开放型嵌入式旋转机械自动平衡控制系统的研究
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摘要
转子自动平衡系统多年来一直是工程技术研究与开发的热点领域,具有很大的发展潜力。该项技术不仅可以消除运行中随机产生的动不平衡、实时减小设备振动,而且可以有效延长转动设备的运行周期、减少故障停机、降低维修费用,经济效应可观。同时其潜在的应用范围极为广泛,目前已知的应用报道,不仅有压缩机、汽轮机、离心分离机等大型机械设备,而且还有类似于硬盘磁头等高精密旋转机构。事实上,任何需要保持旋转体稳定运行的机械机构都是其潜在应用对象,因而转子自动平衡技术的发展及应用前景非常广阔。
作为国家自然科学基金项目《机械复杂系统建模仿真、运行优化和自愈调控理论与方法》(编号：50635010)的组成部分,本课题在总结数种典型自动平衡系统的基础上,以自愈调控理论为指导,讨论了工业应用中自动平衡控制系统可能遇到的几类实际问题及其解决方案；通过数学建模对自动平衡控制算法与不平衡信号处理算法进行了仿真研究；分别就连续注排式平衡头、单一注入式平衡头以及电磁式平衡头等三类平衡头构造了开放型嵌入式自动平衡控制系统,并利用北京化工大学DSE中心超重力机实验台进行物理验证；作为自动平衡最小系统的补充完善,探讨了可用于嵌入式环境的旋转机械自动推理故障诊断系统；最终逐步完善了具有自主知识产权的开放型嵌入式转子自动平衡控制系统样机,为该项技术的国产化、工业化进行了初步探索。课题主要工作有：
(1)典型自动平衡控制系统分析与总结
对北京化工大学DSE中心现有的三类典型自动平衡系统(连续注排式自动平衡系统、单一注液式自动平衡系统、电磁式自动平衡系统)进行了综述与比较,分析了自动平衡系统中各组成部件的结构,研究了配重原理及平衡原理；在此基础上讨论了自动平衡控制系统在工业现场实际应用中需要解决的几个核心问题。
(2)构建开放型嵌入式自动平衡系统硬件平台
针对工业现场可能存在的粉尘环境、振动环境、污染环境及狭窄空间等多种不利情况,选用PC／104标准总线作为系统硬件开发平台并对系统硬件进行功能划分,通过“从顶至底”的模块化设计,在最小功能系统的基础上,针对不同类型平衡头与传感器,配合相应功能的扩展单元模块,进而实现对多种平衡头的控制,最大限度的匹配与利用现有资源。
(3)控制算法仿真与优化
工业转子自动平衡控制有其特殊性,表现在：1)仅允许极小范围内可预见的控制超调,从安全角度而言,一般要求不存在超调；2)系统过渡过程中的振荡不仅是对转子工况的干扰,而且将降低平衡头的平衡能力,需要尽可能抑制；3)随着生产负荷等外部条件的变化,转子系统的振动范围可能发生变化,平衡控制系统需要在多个设定值之间平滑过渡。另一方面,嵌入式系统中可利用的硬件资源十分有限。根据这些特点,本课题着重研究了基于迭代学习算法的自动平衡控制策略并利用向量几何原理改进了基本算法,从理论上证明了其收敛性、鲁棒性等关键性质；建立了超重力机转子数学模型,在模型振动特性分析基础上,对PI增量控制、基本迭代学习控制以及基于几何分析的迭代学习控制进行了仿真研究,并确立了适于转子自动平衡控制的迭代学习算法结构,给出了相关控制参数范围。
(4)不平衡量信号提取与处理
不平衡量信号的提取是平衡控制系统的核心问题之一,直接影响到最终的控制效果,特别是避免平衡控制中的“错调”现象很大程度上依赖于不平衡信号提取的精度与准确性。结合系统硬件资源较少,而且是时变参数测量对象等因素,本课题着重考察了自适应滤波算法在不平衡振动信号提取中的应用,并对基本LMS算法进行了改进。利用国际开源振动测试数据库中的信号数据作为分析基准,对比了基本LMS算法、基于向量分析的LMS算法、维纳滤波等自适应信号处理方法,结果表明基于向量分析的LMS算法在算法复杂度、系统资源消耗、信号提取精度等方面有着较好的均衡性。
(5)构建旋转机械自动推理故障诊断系统
机械振动原因繁多,不是任意振动均可通过自动平衡系统进行校正。作为本课题最小功能系统的扩展模块,旋转机械自动推理故障诊断系统的设计目标是对于不可进行自动平衡的振动进行判别并提供可能故障原因的排列,通过融合粗糙集约简、规则属性化、信息模糊化等手段,降低人工输入次数,令系统自动推理程度得以大幅提高。
(6)开放型嵌入式自动平衡控制系统样机
结合上述各项工作,逐步完善系统结构,获取开放型嵌入式自动平衡控制系统的原始样机。
On-line rotor auto-balancing has been a hot area of engineering research and development over the years, which has a great potential of innovation. This technology can not only eliminate the dynamic random imbalances and reduce real-time equipment vibrations during rotor's running period, but also can effectively extend the operation cycle of rotating machinery, decrease malfunction downtimes, save maintenance costs, which has a very high economic value. Moreover, its potential application area is extremely broad. According to the reports so far, the applications cover not only large mechanical equipment, like compressors, turbines and centrifuges, but also highly precision rotary mechanism such as the hard disk drive heads. In fact, any machinery needs to maintain the stable operation of rotating facility is the latent target, so the development and application prospects of rotor on-line auto-balancing technology are very bright.
