平面涡卷弹簧疲劳试验机控制系统研究
|
摘要
目前,疲劳试验研究的深度和广度都在不断加大,国内已经有很多科研单位、高等院校进行了疲劳设计相关的工作。弹簧疲劳试验机是研究弹簧寿命的重要试验设备,被广泛应用于航空航天、汽车制造、高等院校和科研院所等相关实验室。弹簧疲劳试验机对研究弹簧带材、改进工艺、提高弹簧质量、降低制造成本、确保弹簧产品安全可靠等都有重要的作用。弹簧疲劳试验机种类繁多,但是当前国内很少有专门针对平面涡卷弹簧的疲劳试验机。本课题主要研究平面涡卷弹簧疲劳试验机的控制系统,其技术指标是基于与成都某弹簧生产厂签订合同中注明的技术要求。
试验机的控制系统是试验机的重要组成部分,是决定试验机性能的关键因素。控制系统要求能够保证运动控制的稳定性、准确性和快速性,还要求能够准确判断试件是否发生疲劳断裂,以及疲劳断裂时试件扭转的次数。论文针对控制系统的上述情况进行了设计。
首先,对平面涡卷弹簧的力学特性及试验机的机械传动结构进行研究,确定并分析了疲劳试验过程中各变量之间的关系,为疲劳试验机控制系统设计提供理论依据。
然后,详细介绍了控制系统的软硬件设计,在硬件方面采用松下A4系列电机伺服单元作为执行机构,上位机采用步科公司的MT4000系列人机操作界面以实现人机交互,下位机使用的是西门子的S7-200系列PLC作为控制核心。
最后,使用STEP7-Micro软件开发了PLC控制程序,利用EV5000软件组态人机交互界面。通过实际测试证明,设计的平面涡卷弹簧控制系统的控制可靠性高、运动定位准确、响应快速达到了设计要求,填补了国内这类控制系统的空白。
The depth and extent of fatigue test researching is increasing at present, the working of fatigue project is on process in a lot of domestic graduate school and university. As an important test facility, spring fatigue testing machine plays a key role in studying the life of spring, which is widely used in related laboratories of aerospace, automobile, higher education institutions and research institutes. Spring fatigue testing machine helps us to study the spring strip, improve manufacturing process, raise the quality of spring, lower manufacturing costs, and to ensure the reliability of spring products. There are many kinds of spring fatigue testing machine, however, few of them are specially designed for the flat scroll spring fatigue test. In this thesis, the main task is to study the control system of the flat scroll spring fatigue testing machine, the technical indexes of this thesis are built upon the technical contract signed with a spring plant in Chengdu.
The control system is an important part of the testing machine, which is the key factor to decide the performance of the testing machine. The control system is required to ensure the stability, accuracy and rapidity of motion control, and also required to be able to judge the fatigue fracture of the specimen accurately and record the times of the fatigue torsion. In response to these circumstances, this paper has conducted a special study.
Firstly the paper introduce the mechanical properties of the flat scroll spring and the mechanical structure of the testing machine, and analyze the relationship of variables in the fatigue test process, and these provide theoretical basis for the design of the fatigue testing machine's control system.
Secondly, the paper introduces the hardware and software design of the control system. In terms of hardware, A4series servo motor unit produced by Panasonic is the executing agency of system, the MT4000series HMI produced by Kinco company is made as the operation panel, the Siemens S7-200series PLC is taken as the control core unit.
In terms of software, the PLC control program is developed in the STEP7-Micro Software development environment, the operator interface is designed in the EV5000configure software. Through the test, the control system of the flat scroll spring fatigue testing machine has met the design requirements of high reliability, accurate positioning and fast response, and filled up the blank of this kind of control system in China.
