液压油有效体积弹性模量及测量装置的研究
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摘要
液压系统广泛应用于各类机械装备中,作为工作介质液压油的有效体积弹性模量表征了系统的刚性,是影响系统动态性能的重要参数之一。正是由于具备可压缩性,通常将油液视作液压系统中的弹簧。油液弹性模量是一个动态量,影响因素多,变化复杂,是个难以确定的软参数。如何准确获得弹性模量参数,一直是液压领域基础研究的热点,对液压系统特别是动态响应和稳定性要求高的系统设计与分析具有重要意义。因此,研究液压油有效体积弹性模量在不同工况条件下的动态变化规律,是提高系统性能的一种重要途径,具有很强的工程应用背景和学术研究价值。
本文首次引入液压油动态弹性模量的概念,提出了动态弹性模量的数学模型。这一模型在充分考虑油液工作压力、温度、含气量等工况参数综合影响的基础上,特别考虑了液压系统工作时由于执行器内油液体积实时变动而引起的油液工作压力及其分布的动态变化,有效改善了以往对弹性模量的描述过于单一、不够准确的问题。研制了一种基于定义法的弹性模量检测装置。该装置采用伺服电机加载,并通过高精度压力传感器和位移传感器直接测得封闭容器内油液的压力、体积变化,具有加载压力(0-20 MPa)和加载速度(0.35-4.45%/min)连续可控、综合测量误差小于2.08%等优点,可实现在线且准确测得液压系统中的油液弹性模量。通过抽真空处理,使油液的含气量由12.29%降至7.41%,此时液压伺服系统阶跃响应的超调量减小约5-10%,且系统调整至稳态输出的过程也有所减短。提出了一种基于动态弹性模量的控制参数调整方法。该方法根据执行器内油液弹性模量的变化来实时调节系统增益,使控制参数与液压固有频率更加匹配,从而可保持系统结构不变的基础上最大限度的提高系统动态性能。通过对该方法对应频率分别为2Hz和8 Hz正弦信号的跟踪特性分析,计算和实验结果表明系统的最大跟踪误差降低了25%-30%,相位滞后减小约3.5°-8.6°,过渡过程的超调现象得到明显改善。
论文主要研究内容如下：
第一章,阐述了油液有效体积弹性模量的含义、特点及其在液压系统设计与分析中发挥的重要作用。综述和总结了国内外关于弹性模量的影响因素、测量技术等研究方向的研究历程,进而提出本课题的研究内容和研究目标。
第二章,理论分析了液压油中由溶解气体和游离气体的含量、状态变化引起的混气油液弹性模量的含气效应。运用CFD软件仿真分析了单个气泡和气泡群在油液中的运动特性,揭示了气泡尺寸、油液粘度、工作压力和气泡群体间的相互作用等因素对气泡的上升运动速度及形变特性的影响。
第三章,建立了封闭容腔内混气油液有效体积弹性模量的数学模型,并数值仿真了在不同初始含气量、油液温度等条件下,弹性模量随油液工作压力的变化特性。基于理论分析,设计了一套抽真空除气装置和弹性模量测量装置应用于一大型液压源系统,以提高系统内油液的弹性模量值。
第四章,基于课题研究内容和上一代实验系统的应用结果,研制了弹性模量综合实验台。对其三大关键分系统：闭式系统及其抽真空处理、基于伺服电机加载的弹性模量测量装置和伺服阀控缸系统,作了详细的解决方案、原理结构和关键参数设计。
第五章,分别对不同工况条件下混气油液的含气量测量、抽真空处理、静态弹性模量和动态弹性模量的测量开展相关实验研究。实验结果揭示了抽真空前后油液含气量和动、静态弹性弹性模量的变化规律,重点分析了在一定温度、体积变化率及工作压力范围内油液动态弹性模量的变化机理。
第六章,实验研究了抽真空处理前后液压伺服系统对阶跃信号和不同频率正弦信号的响应特性。结果揭示了油液弹性模量动态变化对超调量、调整时间及信号跟踪能力等系统特性的影响。针对液压伺服系统工作时执行器内油液弹性模量的动态变化,提出了一种基于动态弹性模量的控制参数实时调整方法。经调整后系统的动态性能得到明显改善,跟踪误差显著减小
第七章,概括了全文的主要研究工作,总结了研究成果,并展望了今后在该课题方向展开进一步研究的思路。
Hydraulic systems are widely used in many types of mechanical equipment. Effective fluid bulk modulus taken as the system rigidity plays an important role in the hydraulic systems. Due to its compressibility, the hydraulic fluid is generally regarded as a hydraulic spring. The effective bulk modulus varys with different working conditions and is considered as a soft parameter, and the variations are frequent and very complex. To estimating effective bulk modulus accurately is very important when designing high performance hydraulic systems, especially when the high quality systems with fast response and high stability are concerned. Therefore, researches on the influences of bulk modulus variation, the measurement of bulk modulus and the system behavior analysis based on dynamic bulk modulus are very significant to improve the hydraulic system performance.
