硬支承平衡机测量与校正系统的研制
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摘要
转子由于其质心偏离其转轴而导致的不平衡,在高速运转过程中会导致转子本身产生振动,此振动会加速轴承的损耗并导致机械寿命的缩短。为改善转子的偏心而对不平衡转子进行测试与校正就成了必需的手段。对转子进行平衡作为转子制造的一道工序,对提升产品质量有重要的作用。
课题在对国内转子制造业现状进行调查了解的情况下,针对刚性盘状转子的不平衡情况,开发了测试与校正功能一体化的立式平衡机。能够显著改善目前国内中小企业手动平衡效率低下的情况。
论文从测试与校正两个方面对转子不平衡问题进行了研究。主要内容包括：
对动平衡技术的国内外发展现况和动平衡原理进行了较为详细的阐述,针对转子不平衡的情况,提出了适合盘状刚性转子的不平衡检测方法,及其实现手段,并详细讨论了测量系统的设计细节。内容包括基于影响系数法的不平衡检测方法,基于MCU的主控电路的设计,基于开关电容的自动跟踪滤波器的设计,锁相倍频电路等。
详细论述了针对皮带轮和刹车盘,这两种不同类型的盘状刚性转子而采用的不同的校正方法,校正误差的产生与解决方法。包括刀具的选择,校正模型的设计,伺服电机的选择与控制,可编程控制器硬件的设计与梯形图程序的编写,以及基于组态王的上位机软件的编写等。
The rotor because of its centre of mass away from its axis caused by an unbalance in the process of high-speed operation will lead to the rotor itself to vibrate. This vibration will accelerate the loss of bearing and lead to shortening of mechanical life. In order to improve the rotor eccentricity, testing and correcting of the rotor unbalance becomes necessary means. Rotor balancing as a process of the rotor manufactured plays a important role of improve product quality.
This thesis invents the vertical balancing machines of testing and correcting function to the rigid rotors based on the current situation of domestic manufacturers. This method can significantly improve the low efficiency of manually correction, in domestic small and medium enterprises.
Papers studied from the two aspects of testing and correcting in the rotor unbalance. The main contents are included as following:
The development of balancing machine at home and abroad was introduced, and more details about the principle of dynamic balance. The testing method and of unbalance disc-rigid rotor is discussed. The details which design the testing system including coefficient method, MCU circuit design, auto-tracking filter which based on switched-capacitor auto-tracking filter, phase-locked multiplier circuit were introduced.
For the pulley and the brake disc, these two different types of discoid rigid rotor, we use different correction methods. The error theory, tool selection, correction model design, the choice and control of servo motors, PLC (programmable logic controller) design and ladder programs, the software design of Industrial Personal Computer which based on configuration software.
课题在对国内转子制造业现状进行调查了解的情况下,针对刚性盘状转子的不平衡情况,开发了测试与校正功能一体化的立式平衡机。能够显著改善目前国内中小企业手动平衡效率低下的情况。
论文从测试与校正两个方面对转子不平衡问题进行了研究。主要内容包括：
对动平衡技术的国内外发展现况和动平衡原理进行了较为详细的阐述,针对转子不平衡的情况,提出了适合盘状刚性转子的不平衡检测方法,及其实现手段,并详细讨论了测量系统的设计细节。内容包括基于影响系数法的不平衡检测方法,基于MCU的主控电路的设计,基于开关电容的自动跟踪滤波器的设计,锁相倍频电路等。
详细论述了针对皮带轮和刹车盘,这两种不同类型的盘状刚性转子而采用的不同的校正方法,校正误差的产生与解决方法。包括刀具的选择,校正模型的设计,伺服电机的选择与控制,可编程控制器硬件的设计与梯形图程序的编写,以及基于组态王的上位机软件的编写等。
The rotor because of its centre of mass away from its axis caused by an unbalance in the process of high-speed operation will lead to the rotor itself to vibrate. This vibration will accelerate the loss of bearing and lead to shortening of mechanical life. In order to improve the rotor eccentricity, testing and correcting of the rotor unbalance becomes necessary means. Rotor balancing as a process of the rotor manufactured plays a important role of improve product quality.
This thesis invents the vertical balancing machines of testing and correcting function to the rigid rotors based on the current situation of domestic manufacturers. This method can significantly improve the low efficiency of manually correction, in domestic small and medium enterprises.