试验机的控制系统是试验机的重要组成部分,是决定试验机性能的关键因素。控制系统要求能够保证运动控制的稳定性、准确性和快速性,还要求能够准确判断试件是否发生疲劳断裂,以及疲劳断裂时试件扭转的次数。论文针对控制系统的上述情况进行了设计。
首先,对平面涡卷弹簧的力学特性及试验机的机械传动结构进行研究,确定并分析了疲劳试验过程中各变量之间的关系,为疲劳试验机控制系统设计提供理论依据。
然后,详细介绍了控制系统的软硬件设计,在硬件方面采用松下A4系列电机伺服单元作为执行机构,上位机采用步科公司的MT4000系列人机操作界面以实现人机交互,下位机使用的是西门子的S7-200系列PLC作为控制核心。
最后,使用STEP7-Micro软件开发了PLC控制程序,利用EV5000软件组态人机交互界面。通过实际测试证明,设计的平面涡卷弹簧控制系统的控制可靠性高、运动定位准确、响应快速达到了设计要求,填补了国内这类控制系统的空白。
The depth and extent of fatigue test researching is increasing at present, the working of fatigue project is on process in a lot of domestic graduate school and university. As an important test facility, spring fatigue testing machine plays a key role in studying the life of spring, which is widely used in related laboratories of aerospace, automobile, higher education institutions and research institutes. Spring fatigue testing machine helps us to study the spring strip, improve manufacturing process, raise the quality of spring, lower manufacturing costs, and to ensure the reliability of spring products. There are many kinds of spring fatigue testing machine, however, few of them are specially designed for the flat scroll spring fatigue test. In this thesis, the main task is to study the control system of the flat scroll spring fatigue testing machine, the technical indexes of this thesis are built upon the technical contract signed with a spring plant in Chengdu.
The control system is an important part of the testing machine, which is the key factor to decide the performance of the testing machine. The control system is required to ensure the stability, accuracy and rapidity of motion control, and also required to be able to judge the fatigue fracture of the specimen accurately and record the times of the fatigue torsion. In response to these circumstances, this paper has conducted a special study.
Firstly the paper introduce the mechanical properties of the flat scroll spring and the mechanical structure of the testing machine, and analyze the relationship of variables in the fatigue test process, and these provide theoretical basis for the design of the fatigue testing machine's control system.
Secondly, the paper introduces the hardware and software design of the control system. In terms of hardware, A4series servo motor unit produced by Panasonic is the executing agency of system, the MT4000series HMI produced by Kinco company is made as the operation panel, the Siemens S7-200series PLC is taken as the control core unit.
