永磁交流伺服精密驱动系统机电耦合动力学分析与实验
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摘要
永磁交流伺服精密驱动系统中各子系统之间存在着多物理过程、多参量复杂耦合关系,因此整个系统的动态性能需由子系统之间的耦合关系和系统的输入等确定,而子系统的动态过程也不能仅由单个子系统的结构参数完全确定,也要受到与之有耦合关系的其他子系统的影响。故永磁交流伺服精密驱动系统在完成特定功能的同时,往往潜藏着或表露出种种不良工况,以致难以生产出高质量的产品,甚至出现重大故障,尤其在生产过程中,该系统在非平稳过程中所表现出来的机电耦合现象对系统的安全运行具有极大的危害性,这是由于该系统的电气参数与力学参数相互耦合,共同影响了整个系统的动力学性能。而造成这些设备产生不良状态的原因是对系统中这种多物理过程、多参数间多元多维耦合关系缺乏深层次的机理研究。本文在重庆市重大科技攻关项目《装备制造业典型基础部件关键技术研究及产业化》(项目编号CSTC,2006AA3010)的资助下,对永磁交流伺服精密驱动系统进行了机电耦合动力学分析和实验研究,主要做了以下几个方面的工作:
针对伺服系统具有同时包含多种物理过程,通过多元多维运动来实现多种形式的能量传递与转换,所有动态过程通过不同的耦合形式相互作用的特点,详细分析了伺服系统的精度指标和影响伺服系统的因素;指出精密传动装置影响伺服系统性能的机械结构因素与伺服系统的控制参量有着密切的联系,它们相互影响,形成了很强的耦合关系,这种耦合关系为永磁交流伺服精密驱动系统机电耦合分析提供了理论依据。
从机电耦合的角度出发,对永磁交流伺服精密驱动系统进行了全局机电耦合分析和局部机电耦合分析,建立了该系统的全局机电耦合关系图和永磁同步电动机-精密传动装置子系统机电耦合关系图;采用机电系统分析动力学方法获得了永磁同步电动机-精密传动装置子系统的物理模型和数学模型,推导了该子系统的机电耦合动力学方程;应用数值计算方法对耦合的数学模型进行了算例分析。
基于机电系统全局耦合分析的观点,根据机械系统的力学原理,将永磁交流伺服精密驱动系统归纳为三质量两轴系统,从而建立了该系统的机电耦合振动数学模型;由于该模型的机械力学参数和电气参数之间存在着复杂的非线性耦合关系,用解析方法不易求解,因此建立了该系统的机电耦合振动仿真模型;仿真分析了由于电流调节器参数、阻尼、谐波扰动、间隙以及负载扰动等因素引起的机电耦合振动动态过程。
分析了实验系统的基本组成和原理,完成了实验系统的控制系统设计、硬件部分设计、电气连接部分设计以及软件部分设计,最终构建了以PMAC多轴运动控制卡为核心、以IPC为支撑平台的永磁交流伺服精密驱动系统的实验体系结构;针对本实验系统的实际情况进行了抗干扰分析,从硬件方面进行抗干扰设计,提高系统的可靠性。
以实验系统为基础,完成了实验系统的过渡过程测试、效率测试、系统误差测试(转角偏差测试、重复定位精度测试以及传动误差测试)、空回测试、机电耦合实验以及振动加速度测试实验等实验研究,探索永磁交流伺服精密驱动系统的机电耦合影响,并将物理实验研究与理论分析结果进行对比和验证。
There are many physical processes and complex coupling relationships of many parameters existing between the subsystems of permanent magnet AC servo precision drive system, so the dynamic performance of the whole system is determined by the coupling relationship of the subsystems and the input of the system. However, dynamic process of the subsystem is not only determined by structure parameters of the single subsystem, but also influenced by other subsystems with coupling relationships. Therefore, when specific functions are fulfilled in the permanent magnet AC servo precision drive system, many adverse working conditions are hidden or revealed which lead to difficultly in producing high quality products, and even the major faults. Especially in the production process, because the mutual coupling relationships of electrical parameters and mechanical parameters have an effect on the dynamic performances of the whole system, the electromechanical coupling phenomenon has a great harm to safe operation of this system, which manifests in the non-stationary process. The bad states of these devices are caused by the mechanism which is lack of deep-seated study on multivariate and multidimensional coupling relationships between many physical processes and many parameters. This thesis is funded by Chongqing Municipal Important Science and Technology Key Project, China (CSTC, No. 2006AA3010). The electromechanical coupling dynamic analysis and experiment on the permanent magnet AC servo precision drive system are researched. The major contribution of the work is summarized as followings.
