大流量插装式伺服阀的设计与控制方法研究
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摘要
大流量插装式伺服阀是很多重大机械装备中电液控制系统的核心部件,譬如大型模锻压机、快锻压机、铝合金压铸机等,目前很大程度上还依赖于进口。在以往的研究中,关于插装式伺服阀与实际应用工况相匹配的参数设计方法、以及插装式伺服阀控制器设计的研究较少,阀的性能潜力未能得到充分挖掘,性能进一步提升受到制约。本文将围绕上述两大问题,通过理论建模、仿真分析、实验验证相结合的方法展开研究,主要内容如下：
第一章,对大流量电液比例/伺服插装式节流阀的实现原理及其工程应用背景进行阐述。在分析了国内外相关技术研究现状基础上,提出了本文的主要研究内容。
第二章,对插装式伺服阀结构参数优化设计方法的研究。推导了与使用工况相匹配的主动式插装伺服阀一系列结构参数的设计公式,平衡各项结构参数的相互制约关系。推导了主阀芯所受液压力和液动力的理论公式和简化计算公式,为先导控制腔的参数设计提供依据,并为后续控制器的设计提供了负载模型。
第三章,对伺服比例阀的整体性建模研究。建立了电一机械转换器的集中参数模型,体现了滞环、非线性电感等常见的电磁铁非线性特征。建立了阀体机械运动部件的模型,通过直接测量与间接估算确定了各主要参数值。根据实验拟合了稳态液动力的数学模型。设计了开环和闭环两种实验测试方法,验证了模型的有效性。通过零位处的线性化方法,获取了阀的标称模型,得到其传递函数及状态空间表达式,以及各主要参数的线性化参数值及变动范围。
第四章,对伺服比例阀的非线性滑模控制方法研究。根据伺服比例阀的标称模型频响曲线,分析了曲线上各渐近线方程所代表的动力学约束,推导了这些约束与阀模型参数间的函数式,以此作为后续滑模控制器设计的基础。根据阀的各参数值和阀芯行程限制,采用了基于加加速度约束下、代表时间最优阶跃响应的非线性滑模面,并据此设计了滑模控制系统。通过仿真和实验分别测试了伺服比例阀的阀芯位置闭环阶跃响应和频率响应,并与阀原始配套的模拟PID控制器作了对比,从而验证了上述滑模控制器的性能。
第五章,对伺服比例阀的改进型滑模控制方法研究。针对第四章的非线性滑模控制器,分析了其不足之处,并提出了多项改进方法。引入积分器以解决滑模控制中稳态精度得不到保证的问题。提出了两种速度前馈补偿的方法,以提高阀芯的轨迹跟踪能力。采用了高/低压电源切换技术,进一步提升阀的动态响应。提出了对阀身自带的LVDT位移传感器改造的办法,提取了阀芯运动的位移、速度和加速度信号全状态反馈信号,并成功应用于滑模控制中。设计了基于加速度和加加速度联合约束下、代表时间最优阶跃响应的非线性滑模面,并设计了相应的滑模控制器,给出了应用于实时控制中的实现准则和计算流程,实现了不同负载下滑模状态的稳定性和显著增强的抗负载扰动能力。
第六章,大流量插装式伺服阀的非线性控制方法研究。针对先导级伺服比例阀的频响远低于主级阀频响的特点,忽略主阀芯动态,建立了插装式伺服阀的简化三阶模型,并据此设计控制器。采用了基于模型补偿的鲁棒控制和反步控制方法(backstepping)改造系统的动力学方程、配置系统的极点；采用基于Lyapunov函数和非线性映射的自适应算法,对阀系数、泄漏等参量进行自适应估计,提高模型补偿的精确性。通过仿真分析和实验对比,验证了上述控制算法的性能。
第七章,对全文的主要研究工作进行了总结。阐述了主要研究结论和创新点,并对课题的后续研究提出了展望。
The large-flow cartridge servo valve (LFCSV for short) is the key core component of the electro-hydraulic control systems in many major mechanical equipments, such as the large die-forging press, fast forging hydraulic press, aluminum alloy die-casting machine. However, the LFCSV is still largely dependent on imports. In previous study, the parameter design method of the LFCSV to match the actual application condition, and the controller design method for the LFCSV are rarely mentioned. As a result, the potential performance of the LFCSV has not been fully exploited and the further performance improvement of the valve is limited. The study of this paper will focus on the above two issues, through the combining method of theoretical modeling, simulation analysis and experimental validation. The main contents of the study are as follows:
In chapter1, the realization principle of LFCSV and its engineering practical applications are briefly introduced. A review of LFCSV related technologies is presented. Then the main research contents are put forward.
In chapter2, the design and optimization methods of the structural parameters of the LFCSV are studied. A series of design formulas of the LFCSV are derived, basing on the match with the working condition. The inter-constraints between the structural parameters are balanced. The theoretical formulas and simplified calculation formulas of the hydraulic force and steady-state flow force exerted on the main spool are derived, which provides the basis for the design of the pilot control chamber and provides the load model for the subsequent controller design of the LFCSV.