In terms of software, the PLC control program is developed in the STEP7-Micro Software development environment, the operator interface is designed in the EV5000configure software. Through the test, the control system of the flat scroll spring fatigue testing machine has met the design requirements of high reliability, accurate positioning and fast response, and filled up the blank of this kind of control system in China.
引文
[1]李舜酩.机械疲劳与可靠性设计.科学出版社,2006：1-2
[2]胡刚,杨宗英.基于振动分析的单轴疲劳试验机动态力误差的研究与试验.船舶工程,2012(34)：73-76
[3]赵少汴,王忠保.疲劳设计.机械工业出版社.1992：1-5
[4]陈蓓,姜伟.电磁谐振式高频疲劳试验系统动态特性分析.机电工程,2012,12：1423-1425
[5]程育仁,缪龙秀,侯炳麟.疲劳强度.中国铁道出版社,1990
[6]余万里.轨道车辆抗侧滚扭杆系统疲劳试验研究.机械工程师2011(3)：30-31
[7]张乐尊.高国庆.汽车扭簧断裂失效分析.材料热处理技术2010(12)：24-26
[8]李维荣.圆柱螺旋弹簧疲劳试验方法研究.机械科学研究总院硕士学位论文,2007：15-18
[9]杨晓东.网架结构节点疲劳试验设计及数据分析.太原理工大学硕士学位论文.2008：1-3
[10]李骋,张国栋.确定高周应力疲劳S-N曲线的方法研究.燃气涡轮试验与研究,2008,21(2)：39-43
[11]孙振华INSTRON-1343电液伺服疲劳试验机计算机控制及数据处理系统及实验技术与管理,1999,16(2)：34-35
[12]沈姗姗,姜伟.高频疲劳试验动载载荷控制系统研究.试验技术与试验机.2012(20)：959-963
[13]CHEE-HOEFOONG, MARIAN WIERCIGROCH and WILLIAMF. DEANS. An Experimental Rig to Investigate Fatigue Crack Growth Under Dynamic Loading[J], Meccanica,2003(38):19-31
[14]王洗宗.日本,德国与美国试验机产业结构变化的研究.试验技术与试验机.1992(2)：4-9
[15]张静华.新技术革命对试验机的影响.试验机与试验材料,1985(1)：4-6
[16]张洋.扭转疲劳试验机电气控制系统的设计.南京理工大学硕士学位论文.2007：1-4
[17]汪曾祥,魏先英,刘祥至.弹簧设计手册.上海科学技术文献出版社.1986
[18]Elber W. The significance of fatigue crack closure Damage Tolerance in Aircraft Structures.ASTMSTP 197
[19]陈楠,陈曦.涡旋柔性弹簧型线设计及有限元分析.2005
[20]陈雪勇,张胜兰.涡卷弹簧在电机中的力学特性分析.湖南农机.2012：48-51
[21]李芹,刘平.蜗轮蜗杆试验台疲劳测试及控制系统仿真.计算机测量与控制.2012(12)：3154-3157
[22]Richard M, Scott R, Miskimins M. Flexure Springs Applied to Low-cost Linear Drive Cryocoolers. Proceedings of SPIE,2000,4130(1):406-412
[23]Gaunekar A S, Goddenhenrich T, Heiden C. Finite Element Analysis and Testing of Flexure Bearing Elements. Cryogenics,1996,36(5):359-364
[24]倪文波,王雪梅.基于Labview的车辆冲击试验台测控系统设计.计算机测量与控制.2006,15(12)：1739-1741
[25]王洪.大跨越架空输电线路分裂导线的微风振动及防振研究.华北电力大学博士学位论文,2009：52-53
[26]金双鹏,程鹏.弹簧的失效分析与预防技术.2011(9)：140-143
[27]赵建玉,王旭东.电液伺服疲劳试验机的计算机控制研究.仪器仪表学 报,2002,23(3)：320-323
[28]田庆敏.卧式冲击疲劳试验机的结构设计及性能分析.南京理工大学硕士学位论文.2012
[29]包华明,刘江.基于ADAMS的VTD350进给伺服系统的仿真与设计.机械设计与制造.2013(3)：59-62
[30]田健男.精密绕线机控制系统设计与实现.电子科技大学,2012：5-6
[31]Frey G, Litz L. Formal methods in PLC programming. IEEE International Conference,2000, (4):2431-2436