As a part of the National Natural Science Foundation Project:"the theory and method for complex mechanical systems modeling, simulation, operation optimization and self-recoverling control" (No.50635010), this research project first summarized several typical auto-balancing system, and then discussed several industrial field problems auto-balancing control system may encounter and their solutions under the guidance of self-recovering theory. The simulation studies of self-recovering control and signal processing algorithms for auto-balancing were done using a custom-built mathematical higee rotor model. Three different on-line auto-balancing control systems were built up respectively for three different kinds of balancers which are the continuous injection-discharge liquid balancer, the single injection liquid and the electromagnetic balancer. All the systems were physical tested through the experimental platform. An embedded usage customized auto-reasoning fault diagnosis system for rotating machinery got studied as a part of wellappointedness of the minimum auto-balancing control system. Finally, a prototype control system with independent intellectual property was completed, which may build the initial foundation for the localization and industrialization of this bright technology. The main taskes of this project contained:
(1) Comparison and analysis of typical auto-balancing systems
There are three kinds of auto-balancing system in the DSE Center of Beijing University of Chemical Technology, which are:the continuous injection-discharge liquid auto-balancing system, the single injection liquid auto-balancing system, and the electromagnetic auto-balancing system. They represent the main realization forms of auto-balancing theory. Based on the review and comparison, system structures were analyzed, the balancing principles were investigated, and some key issues on auto-balancing control system, which need to be solved in the industrial application field, were come into question.
(2) Hardware realization of open embedded auto-balancing system
Dust, vibration, pollution or narrow install space, are just some cases of the adverse conditions which may exist in the industrial field. Hence, PC/104 bus was chosen as the system hardware platform. After the system function division, hardware modules were designed "from the top to the bottom". According to the different types of balancers and sensors, corresponding expansion modular boards can be loaded to the minimum function system. In this way, the existing resources could be maximizing used.
(3) Simulation and optimization of auto-balancing control algorithms
The auto-balancing control process of an industrial rotor has its own particularity, manifested in:1) only a very small range of overshoot is allowed, otherwise it may cause malfunctions. In general, no overshoot is demanded; 2) the transition oscillation is a kind of interference to the balance ability of the balancer, hence it should be inhibited as much as possible; 3) With the change in production load or other external conditions, the vibration range of rotor system may be different, balance control system needes smooth transitions between multiple setpoints. On the other hand, the whole control process will be realized in an embedded system which has limited available hardware resources. So in this project, the Iterative Learning Control (ILC) algorithm was highly focused on. Vector Geometry was used to improve the basic algorithm of ILC. Then a mathematical model of higee rotor was achieved. Based on it, the standard PI increment control algorithm, the basic ILC algorithm and its modification algorithm with vector analysis got compared. With the conclusions of theory analysis and simulation studies, the algorithm structure of ILC suitable for auto-balancing control was eventually established, and the ranges of control parameters were given out.
(4) Extraction and processing of unbalance signal
Unbalance signal extrction is a big issue in balancing control system, which has a direct impact on the final control effects. In particular, to avoid the "wrong direction" phenomenon during the control process greatly dependents on the precision and accuracy of this extraction progress. Due to the limited hardware resources, time-varying parameters and other factors, adaptive filtering algorithm was used here, and the basic LMS algorithm has been modified. An international open-source database of vibration signal was used as the benchmark to test and compare the adaptive signal processing ability of the basic LMS algorithm, its modification algorithm and the Wiener filter. The results showed that the modified LMS algorithm based on vector analysis had a good balance in the computational complexity, the system resource consumption, the signal extraction precision and other indexes.
(5) Construction of auto-reasoning mechanism for rotating machinery fault diagnosis system
There are so many reasons leading to mechanical vibration that not any one can be inhibited by the auto-balancing system. As an extension module of this open embedded auto-balancing system, the design target of rotating machinery auto-reasoning fault diagnosis system is to distinguish the vibration reason in order to determine whether the auto-balancing system run or not. Moreover, it may provide a guidance of possible fault cause to on-site operators. The degree of auto-reasoning was substantial increased by rough set simplification, rule property restructured, and fuzzy information.