The concept of dynamic fluid bulk modulus was first introduced and its mathematical model was proposed in this study. The model is taking the effect of working pressure, fluid temperature and air content into account, especially the dynamic pressure oscillation produced by the fluid volume change in the actuator. The model can effectively improve the accuracy of the bulk modulus in description. A measuring device was developed based on the bulk modulus definition. In this device, a servo motor was employed to load the fluid sample and two sensors with high accuracy were used to detect its pressure and volume in real-time. The loading force (0-20 MPa) and speed (0.35-4.45%/min) can be easily conrolled, and the measuring error was expected less than 2.08%. Adopting the vacuum-pumping treatment, the air content of the hydraulic system was reduced from 12.29% to 7.41%. The step response results show that the overdhoot reduces 5-10% as air content decreases 4.88%, and the settling time is also decreased. A method according to the dynamic fluid bulk modulus was proposed to adjust the control parameters of hydraulic systems. The system gain was adjusting with the variation of the fluid bulk modulus in real-time in order to meet the hydraulic nature frequency. The sine response results show that when the control parameters are adjusted following this method, the error of the system output reduces about 25-30% and the phase lag reduces about 3.5°8.6°. The displacement overshoot is also decreased.
In chapter 1, the definition, typicality and action of effective fluid bulk modulus in hydraulic systems were discussed. The current research progresses on bulk modulus measurement and the influences of different working parameters were reviewed. The main research subjects were presented.
In chapter 2, the air effect caused by the variation of air volume and air bubble state was presented, and its influence on bulk modulus was analyzed. The air movement characterics of both the single air buble and air bubbles in swarm were simulated. The influences of bubble diameter, fluid viscosity, pressure and interaction between different air bubbles on the behaviors of ascending velocity and distortion were analyzed.
In chapter 3, the mathematical model of effective fluid bulk modulus was presented, and the bulk modulus variation with pressure under different air content and working temperature was simulated. Based on the analysis, a power unit adopting vacuum pumping and bulk modulus measurement was designed to improve the effective fluid bulk modulus.
In chapter 4, a test rig consisting of vacuum pumping treatment, bulk modulus measurement and hydraulic servo motion was designed. The bulk modulus measuring device consists of a pressure sensor, a displacement sensor, a temperature sensor and a test chamber loading by a servo motor.
In chapter 5, the air volume measurement, vacuum pumping treatment and bulk modulus measurement were carried out. Based on the experimental results, the bulk modulus variation with pressure under different air contents, working temperature and fluid volume changing rate was analyzed.
In chapter 6, Step responses and sine wave responses of a valve-controlled cylinder were tested under different air content. The experimental results show that the bulk modulus varies instantaneously with working pressure. The overshoot and the settling time influenced by dynamic bulk modulus were analyzed. A method for improving the system behavior by regulating the control parameters with the dynamic bulk modulus variation was proposed.
In chapter 7, conclusions according to the work were summarized and future research proposals were suggested.
本文首次引入液压油动态弹性模量的概念,提出了动态弹性模量的数学模型。这一模型在充分考虑油液工作压力、温度、含气量等工况参数综合影响的基础上,特别考虑了液压系统工作时由于执行器内油液体积实时变动而引起的油液工作压力及其分布的动态变化,有效改善了以往对弹性模量的描述过于单一、不够准确的问题。研制了一种基于定义法的弹性模量检测装置。该装置采用伺服电机加载,并通过高精度压力传感器和位移传感器直接测得封闭容器内油液的压力、体积变化,具有加载压力(0-20 MPa)和加载速度(0.35-4.45%/min)连续可控、综合测量误差小于2.08%等优点,可实现在线且准确测得液压系统中的油液弹性模量。通过抽真空处理,使油液的含气量由12.29%降至7.41%,此时液压伺服系统阶跃响应的超调量减小约5-10%,且系统调整至稳态输出的过程也有所减短。提出了一种基于动态弹性模量的控制参数调整方法。该方法根据执行器内油液弹性模量的变化来实时调节系统增益,使控制参数与液压固有频率更加匹配,从而可保持系统结构不变的基础上最大限度的提高系统动态性能。通过对该方法对应频率分别为2Hz和8 Hz正弦信号的跟踪特性分析,计算和实验结果表明系统的最大跟踪误差降低了25%-30%,相位滞后减小约3.5°-8.6°,过渡过程的超调现象得到明显改善。
论文主要研究内容如下：
第一章,阐述了油液有效体积弹性模量的含义、特点及其在液压系统设计与分析中发挥的重要作用。综述和总结了国内外关于弹性模量的影响因素、测量技术等研究方向的研究历程,进而提出本课题的研究内容和研究目标。
第二章,理论分析了液压油中由溶解气体和游离气体的含量、状态变化引起的混气油液弹性模量的含气效应。运用CFD软件仿真分析了单个气泡和气泡群在油液中的运动特性,揭示了气泡尺寸、油液粘度、工作压力和气泡群体间的相互作用等因素对气泡的上升运动速度及形变特性的影响。
第三章,建立了封闭容腔内混气油液有效体积弹性模量的数学模型,并数值仿真了在不同初始含气量、油液温度等条件下,弹性模量随油液工作压力的变化特性。基于理论分析,设计了一套抽真空除气装置和弹性模量测量装置应用于一大型液压源系统,以提高系统内油液的弹性模量值。
第四章,基于课题研究内容和上一代实验系统的应用结果,研制了弹性模量综合实验台。对其三大关键分系统：闭式系统及其抽真空处理、基于伺服电机加载的弹性模量测量装置和伺服阀控缸系统,作了详细的解决方案、原理结构和关键参数设计。
第五章,分别对不同工况条件下混气油液的含气量测量、抽真空处理、静态弹性模量和动态弹性模量的测量开展相关实验研究。实验结果揭示了抽真空前后油液含气量和动、静态弹性弹性模量的变化规律,重点分析了在一定温度、体积变化率及工作压力范围内油液动态弹性模量的变化机理。