The servo system has the characteristics which include many physical processes, achieve various forms of energy transfer and conversion through multivariate and multidimensional motions, and has the interaction on all dynamic processes through different coupling forms. Then, there is a detailed analysis on the accuracy indexes of servo system and the factors influencing on the servo system, and a close relationship between mechanical structure factors of precision transmission and control parameters of servo system is pointed out. Because the mechanical structure factors and the control parameters interact to each other and form a strong coupling relationship, this relationship provides a theoretical basis for electromechanical coupling analysis of the permanent magnet AC servo precision drive system.
From the electromechanical coupling point of view, when the global and local electromechanical coupling analysises are carried out on the permanent magnet AC servo precision drive system, the global electromechanical coupling relationship of the system is built up, and the electromechanical coupling diagram of PMSM-precision transmission subsystem is also established. Furthermore, the physical and mathematical models of this subsystem are obtained by analytical dynamics method of electromechanical system, and the electromechanical dynamic equations of this subsystem are deduced. Finally, the mathematical model is analyzed by examples through the numerical method.
Based on global coupling view of the electromechanical system, and according to mechanics principle of the mechanical system, the permanent magnet AC servo precision drive system is concluded to the three qualities-two shafts system. Then the electromechanical coupling vibration mathematical model of this system is set up. Owing to the complex nonlinear coupling relationship between mechanical parameters and electrical parameters of this model, it is difficult to solve this model by analytical method. Therefore the simulation model is built up. What’s more, the dynamic processes of electromechanical coupling vibration are simulated which are caused by current regulator parameters, damping, harmonic disturbance, gap, load disturbance, and so on.
The basic composition and principle of the experiment system are analyzed, and then the control system design, the hardware design, the electrical connection design, and the software design are accomplished. Finally, the experiment system structure of the permanent magnet AC servo precision drive system is constructed which are PMAC as the core and IPC as the support platform. According to the actual situation of this experiment system, the anti-interference analysis is performed, and the anti-interference design is carried out from hardware aspects, which improves the reliability of the system.
On the basis of the experiment system, experimental studies are achieved, such as transient test, efficiency test, system error test(angle deviation test, repetitive positioning accuracy test, transmission error test), backlash test, electromechanical coupling test, vibration acceleration test, and so on. Electromechanical coupling influence is explored in the permanent magnet AC servo precision drive system, and the theoretical analysis results are compared and validated by the experimental studies.
针对伺服系统具有同时包含多种物理过程,通过多元多维运动来实现多种形式的能量传递与转换,所有动态过程通过不同的耦合形式相互作用的特点,详细分析了伺服系统的精度指标和影响伺服系统的因素;指出精密传动装置影响伺服系统性能的机械结构因素与伺服系统的控制参量有着密切的联系,它们相互影响,形成了很强的耦合关系,这种耦合关系为永磁交流伺服精密驱动系统机电耦合分析提供了理论依据。
从机电耦合的角度出发,对永磁交流伺服精密驱动系统进行了全局机电耦合分析和局部机电耦合分析,建立了该系统的全局机电耦合关系图和永磁同步电动机-精密传动装置子系统机电耦合关系图;采用机电系统分析动力学方法获得了永磁同步电动机-精密传动装置子系统的物理模型和数学模型,推导了该子系统的机电耦合动力学方程;应用数值计算方法对耦合的数学模型进行了算例分析。
基于机电系统全局耦合分析的观点,根据机械系统的力学原理,将永磁交流伺服精密驱动系统归纳为三质量两轴系统,从而建立了该系统的机电耦合振动数学模型;由于该模型的机械力学参数和电气参数之间存在着复杂的非线性耦合关系,用解析方法不易求解,因此建立了该系统的机电耦合振动仿真模型;仿真分析了由于电流调节器参数、阻尼、谐波扰动、间隙以及负载扰动等因素引起的机电耦合振动动态过程。
分析了实验系统的基本组成和原理,完成了实验系统的控制系统设计、硬件部分设计、电气连接部分设计以及软件部分设计,最终构建了以PMAC多轴运动控制卡为核心、以IPC为支撑平台的永磁交流伺服精密驱动系统的实验体系结构;针对本实验系统的实际情况进行了抗干扰分析,从硬件方面进行抗干扰设计,提高系统的可靠性。
以实验系统为基础,完成了实验系统的过渡过程测试、效率测试、系统误差测试(转角偏差测试、重复定位精度测试以及传动误差测试)、空回测试、机电耦合实验以及振动加速度测试实验等实验研究,探索永磁交流伺服精密驱动系统的机电耦合影响,并将物理实验研究与理论分析结果进行对比和验证。