[32]周万珍,高鸿斌编著.PLC分析与设计应用.电子工业出版社,2004
[33]黄凤娟,基于单片机的温度控制系统在温室大棚中的设计与实现.安徽：安徽大学,2006
[34]杨健,余菁等.PLC在水净化过程中的应用.电气传动.2005,35(9)：62-64
[35]王建国,吕原君.基于PLC的裂纹检测台研制.数控技术.2006,(9)：70-72
[36]唐国兰.基于PLC的高速全自动包装机控制系统的应用研究.电子科技大学,2004
[37]Panasonic.Panasonic-Minas-A4-Servos:2
[38]松下.Minas A4系列AC伺服驱动器说明书：12-13
[39]杨上陆,董湘怀.基于PMAC和松下伺服电机的电子横移控制系统研究.2004,(11)：73-76
[40]崔晓.高频电液伺服振动台的研究[D].沈阳：沈阳工业大学,2005
[41]扭转疲劳试验机电气控制系统的设计
[42]邓丽芳.PLC在一台自耦变压器起动多台电动机中的应用.沿海企业与科技.2006(08)
[43]Ball K. PLC I/O systems news, views, and networks[J].Control Engineering, 1997,44(14):81-88
[44]齐从谦,王士兰.PLC技术及应用.北京：机械工业出版社,2000.8
[45]IEC, IEC61131-1,2nd Ed. Programmable Controllers Programming Languages[S], International Electro technical Commission,2003
[46]叶晓光.PLC在组合机床的控制应用探讨.制造业自动化.2011(10)：146-148
[47]孙增圻.计算机控制理论与应用.清华大学出版社,2008：1-5
[48]Mathias Schreyer. Systematic software design for PLC operated automation systems [M]. Hong Kong University of Science and Technology,2001.5
[49]W. Bolton. Programmable Logic Controllers(fourth edition)
[50]李胜勇.JZ6-660全自动高速吸塑成型机智能温度测控及运动自动控制系统的研究与实现.硕士学位论文,广东工业大学图馆,2003
[51]李德英.基于PLC的液压实验台监控系统的开发与研制.中南大学,2011
[52]徐宝亮.新型弯扭联合作用疲劳试验机的设计研究[D].哈尔滨工业大学,2006
[53]吴亚雄.毛巾印花机PLC控制系统及设计.单位：重庆海康实业有限公司设备能源部,中国工控网专业论文,2003
[54].S7-200可编程控制器系统手册SIEMENS
[55]宋伯生.编程理论算法及技巧.机械工业出版社2005
[56]Safonov, Large Seale Systems Modeling and Control. Proceedings of the IEEE, 1985,8(73):1340-1341
[57]宋伯生.可编程控制器配置,编程,联网.中国劳动出版社,1998.12
[2]胡刚,杨宗英.基于振动分析的单轴疲劳试验机动态力误差的研究与试验.船舶工程,2012(34)：73-76
[3]赵少汴,王忠保.疲劳设计.机械工业出版社.1992：1-5
[4]陈蓓,姜伟.电磁谐振式高频疲劳试验系统动态特性分析.机电工程,2012,12：1423-1425
[5]程育仁,缪龙秀,侯炳麟.疲劳强度.中国铁道出版社,1990
[6]余万里.轨道车辆抗侧滚扭杆系统疲劳试验研究.机械工程师2011(3)：30-31
[7]张乐尊.高国庆.汽车扭簧断裂失效分析.材料热处理技术2010(12)：24-26
[8]李维荣.圆柱螺旋弹簧疲劳试验方法研究.机械科学研究总院硕士学位论文,2007：15-18
[9]杨晓东.网架结构节点疲劳试验设计及数据分析.太原理工大学硕士学位论文.2008：1-3
[10]李骋,张国栋.确定高周应力疲劳S-N曲线的方法研究.燃气涡轮试验与研究,2008,21(2)：39-43
[11]孙振华INSTRON-1343电液伺服疲劳试验机计算机控制及数据处理系统及实验技术与管理,1999,16(2)：34-35
[12]沈姗姗,姜伟.高频疲劳试验动载载荷控制系统研究.试验技术与试验机.2012(20)：959-963
[13]CHEE-HOEFOONG, MARIAN WIERCIGROCH and WILLIAMF. DEANS. An Experimental Rig to Investigate Fatigue Crack Growth Under Dynamic Loading[J], Meccanica,2003(38):19-31
[14]王洗宗.日本,德国与美国试验机产业结构变化的研究.试验技术与试验机.1992(2)：4-9
[15]张静华.新技术革命对试验机的影响.试验机与试验材料,1985(1)：4-6
[16]张洋.扭转疲劳试验机电气控制系统的设计.南京理工大学硕士学位论文.2007：1-4
[17]汪曾祥,魏先英,刘祥至.弹簧设计手册.上海科学技术文献出版社.1986