(6) The prototype of open embedded auto-balancing control system
Base on the previous studies, the system structure was improved step by step, finally achieved its original prototype.
作为国家自然科学基金项目《机械复杂系统建模仿真、运行优化和自愈调控理论与方法》(编号：50635010)的组成部分,本课题在总结数种典型自动平衡系统的基础上,以自愈调控理论为指导,讨论了工业应用中自动平衡控制系统可能遇到的几类实际问题及其解决方案；通过数学建模对自动平衡控制算法与不平衡信号处理算法进行了仿真研究；分别就连续注排式平衡头、单一注入式平衡头以及电磁式平衡头等三类平衡头构造了开放型嵌入式自动平衡控制系统,并利用北京化工大学DSE中心超重力机实验台进行物理验证；作为自动平衡最小系统的补充完善,探讨了可用于嵌入式环境的旋转机械自动推理故障诊断系统；最终逐步完善了具有自主知识产权的开放型嵌入式转子自动平衡控制系统样机,为该项技术的国产化、工业化进行了初步探索。课题主要工作有：
(1)典型自动平衡控制系统分析与总结
对北京化工大学DSE中心现有的三类典型自动平衡系统(连续注排式自动平衡系统、单一注液式自动平衡系统、电磁式自动平衡系统)进行了综述与比较,分析了自动平衡系统中各组成部件的结构,研究了配重原理及平衡原理；在此基础上讨论了自动平衡控制系统在工业现场实际应用中需要解决的几个核心问题。
(2)构建开放型嵌入式自动平衡系统硬件平台
针对工业现场可能存在的粉尘环境、振动环境、污染环境及狭窄空间等多种不利情况,选用PC／104标准总线作为系统硬件开发平台并对系统硬件进行功能划分,通过“从顶至底”的模块化设计,在最小功能系统的基础上,针对不同类型平衡头与传感器,配合相应功能的扩展单元模块,进而实现对多种平衡头的控制,最大限度的匹配与利用现有资源。
(3)控制算法仿真与优化
工业转子自动平衡控制有其特殊性,表现在：1)仅允许极小范围内可预见的控制超调,从安全角度而言,一般要求不存在超调；2)系统过渡过程中的振荡不仅是对转子工况的干扰,而且将降低平衡头的平衡能力,需要尽可能抑制；3)随着生产负荷等外部条件的变化,转子系统的振动范围可能发生变化,平衡控制系统需要在多个设定值之间平滑过渡。另一方面,嵌入式系统中可利用的硬件资源十分有限。根据这些特点,本课题着重研究了基于迭代学习算法的自动平衡控制策略并利用向量几何原理改进了基本算法,从理论上证明了其收敛性、鲁棒性等关键性质；建立了超重力机转子数学模型,在模型振动特性分析基础上,对PI增量控制、基本迭代学习控制以及基于几何分析的迭代学习控制进行了仿真研究,并确立了适于转子自动平衡控制的迭代学习算法结构,给出了相关控制参数范围。
(4)不平衡量信号提取与处理
不平衡量信号的提取是平衡控制系统的核心问题之一,直接影响到最终的控制效果,特别是避免平衡控制中的“错调”现象很大程度上依赖于不平衡信号提取的精度与准确性。结合系统硬件资源较少,而且是时变参数测量对象等因素,本课题着重考察了自适应滤波算法在不平衡振动信号提取中的应用,并对基本LMS算法进行了改进。利用国际开源振动测试数据库中的信号数据作为分析基准,对比了基本LMS算法、基于向量分析的LMS算法、维纳滤波等自适应信号处理方法,结果表明基于向量分析的LMS算法在算法复杂度、系统资源消耗、信号提取精度等方面有着较好的均衡性。
(5)构建旋转机械自动推理故障诊断系统
机械振动原因繁多,不是任意振动均可通过自动平衡系统进行校正。作为本课题最小功能系统的扩展模块,旋转机械自动推理故障诊断系统的设计目标是对于不可进行自动平衡的振动进行判别并提供可能故障原因的排列,通过融合粗糙集约简、规则属性化、信息模糊化等手段,降低人工输入次数,令系统自动推理程度得以大幅提高。
(6)开放型嵌入式自动平衡控制系统样机
结合上述各项工作,逐步完善系统结构,获取开放型嵌入式自动平衡控制系统的原始样机。
On-line rotor auto-balancing has been a hot area of engineering research and development over the years, which has a great potential of innovation. This technology can not only eliminate the dynamic random imbalances and reduce real-time equipment vibrations during rotor's running period, but also can effectively extend the operation cycle of rotating machinery, decrease malfunction downtimes, save maintenance costs, which has a very high economic value. Moreover, its potential application area is extremely broad. According to the reports so far, the applications cover not only large mechanical equipment, like compressors, turbines and centrifuges, but also highly precision rotary mechanism such as the hard disk drive heads. In fact, any machinery needs to maintain the stable operation of rotating facility is the latent target, so the development and application prospects of rotor on-line auto-balancing technology are very bright.