In chapter3, the modelling of the servo-solenoid valve (SSV for short) is discussed. A lumped-parameter model of proportional solenoid is built based on the principle of nonlinear circuit. This model takes into account the hysteresis, magnetic saturation and other highly parametric nonlinearity which are common in the solenoid. The model of mechanical motion part of the SSV is built based on kinetic equation and the values of parameters are gained by direct measurements and indirect calculation. The steady-state flow force is measured by experiment and its mathematical model is provided. Two methods including open-loop test and closed-loop test are designed, which validate the combination model of the SSV.
In chapter4, the nonlinear sliding-mode (SLM) control of the SSV is studied. The nominal model of the SSV is built by linearizing the dynamics on the null position. Through the frequency response of the identified model, the kinetic constraints of the valve under the power limitation are analyzed, which comes out the maximum available velocity, acceleration and jerk for the SLM control design later. According to the variation ranges of the model parameters and the limitation of the spool's stroke, a nonlinear SLM surface based on the maximum jerk and time-optimal step response is used and the SLM controller is designed. The step responses and frequency responses of the SSV with the SLM controller are tested by simulation and experiments, which exhibits its performance advantages when compared to traditional PID analogue controller.
In chapter5, the improved SLM control methods of the SSV are investigated. With the analysis of the existing disadvantages of traditional SLM control used in chapter4, some effective modifications are proposed. Specifically, the integral element and two types of velocity feed-forward are used to eliminate steady-state error and enhance trajectory tracking ability respectively. The switch of power supply is employed to improve dynamic response of the SSV, and the modification of LVDT is designed to obtain full-state feedback signals which have been effectively applied in the SLM control of the SSV. A novel SLM surface is proposed which takes into account both spool's acceleration and jerk limitation. And subsequently the SLM control strategy is developed with the new SLM surface. Experimental studies are conducted which demonstrates that the nonlinear SLM controller proposed by this paper could guarantee the continuous and stable sliding mode state, realize the time-optimal step response of the valve and exhibit strong disturbance rejection abilities.
In chapter6, the nonlinear control strategy of the LFCSV is studied. The dynamics of the main valve is ignored, as the natural frequency of the pilot valve (namely, SSV) is much lower than that of the main vale. Then the simplified3-order model of the LFCSV is built and the nonlinear adaptive-robust controller (ARC) is designed. The robust control and backstepping method based on the model compensation are used to reform the dynamics and assign the pole of the plant. The adaptive control algorithm based on the Lyapunov function and nonlinear projection is employed to adaptively estimate the parameters such as the leakage and valve's coefficients, and to increase the accuracy of model compensation. Finally, the performance of designed controller is validated through the simulation analysis and experimental contrast.
In chapter7, the main work of this dissertation is summarized. Conclusions and innovative points are introduced. Finally, the subsequent research on the LFCSV is prospected.
第一章,对大流量电液比例/伺服插装式节流阀的实现原理及其工程应用背景进行阐述。在分析了国内外相关技术研究现状基础上,提出了本文的主要研究内容。
第二章,对插装式伺服阀结构参数优化设计方法的研究。推导了与使用工况相匹配的主动式插装伺服阀一系列结构参数的设计公式,平衡各项结构参数的相互制约关系。推导了主阀芯所受液压力和液动力的理论公式和简化计算公式,为先导控制腔的参数设计提供依据,并为后续控制器的设计提供了负载模型。
第三章,对伺服比例阀的整体性建模研究。建立了电一机械转换器的集中参数模型,体现了滞环、非线性电感等常见的电磁铁非线性特征。建立了阀体机械运动部件的模型,通过直接测量与间接估算确定了各主要参数值。根据实验拟合了稳态液动力的数学模型。设计了开环和闭环两种实验测试方法,验证了模型的有效性。通过零位处的线性化方法,获取了阀的标称模型,得到其传递函数及状态空间表达式,以及各主要参数的线性化参数值及变动范围。
第四章,对伺服比例阀的非线性滑模控制方法研究。根据伺服比例阀的标称模型频响曲线,分析了曲线上各渐近线方程所代表的动力学约束,推导了这些约束与阀模型参数间的函数式,以此作为后续滑模控制器设计的基础。根据阀的各参数值和阀芯行程限制,采用了基于加加速度约束下、代表时间最优阶跃响应的非线性滑模面,并据此设计了滑模控制系统。通过仿真和实验分别测试了伺服比例阀的阀芯位置闭环阶跃响应和频率响应,并与阀原始配套的模拟PID控制器作了对比,从而验证了上述滑模控制器的性能。
第五章,对伺服比例阀的改进型滑模控制方法研究。针对第四章的非线性滑模控制器,分析了其不足之处,并提出了多项改进方法。引入积分器以解决滑模控制中稳态精度得不到保证的问题。提出了两种速度前馈补偿的方法,以提高阀芯的轨迹跟踪能力。采用了高/低压电源切换技术,进一步提升阀的动态响应。提出了对阀身自带的LVDT位移传感器改造的办法,提取了阀芯运动的位移、速度和加速度信号全状态反馈信号,并成功应用于滑模控制中。设计了基于加速度和加加速度联合约束下、代表时间最优阶跃响应的非线性滑模面,并设计了相应的滑模控制器,给出了应用于实时控制中的实现准则和计算流程,实现了不同负载下滑模状态的稳定性和显著增强的抗负载扰动能力。
第六章,大流量插装式伺服阀的非线性控制方法研究。针对先导级伺服比例阀的频响远低于主级阀频响的特点,忽略主阀芯动态,建立了插装式伺服阀的简化三阶模型,并据此设计控制器。采用了基于模型补偿的鲁棒控制和反步控制方法(backstepping)改造系统的动力学方程、配置系统的极点；采用基于Lyapunov函数和非线性映射的自适应算法,对阀系数、泄漏等参量进行自适应估计,提高模型补偿的精确性。通过仿真分析和实验对比,验证了上述控制算法的性能。
第七章,对全文的主要研究工作进行了总结。阐述了主要研究结论和创新点,并对课题的后续研究提出了展望。