第六章,实验研究了抽真空处理前后液压伺服系统对阶跃信号和不同频率正弦信号的响应特性。结果揭示了油液弹性模量动态变化对超调量、调整时间及信号跟踪能力等系统特性的影响。针对液压伺服系统工作时执行器内油液弹性模量的动态变化,提出了一种基于动态弹性模量的控制参数实时调整方法。经调整后系统的动态性能得到明显改善,跟踪误差显著减小
第七章,概括了全文的主要研究工作,总结了研究成果,并展望了今后在该课题方向展开进一步研究的思路。
Hydraulic systems are widely used in many types of mechanical equipment. Effective fluid bulk modulus taken as the system rigidity plays an important role in the hydraulic systems. Due to its compressibility, the hydraulic fluid is generally regarded as a hydraulic spring. The effective bulk modulus varys with different working conditions and is considered as a soft parameter, and the variations are frequent and very complex. To estimating effective bulk modulus accurately is very important when designing high performance hydraulic systems, especially when the high quality systems with fast response and high stability are concerned. Therefore, researches on the influences of bulk modulus variation, the measurement of bulk modulus and the system behavior analysis based on dynamic bulk modulus are very significant to improve the hydraulic system performance.
The concept of dynamic fluid bulk modulus was first introduced and its mathematical model was proposed in this study. The model is taking the effect of working pressure, fluid temperature and air content into account, especially the dynamic pressure oscillation produced by the fluid volume change in the actuator. The model can effectively improve the accuracy of the bulk modulus in description. A measuring device was developed based on the bulk modulus definition. In this device, a servo motor was employed to load the fluid sample and two sensors with high accuracy were used to detect its pressure and volume in real-time. The loading force (0-20 MPa) and speed (0.35-4.45%/min) can be easily conrolled, and the measuring error was expected less than 2.08%. Adopting the vacuum-pumping treatment, the air content of the hydraulic system was reduced from 12.29% to 7.41%. The step response results show that the overdhoot reduces 5-10% as air content decreases 4.88%, and the settling time is also decreased. A method according to the dynamic fluid bulk modulus was proposed to adjust the control parameters of hydraulic systems. The system gain was adjusting with the variation of the fluid bulk modulus in real-time in order to meet the hydraulic nature frequency. The sine response results show that when the control parameters are adjusted following this method, the error of the system output reduces about 25-30% and the phase lag reduces about 3.5°8.6°. The displacement overshoot is also decreased.
In chapter 1, the definition, typicality and action of effective fluid bulk modulus in hydraulic systems were discussed. The current research progresses on bulk modulus measurement and the influences of different working parameters were reviewed. The main research subjects were presented.
In chapter 2, the air effect caused by the variation of air volume and air bubble state was presented, and its influence on bulk modulus was analyzed. The air movement characterics of both the single air buble and air bubbles in swarm were simulated. The influences of bubble diameter, fluid viscosity, pressure and interaction between different air bubbles on the behaviors of ascending velocity and distortion were analyzed.
In chapter 3, the mathematical model of effective fluid bulk modulus was presented, and the bulk modulus variation with pressure under different air content and working temperature was simulated. Based on the analysis, a power unit adopting vacuum pumping and bulk modulus measurement was designed to improve the effective fluid bulk modulus.
In chapter 4, a test rig consisting of vacuum pumping treatment, bulk modulus measurement and hydraulic servo motion was designed. The bulk modulus measuring device consists of a pressure sensor, a displacement sensor, a temperature sensor and a test chamber loading by a servo motor.
In chapter 5, the air volume measurement, vacuum pumping treatment and bulk modulus measurement were carried out. Based on the experimental results, the bulk modulus variation with pressure under different air contents, working temperature and fluid volume changing rate was analyzed.
In chapter 6, Step responses and sine wave responses of a valve-controlled cylinder were tested under different air content. The experimental results show that the bulk modulus varies instantaneously with working pressure. The overshoot and the settling time influenced by dynamic bulk modulus were analyzed. A method for improving the system behavior by regulating the control parameters with the dynamic bulk modulus variation was proposed.
In chapter 7, conclusions according to the work were summarized and future research proposals were suggested.
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