大功率磁流变传动技术及温度效应研究
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摘要
磁流变传动以磁流变液为工作介质，依靠传动界面间磁流变液的剪切应力来传递动力，通过控制外加磁场强度实现传递扭矩的无级调定。作为一种新型动力传递形式，它具有反应迅速可逆、控制简单且能耗低、抗外界干扰能力强等特点，在机电设备软启动、软制动、无级调速和过载保护等方面具有广泛的应用前景。针对当前磁流变传动技术研究中存在的问题，本文将就以下几个方面开展深入研究。
分别从宏观和微观两方面阐述了磁流变效应的形成机理和磁流变液的本构模型，详细介绍了磁流变液的基本组成和主要性能指标；结合理论分析和实验测试研究了磁流变液各组分材料性能的温度特性，包括软磁性颗粒的磁化性能、基载液的动力粘度和热膨胀特性；采用基液置换法制备出多种磁流变液样品，并分别测试了磁流变液样品的磁温特性、剪切应力—温度特性以及温度稳定性，得到了温度对磁流变液材料性能的影响机理和影响规律。
介绍了磁流变调速控制系统的基本组成及控制原理和特点，建立系统输出转速控制数学模型，并对调速起动的时间响应进行数值计算，分析了励磁电流、输入转速和负载扭矩对响应时间的影响；计算了调速过程中磁流变液的温度变化以及由此引发的传递扭矩下降值，并建立考虑温度效应的速度控制模型以分析温度变化对磁流变调速控制的影响，进而提出一种微调电流补偿方式来弥补温升引起的扭矩下降，并对采用温度补偿前后的调速控制性能进行对比研究。
针对大功率动力传递应用场合的要求，设计了一种新型大功率磁流变传动装置；利用ANSYS软件对所设计磁路进行有限元仿真，得到了磁场总体分布规律以及工作间隙中磁感应强度的分布特点和影响因素，并通过电磁场实验予以验证；从理论研究方面分析了工作磁感应强度和主、从动盘角速度差等因素对所设计的磁流变传动装置动力传递和调速控制性能的影响规律。
基于流体计算控制方程和温度场计算方程，建立磁流变传动装置热流耦合数学模型，并利用计算流体动力学软件CFX进行数值模拟，得到了不同工况下传动装置内部冷却液的速度场、压力场以及传动装置的稳态和瞬态温度场，并分析滑差功率、旋转速度、进水速度和温度以及冷却液特性等因素对磁流变传动装置热流耦合场的影响。
设计并研制了大功率磁流变传动实验系统，对大滑差功率下磁流变传动装置的动力传递和响应性能以及磁流变液的温升特性开展大量实验研究，并分别测试了该传动装置的最大许用稳态和瞬态滑差功率，结果验证了所设计的大功率磁流变传动装置的可靠性和水冷散热方式的有效性。
本文所取得的研究成果对于磁流变传动技术的深入研究具有重要的指导意义，能够为大功率磁流变传动装置的设计和磁流变传动技术的推广应用提供技术支持。
Magnetorheological (MR) transmission adopts the magnetorheological fluid (MRF) asworking medium and relies on the shear stress of MRF between transmission interfaces forpower transmission. The transmitted torque can be continuously regulated throughcontrolling the applied magnetic field. As a new power transmission form, MR transmissionhas many advantages, such as a quick and reversible response, simple control and lowenergy consumption, as well as high anti-interference ability, etc.. Therefore, it possesses abroad application prospect in the fields of soft start, soft brake, stepless speed control andoverload protection for mechanical equipment. According to the existing problems incurrent studies of MR transmission, this dissertation will conduct an in-depth research fromthe following aspects.
Formation mechanism of MR effect and constitutive model of MRF are explainedseparately from macro and micro aspects. A detailed introduction to basic compositions andkey performance indicators of MRF is conducted. Then, temperature effect on materialproperties of the MRF compositions, including magnetization performance of soft magneticparticle as well as dynamic viscosity and thermal expansion characteristic of carrier fluid, isstudied combining with theoretical analysis and experimental test. Several MRF samplesare prepared using the base-fluid replacement method. Thereafter, experimental tests arecarried out on the magnetism-temperature characteristic, shear stress-temperature propertyand temperature stability of MRF samples. And the influence mechanism and influencelaws of the temperature on material properties of MRF are obtained.