[18]Elber W. The significance of fatigue crack closure Damage Tolerance in Aircraft Structures.ASTMSTP 197
[19]陈楠,陈曦.涡旋柔性弹簧型线设计及有限元分析.2005
[20]陈雪勇,张胜兰.涡卷弹簧在电机中的力学特性分析.湖南农机.2012：48-51
[21]李芹,刘平.蜗轮蜗杆试验台疲劳测试及控制系统仿真.计算机测量与控制.2012(12)：3154-3157
[22]Richard M, Scott R, Miskimins M. Flexure Springs Applied to Low-cost Linear Drive Cryocoolers. Proceedings of SPIE,2000,4130(1):406-412
[23]Gaunekar A S, Goddenhenrich T, Heiden C. Finite Element Analysis and Testing of Flexure Bearing Elements. Cryogenics,1996,36(5):359-364
[24]倪文波,王雪梅.基于Labview的车辆冲击试验台测控系统设计.计算机测量与控制.2006,15(12)：1739-1741
[25]王洪.大跨越架空输电线路分裂导线的微风振动及防振研究.华北电力大学博士学位论文,2009：52-53
[26]金双鹏,程鹏.弹簧的失效分析与预防技术.2011(9)：140-143
[27]赵建玉,王旭东.电液伺服疲劳试验机的计算机控制研究.仪器仪表学 报,2002,23(3)：320-323
[28]田庆敏.卧式冲击疲劳试验机的结构设计及性能分析.南京理工大学硕士学位论文.2012
[29]包华明,刘江.基于ADAMS的VTD350进给伺服系统的仿真与设计.机械设计与制造.2013(3)：59-62
[30]田健男.精密绕线机控制系统设计与实现.电子科技大学,2012：5-6
[31]Frey G, Litz L. Formal methods in PLC programming. IEEE International Conference,2000, (4):2431-2436
[32]周万珍,高鸿斌编著.PLC分析与设计应用.电子工业出版社,2004
[33]黄凤娟,基于单片机的温度控制系统在温室大棚中的设计与实现.安徽：安徽大学,2006
[34]杨健,余菁等.PLC在水净化过程中的应用.电气传动.2005,35(9)：62-64
[35]王建国,吕原君.基于PLC的裂纹检测台研制.数控技术.2006,(9)：70-72
[36]唐国兰.基于PLC的高速全自动包装机控制系统的应用研究.电子科技大学,2004
[37]Panasonic.Panasonic-Minas-A4-Servos:2
[38]松下.Minas A4系列AC伺服驱动器说明书：12-13
[39]杨上陆,董湘怀.基于PMAC和松下伺服电机的电子横移控制系统研究.2004,(11)：73-76
[40]崔晓.高频电液伺服振动台的研究[D].沈阳：沈阳工业大学,2005
[41]扭转疲劳试验机电气控制系统的设计
[42]邓丽芳.PLC在一台自耦变压器起动多台电动机中的应用.沿海企业与科技.2006(08)
[43]Ball K. PLC I/O systems news, views, and networks[J].Control Engineering, 1997,44(14):81-88
[44]齐从谦,王士兰.PLC技术及应用.北京：机械工业出版社,2000.8
[45]IEC, IEC61131-1,2nd Ed. Programmable Controllers Programming Languages[S], International Electro technical Commission,2003
[46]叶晓光.PLC在组合机床的控制应用探讨.制造业自动化.2011(10)：146-148
[47]孙增圻.计算机控制理论与应用.清华大学出版社,2008：1-5
[48]Mathias Schreyer. Systematic software design for PLC operated automation systems [M]. Hong Kong University of Science and Technology,2001.5
[49]W. Bolton. Programmable Logic Controllers(fourth edition)
[50]李胜勇.JZ6-660全自动高速吸塑成型机智能温度测控及运动自动控制系统的研究与实现.硕士学位论文,广东工业大学图馆,2003
[51]李德英.基于PLC的液压实验台监控系统的开发与研制.中南大学,2011
[52]徐宝亮.新型弯扭联合作用疲劳试验机的设计研究[D].哈尔滨工业大学,2006
[53]吴亚雄.毛巾印花机PLC控制系统及设计.单位：重庆海康实业有限公司设备能源部,中国工控网专业论文,2003
[54].S7-200可编程控制器系统手册SIEMENS
[55]宋伯生.编程理论算法及技巧.机械工业出版社2005
[56]Safonov, Large Seale Systems Modeling and Control. Proceedings of the IEEE, 1985,8(73):1340-1341
[57]宋伯生.可编程控制器配置,编程,联网.中国劳动出版社,1998.12