Papers studied from the two aspects of testing and correcting in the rotor unbalance. The main contents are included as following:
The development of balancing machine at home and abroad was introduced, and more details about the principle of dynamic balance. The testing method and of unbalance disc-rigid rotor is discussed. The details which design the testing system including coefficient method, MCU circuit design, auto-tracking filter which based on switched-capacitor auto-tracking filter, phase-locked multiplier circuit were introduced.
For the pulley and the brake disc, these two different types of discoid rigid rotor, we use different correction methods. The error theory, tool selection, correction model design, the choice and control of servo motors, PLC (programmable logic controller) design and ladder programs, the software design of Industrial Personal Computer which based on configuration software.
引文
[1](日)三轮修三,下村玄.朱晓农译.旋转机械的平衡[M].北京：机械工业出版社,1992,12~25.
[2]周士炎.动平衡标准及其评价[J].世界标准化与质量管理.1995(12)：23-29.
[3]Goodman T P.A least square method for computing balance corrections[J].ASME J of Engineering for Industry,1964,86(2):234-242.
[4]Parkinson A G,Darlow M S,Smalley A J.An Introduction to a Unified Approach to Flexible Rotor Balancing.The Gas Turbine Conference and Exhibit and Solar Energy Conference,1979:1-14.
[5]屈梁生,邱海,徐光华.全息动平衡技术：原理与实践.中国机械工程,1998,9(1)：60-63.
[6]Xu B,Qu L.A New Practical Modal Method for Rotor Balancing.Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2001,215(2):179-190.
[7]章璟璇,唐云冰,罗贵火.最小二乘影响系数法的优化改进[J].南京航空航天大学学报,2005,(01)：110-113.
[8]刘健,潘双夏,杨克己,冯培恩.动平衡机系统误差分析及标定方法研究[J].组合机床与自动化加工技术,2004,(04).
[9]王晓升.考虑平衡质量受限时最小二乘法影响系数法的改进[J].西安交通大学学报,1998,32(11)：76-80.
[10]邓理博,程礼,李全通.转子动平衡影响系数法改进[J].机械科学与技术,2007(5)：631-634.
[11]唐善华.刚性转子动平衡测试原理与实现[J].煤矿机械,2007,(08).
[12]叶能安,余汝生.动平衡原理与动平衡机[M].武汉：华中工学院出版社,1985.
[13]申克公司.产品目录.上海：上海申克试验机有限公司出版,2009.
[14]Dyer S S,Jianjun shi.Robusl optimal influence-Coefficienl control of multiple-plane active rotor balancing systems[J].Transactions of the ASME-Joumal of dynamic Systems(Measurement and Control),2002,124,(1):41-46.
[15]邓旺群,唐广,高德平.转子动力特性及动平衡研究综述[J].燃气涡轮试验与研究,2008,(02)：57-62.
[16]伍良生,张云禧,周大帅,朱美玲.以DSP为核心的高速主轴在线动平衡控制器的设计[J]现代制造工程,2008,(08)：12-15.
[17]李顶根.新型立式动平衡机的研制与工件动不平衡量的测量[D]华中科技大学,2004.
[18]Benneff P.Virtual Instrument What they are,where they are at[J].Electronic Products,1993,(7): 37-39.
[19]王洪,彭熙伟,李古宏,侯增广.基于FFT的车轮动平衡检测技术[J]北京理工大学学报,2002,(03)：300-302.
[20]任海军,蒋和生.小波分析在摩托车曲轴总成动平衡检测中的应用[J].机械,2008,(08)：62-65.
[21]曹树谦.高维复杂转子系统非线性动力学的若干现代问题研究[D].天津大学,2003.
[22]Pashkov E.N,Nesterenko V.P.Transienls of rotation system with autobalancer filled with liquid[J].ModernTechniques and technology,2001,77-78.
[23]Watkins J, Lee K, Hernandez C. Adaptive Auto-Balancing Control of Magnetic Bearings for an Optical Chopper. Proceedings of the American Control Conference,2001,2:1298-1303.
[24]Chung J,Jang I.Dynamic Response and Stability Analysis of an Automatic Ball Balancer for a Flexible Rotor[J].Sound and Vibration,2003,259(1):31-43.
[25]David B.Miller,Ann Arbor,Mich.Testing armature balance:Correction methods[J].Electrical Manufacturing,1990,4(2):15-17.
[26]S.ZHOU.Optimal One-plane Active Balancing of Rigid Rotor During Accelerantion[J].Journal of Sound and Vibration,2002,249(1):196-205.