An introduction to basic components, control principle and characteristic of MR speedcontrol system is performed. Then, mathematical control model for the output speed of thesystem is established and the time response of MR speed start is numerically calculated.The influence of excitation current, input speed and load torque on the response time isanalyzed as well. Both the temperature variation of MRF and the consequent torque declinein the speed control process are calculated. Then, a speed control model considering thetemperature effect is built and the effect of temperature variation on MR speed control isdiscussed. Moreover, a current fine-tuning compensation method for compensating thetorque decline caused by temperature rise is proposed and the speed control performanceswith/without temperature compensation method are contrastively studied.
Aiming at the requirements for high-power transmission application fields, a novelhigh-power MR transmission device (MRTD) is designed. Then, finite element simulation is conducted on the designed magnetic circuit using the ANSYS software, and the overallmagnetic field distribution and the distribution laws and influence factors of magneticinduction in the working gap are obtained. An electromagnetic field experiment isconducted to verify the simulation results. Moreover, the influence laws of workingmagnetic induction and angular speed difference between drive and driven plate on powertransmission and speed control performance of the designed MRTD are theoreticallyinvestigated as well.
Based on computational fluid dynamics (CFD) equations and temperature fieldcalculation equations, a heat-flow coupling model of MRTD is established and numericalcalculation is conducted with the CFD software CFX. Velocity and pressure fields ofinternal cooling liquid as well as steady and transient temperature fields of MRTD undervarious working conditions are obtained. Then, the influence laws of slip power, rotationalspeed, inlet speed and temperature, as well as cooling fluid characteristic on the heat-flowcoupling field of MRTD are discussed.
An experimental system for high-power MR transmision is designed and fabricated.Then, a large number of experimental studies are conducted on the power transmission andresponse performance, as well as temperature rise characteristics of MRF under high slippower conditions. Moreover, maximum allowable steady and transient slip power are testedas well. Experiments results validate the reliability of the designed high-power MRTD andthe effectiveness of the proposed water cooling method.
Research results from this dissertation play an important guiding significance to thethorough study of MR transmission technology and they could provide a technical supportfor the design of high-power MRTD and the widespread application of MR transmissiontechnology.
分别从宏观和微观两方面阐述了磁流变效应的形成机理和磁流变液的本构模型，详细介绍了磁流变液的基本组成和主要性能指标；结合理论分析和实验测试研究了磁流变液各组分材料性能的温度特性，包括软磁性颗粒的磁化性能、基载液的动力粘度和热膨胀特性；采用基液置换法制备出多种磁流变液样品，并分别测试了磁流变液样品的磁温特性、剪切应力—温度特性以及温度稳定性，得到了温度对磁流变液材料性能的影响机理和影响规律。
介绍了磁流变调速控制系统的基本组成及控制原理和特点，建立系统输出转速控制数学模型，并对调速起动的时间响应进行数值计算，分析了励磁电流、输入转速和负载扭矩对响应时间的影响；计算了调速过程中磁流变液的温度变化以及由此引发的传递扭矩下降值，并建立考虑温度效应的速度控制模型以分析温度变化对磁流变调速控制的影响，进而提出一种微调电流补偿方式来弥补温升引起的扭矩下降，并对采用温度补偿前后的调速控制性能进行对比研究。
针对大功率动力传递应用场合的要求，设计了一种新型大功率磁流变传动装置；利用ANSYS软件对所设计磁路进行有限元仿真，得到了磁场总体分布规律以及工作间隙中磁感应强度的分布特点和影响因素，并通过电磁场实验予以验证；从理论研究方面分析了工作磁感应强度和主、从动盘角速度差等因素对所设计的磁流变传动装置动力传递和调速控制性能的影响规律。
基于流体计算控制方程和温度场计算方程，建立磁流变传动装置热流耦合数学模型，并利用计算流体动力学软件CFX进行数值模拟，得到了不同工况下传动装置内部冷却液的速度场、压力场以及传动装置的稳态和瞬态温度场，并分析滑差功率、旋转速度、进水速度和温度以及冷却液特性等因素对磁流变传动装置热流耦合场的影响。
设计并研制了大功率磁流变传动实验系统，对大滑差功率下磁流变传动装置的动力传递和响应性能以及磁流变液的温升特性开展大量实验研究，并分别测试了该传动装置的最大许用稳态和瞬态滑差功率，结果验证了所设计的大功率磁流变传动装置的可靠性和水冷散热方式的有效性。
本文所取得的研究成果对于磁流变传动技术的深入研究具有重要的指导意义，能够为大功率磁流变传动装置的设计和磁流变传动技术的推广应用提供技术支持。