The large-flow cartridge servo valve (LFCSV for short) is the key core component of the electro-hydraulic control systems in many major mechanical equipments, such as the large die-forging press, fast forging hydraulic press, aluminum alloy die-casting machine. However, the LFCSV is still largely dependent on imports. In previous study, the parameter design method of the LFCSV to match the actual application condition, and the controller design method for the LFCSV are rarely mentioned. As a result, the potential performance of the LFCSV has not been fully exploited and the further performance improvement of the valve is limited. The study of this paper will focus on the above two issues, through the combining method of theoretical modeling, simulation analysis and experimental validation. The main contents of the study are as follows:
In chapter1, the realization principle of LFCSV and its engineering practical applications are briefly introduced. A review of LFCSV related technologies is presented. Then the main research contents are put forward.
In chapter2, the design and optimization methods of the structural parameters of the LFCSV are studied. A series of design formulas of the LFCSV are derived, basing on the match with the working condition. The inter-constraints between the structural parameters are balanced. The theoretical formulas and simplified calculation formulas of the hydraulic force and steady-state flow force exerted on the main spool are derived, which provides the basis for the design of the pilot control chamber and provides the load model for the subsequent controller design of the LFCSV.
In chapter3, the modelling of the servo-solenoid valve (SSV for short) is discussed. A lumped-parameter model of proportional solenoid is built based on the principle of nonlinear circuit. This model takes into account the hysteresis, magnetic saturation and other highly parametric nonlinearity which are common in the solenoid. The model of mechanical motion part of the SSV is built based on kinetic equation and the values of parameters are gained by direct measurements and indirect calculation. The steady-state flow force is measured by experiment and its mathematical model is provided. Two methods including open-loop test and closed-loop test are designed, which validate the combination model of the SSV.
In chapter4, the nonlinear sliding-mode (SLM) control of the SSV is studied. The nominal model of the SSV is built by linearizing the dynamics on the null position. Through the frequency response of the identified model, the kinetic constraints of the valve under the power limitation are analyzed, which comes out the maximum available velocity, acceleration and jerk for the SLM control design later. According to the variation ranges of the model parameters and the limitation of the spool's stroke, a nonlinear SLM surface based on the maximum jerk and time-optimal step response is used and the SLM controller is designed. The step responses and frequency responses of the SSV with the SLM controller are tested by simulation and experiments, which exhibits its performance advantages when compared to traditional PID analogue controller.
In chapter5, the improved SLM control methods of the SSV are investigated. With the analysis of the existing disadvantages of traditional SLM control used in chapter4, some effective modifications are proposed. Specifically, the integral element and two types of velocity feed-forward are used to eliminate steady-state error and enhance trajectory tracking ability respectively. The switch of power supply is employed to improve dynamic response of the SSV, and the modification of LVDT is designed to obtain full-state feedback signals which have been effectively applied in the SLM control of the SSV. A novel SLM surface is proposed which takes into account both spool's acceleration and jerk limitation. And subsequently the SLM control strategy is developed with the new SLM surface. Experimental studies are conducted which demonstrates that the nonlinear SLM controller proposed by this paper could guarantee the continuous and stable sliding mode state, realize the time-optimal step response of the valve and exhibit strong disturbance rejection abilities.
In chapter6, the nonlinear control strategy of the LFCSV is studied. The dynamics of the main valve is ignored, as the natural frequency of the pilot valve (namely, SSV) is much lower than that of the main vale. Then the simplified3-order model of the LFCSV is built and the nonlinear adaptive-robust controller (ARC) is designed. The robust control and backstepping method based on the model compensation are used to reform the dynamics and assign the pole of the plant. The adaptive control algorithm based on the Lyapunov function and nonlinear projection is employed to adaptively estimate the parameters such as the leakage and valve's coefficients, and to increase the accuracy of model compensation. Finally, the performance of designed controller is validated through the simulation analysis and experimental contrast.
In chapter7, the main work of this dissertation is summarized. Conclusions and innovative points are introduced. Finally, the subsequent research on the LFCSV is prospected.
引文
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