also make the valve possess the ability of fault tolerance by means of working in open-loop control once the closed-loop channel is in trouble.
引文
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