Magnetorheological (MR) transmission adopts the magnetorheological fluid (MRF) asworking medium and relies on the shear stress of MRF between transmission interfaces forpower transmission. The transmitted torque can be continuously regulated throughcontrolling the applied magnetic field. As a new power transmission form, MR transmissionhas many advantages, such as a quick and reversible response, simple control and lowenergy consumption, as well as high anti-interference ability, etc.. Therefore, it possesses abroad application prospect in the fields of soft start, soft brake, stepless speed control andoverload protection for mechanical equipment. According to the existing problems incurrent studies of MR transmission, this dissertation will conduct an in-depth research fromthe following aspects.
Formation mechanism of MR effect and constitutive model of MRF are explainedseparately from macro and micro aspects. A detailed introduction to basic compositions andkey performance indicators of MRF is conducted. Then, temperature effect on materialproperties of the MRF compositions, including magnetization performance of soft magneticparticle as well as dynamic viscosity and thermal expansion characteristic of carrier fluid, isstudied combining with theoretical analysis and experimental test. Several MRF samplesare prepared using the base-fluid replacement method. Thereafter, experimental tests arecarried out on the magnetism-temperature characteristic, shear stress-temperature propertyand temperature stability of MRF samples. And the influence mechanism and influencelaws of the temperature on material properties of MRF are obtained.
An introduction to basic components, control principle and characteristic of MR speedcontrol system is performed. Then, mathematical control model for the output speed of thesystem is established and the time response of MR speed start is numerically calculated.The influence of excitation current, input speed and load torque on the response time isanalyzed as well. Both the temperature variation of MRF and the consequent torque declinein the speed control process are calculated. Then, a speed control model considering thetemperature effect is built and the effect of temperature variation on MR speed control isdiscussed. Moreover, a current fine-tuning compensation method for compensating thetorque decline caused by temperature rise is proposed and the speed control performanceswith/without temperature compensation method are contrastively studied.
Aiming at the requirements for high-power transmission application fields, a novelhigh-power MR transmission device (MRTD) is designed. Then, finite element simulation is conducted on the designed magnetic circuit using the ANSYS software, and the overallmagnetic field distribution and the distribution laws and influence factors of magneticinduction in the working gap are obtained. An electromagnetic field experiment isconducted to verify the simulation results. Moreover, the influence laws of workingmagnetic induction and angular speed difference between drive and driven plate on powertransmission and speed control performance of the designed MRTD are theoreticallyinvestigated as well.
Based on computational fluid dynamics (CFD) equations and temperature fieldcalculation equations, a heat-flow coupling model of MRTD is established and numericalcalculation is conducted with the CFD software CFX. Velocity and pressure fields ofinternal cooling liquid as well as steady and transient temperature fields of MRTD undervarious working conditions are obtained. Then, the influence laws of slip power, rotationalspeed, inlet speed and temperature, as well as cooling fluid characteristic on the heat-flowcoupling field of MRTD are discussed.
An experimental system for high-power MR transmision is designed and fabricated.Then, a large number of experimental studies are conducted on the power transmission andresponse performance, as well as temperature rise characteristics of MRF under high slippower conditions. Moreover, maximum allowable steady and transient slip power are testedas well. Experiments results validate the reliability of the designed high-power MRTD andthe effectiveness of the proposed water cooling method.
Research results from this dissertation play an important guiding significance to thethorough study of MR transmission technology and they could provide a technical supportfor the design of high-power MRTD and the widespread application of MR transmissiontechnology.
引文
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