As a part of the National Natural Science Foundation Project:"the theory and method for complex mechanical systems modeling, simulation, operation optimization and self-recoverling control" (No.50635010), this research project first summarized several typical auto-balancing system, and then discussed several industrial field problems auto-balancing control system may encounter and their solutions under the guidance of self-recovering theory. The simulation studies of self-recovering control and signal processing algorithms for auto-balancing were done using a custom-built mathematical higee rotor model. Three different on-line auto-balancing control systems were built up respectively for three different kinds of balancers which are the continuous injection-discharge liquid balancer, the single injection liquid and the electromagnetic balancer. All the systems were physical tested through the experimental platform. An embedded usage customized auto-reasoning fault diagnosis system for rotating machinery got studied as a part of wellappointedness of the minimum auto-balancing control system. Finally, a prototype control system with independent intellectual property was completed, which may build the initial foundation for the localization and industrialization of this bright technology. The main taskes of this project contained:
(1) Comparison and analysis of typical auto-balancing systems
There are three kinds of auto-balancing system in the DSE Center of Beijing University of Chemical Technology, which are:the continuous injection-discharge liquid auto-balancing system, the single injection liquid auto-balancing system, and the electromagnetic auto-balancing system. They represent the main realization forms of auto-balancing theory. Based on the review and comparison, system structures were analyzed, the balancing principles were investigated, and some key issues on auto-balancing control system, which need to be solved in the industrial application field, were come into question.
(2) Hardware realization of open embedded auto-balancing system
Dust, vibration, pollution or narrow install space, are just some cases of the adverse conditions which may exist in the industrial field. Hence, PC/104 bus was chosen as the system hardware platform. After the system function division, hardware modules were designed "from the top to the bottom". According to the different types of balancers and sensors, corresponding expansion modular boards can be loaded to the minimum function system. In this way, the existing resources could be maximizing used.
(3) Simulation and optimization of auto-balancing control algorithms
The auto-balancing control process of an industrial rotor has its own particularity, manifested in:1) only a very small range of overshoot is allowed, otherwise it may cause malfunctions. In general, no overshoot is demanded; 2) the transition oscillation is a kind of interference to the balance ability of the balancer, hence it should be inhibited as much as possible; 3) With the change in production load or other external conditions, the vibration range of rotor system may be different, balance control system needes smooth transitions between multiple setpoints. On the other hand, the whole control process will be realized in an embedded system which has limited available hardware resources. So in this project, the Iterative Learning Control (ILC) algorithm was highly focused on. Vector Geometry was used to improve the basic algorithm of ILC. Then a mathematical model of higee rotor was achieved. Based on it, the standard PI increment control algorithm, the basic ILC algorithm and its modification algorithm with vector analysis got compared. With the conclusions of theory analysis and simulation studies, the algorithm structure of ILC suitable for auto-balancing control was eventually established, and the ranges of control parameters were given out.
(4) Extraction and processing of unbalance signal
Unbalance signal extrction is a big issue in balancing control system, which has a direct impact on the final control effects. In particular, to avoid the "wrong direction" phenomenon during the control process greatly dependents on the precision and accuracy of this extraction progress. Due to the limited hardware resources, time-varying parameters and other factors, adaptive filtering algorithm was used here, and the basic LMS algorithm has been modified. An international open-source database of vibration signal was used as the benchmark to test and compare the adaptive signal processing ability of the basic LMS algorithm, its modification algorithm and the Wiener filter. The results showed that the modified LMS algorithm based on vector analysis had a good balance in the computational complexity, the system resource consumption, the signal extraction precision and other indexes.
(5) Construction of auto-reasoning mechanism for rotating machinery fault diagnosis system
There are so many reasons leading to mechanical vibration that not any one can be inhibited by the auto-balancing system. As an extension module of this open embedded auto-balancing system, the design target of rotating machinery auto-reasoning fault diagnosis system is to distinguish the vibration reason in order to determine whether the auto-balancing system run or not. Moreover, it may provide a guidance of possible fault cause to on-site operators. The degree of auto-reasoning was substantial increased by rough set simplification, rule property restructured, and fuzzy information.
(6) The prototype of open embedded auto-balancing control system
Base on the previous studies, the system structure was improved step by step, finally achieved its original prototype.
引文
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