There are many physical processes and complex coupling relationships of many parameters existing between the subsystems of permanent magnet AC servo precision drive system, so the dynamic performance of the whole system is determined by the coupling relationship of the subsystems and the input of the system. However, dynamic process of the subsystem is not only determined by structure parameters of the single subsystem, but also influenced by other subsystems with coupling relationships. Therefore, when specific functions are fulfilled in the permanent magnet AC servo precision drive system, many adverse working conditions are hidden or revealed which lead to difficultly in producing high quality products, and even the major faults. Especially in the production process, because the mutual coupling relationships of electrical parameters and mechanical parameters have an effect on the dynamic performances of the whole system, the electromechanical coupling phenomenon has a great harm to safe operation of this system, which manifests in the non-stationary process. The bad states of these devices are caused by the mechanism which is lack of deep-seated study on multivariate and multidimensional coupling relationships between many physical processes and many parameters. This thesis is funded by Chongqing Municipal Important Science and Technology Key Project, China (CSTC, No. 2006AA3010). The electromechanical coupling dynamic analysis and experiment on the permanent magnet AC servo precision drive system are researched. The major contribution of the work is summarized as followings.
The servo system has the characteristics which include many physical processes, achieve various forms of energy transfer and conversion through multivariate and multidimensional motions, and has the interaction on all dynamic processes through different coupling forms. Then, there is a detailed analysis on the accuracy indexes of servo system and the factors influencing on the servo system, and a close relationship between mechanical structure factors of precision transmission and control parameters of servo system is pointed out. Because the mechanical structure factors and the control parameters interact to each other and form a strong coupling relationship, this relationship provides a theoretical basis for electromechanical coupling analysis of the permanent magnet AC servo precision drive system.
From the electromechanical coupling point of view, when the global and local electromechanical coupling analysises are carried out on the permanent magnet AC servo precision drive system, the global electromechanical coupling relationship of the system is built up, and the electromechanical coupling diagram of PMSM-precision transmission subsystem is also established. Furthermore, the physical and mathematical models of this subsystem are obtained by analytical dynamics method of electromechanical system, and the electromechanical dynamic equations of this subsystem are deduced. Finally, the mathematical model is analyzed by examples through the numerical method.
Based on global coupling view of the electromechanical system, and according to mechanics principle of the mechanical system, the permanent magnet AC servo precision drive system is concluded to the three qualities-two shafts system. Then the electromechanical coupling vibration mathematical model of this system is set up. Owing to the complex nonlinear coupling relationship between mechanical parameters and electrical parameters of this model, it is difficult to solve this model by analytical method. Therefore the simulation model is built up. What’s more, the dynamic processes of electromechanical coupling vibration are simulated which are caused by current regulator parameters, damping, harmonic disturbance, gap, load disturbance, and so on.
The basic composition and principle of the experiment system are analyzed, and then the control system design, the hardware design, the electrical connection design, and the software design are accomplished. Finally, the experiment system structure of the permanent magnet AC servo precision drive system is constructed which are PMAC as the core and IPC as the support platform. According to the actual situation of this experiment system, the anti-interference analysis is performed, and the anti-interference design is carried out from hardware aspects, which improves the reliability of the system.
On the basis of the experiment system, experimental studies are achieved, such as transient test, efficiency test, system error test(angle deviation test, repetitive positioning accuracy test, transmission error test), backlash test, electromechanical coupling test, vibration acceleration test, and so on. Electromechanical coupling influence is explored in the permanent magnet AC servo precision drive system, and the theoretical analysis results are compared and validated by the experimental studies.
引文
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