[27]John F.Shirtle,Max B.Mendel.Predicting dynamic imbalance in rotors[J].Probabilistic Eng ineering Mechanics,1996,25(9):31-35.
[28]Jong-Soo Kim,Soo-Hun LeeThe.stability of active balancing control using influence co efficients for a variable rotor system[J]. Manuf Technol,2003,(22):562-567.
[29]Y.Kang,Y.P.Chang,M.H.TSENG,et al.A Modified Approach Based On Influence Coefficient Method For Balancing Crank-Shafts[J].Journal of Sound and vibration,2000,234(2):277-296.
[30]Dyer S W, Ni J. Adaptive Influence Coefficient Control of Single-Plane Active Balancing Systems for Rotating Machinery. American Society of Mechanical Engineers, Manufacturing Engineering Division,1999,10:747-775.
[31]陈文勇,王秋晓,王世耕.一种动平衡测试系统测试方法的研究[J].机械研究与应用,2003,(02)：36-38.
[32]陈华,王宝瑞,罗锋.动平衡测量中微弱振动信号采集的实现[J]仪表技术与传感器,2008,(07)：99-102.
[33]何兵.汽车双联传动轴动平衡测试系统研究[D].重庆大学,2005.
[34]胡益飞.动平衡机半自动化系统的研制[J].电机设计与加工,2005(11)：60-62.
[35]张国.组态王DDE通信[J].试验技术与试验机,2005,(03).
[36]毛君,刘克铭,徐广明.基于C8051F020单片机的串口通信应用[J].煤矿机械,2005,(05)：79-81.
[37]舒红宇,张仪栋,谢凌飞.基于C8051F020单片机与MXA2500GL传感器的振动信号分布式检测方法[J].仪表技术与传感器,2005,(10)：46-58.
[38]苏维嘉,李书新.基于C8051F的动平衡测试系统[J].单片机开发与应用,2008(20)：159-160.
[39]陈怀超,丛培田.基于开关电容的自动跟踪滤波器的设计及研究[J].仪表技术与传感器,2003,(10)：38-39.
[40]陶利民,李岳,温熙森.基于开关电容技术的信号跟踪滤波方法及其在转子动平衡中的应用[J].中国机械工程,2007,(04)：427-430.
[41]陶利民,肖定邦,温熙森.用于动平衡测试的MDAC窄带跟踪滤波器[J].国防科技大学学报,2006,(02)102-116.
[42]黄凤娟.用锁相环CD4046实现电动机转速测量的研究[J].重庆科技学院学报(自然科学版),2007,(01)：49-52.
[43]廖冬初,廖想,蔡华锋,程诚.基于铣削去重的刹车盘平衡机控制系统研究[J].计算技术与自动化,2009,(04)：45-48.
[44]刘健,潘双夏.两工位全自动动平衡机气动系统设计.液压与气动,2004(9)：43-46.
[45]吕云飞.火车轮对动平衡数控校正系统的研究[D].华中科技大学,2001.
[46]田洪伟.汽车制动鼓自动平衡去重检测系统设计[D].长春工业大学,2004.
[47]杨克己.动平衡数控去重系统及其关键技术的研究[J].机电工程,2005(5)：4-8.
[48]陈卓.PLC与上位计算机通讯监控系统的研究与应用[D].重庆大学,2004.
[49]李莉.转子不平衡量自动钻削校正系统研究[D].上海交通大学,2008.
[50]松下MINAS A4系列伺服电机驱动器使用说明书
[2]周士炎.动平衡标准及其评价[J].世界标准化与质量管理.1995(12)：23-29.
[3]Goodman T P.A least square method for computing balance corrections[J].ASME J of Engineering for Industry,1964,86(2):234-242.
[4]Parkinson A G,Darlow M S,Smalley A J.An Introduction to a Unified Approach to Flexible Rotor Balancing.The Gas Turbine Conference and Exhibit and Solar Energy Conference,1979:1-14.
[5]屈梁生,邱海,徐光华.全息动平衡技术：原理与实践.中国机械工程,1998,9(1)：60-63.
[6]Xu B,Qu L.A New Practical Modal Method for Rotor Balancing.Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2001,215(2):179-190.
[7]章璟璇,唐云冰,罗贵火.最小二乘影响系数法的优化改进[J].南京航空航天大学学报,2005,(01)：110-113.
[8]刘健,潘双夏,杨克己,冯培恩.动平衡机系统误差分析及标定方法研究[J].组合机床与自动化加工技术,2004,(04).
[9]王晓升.考虑平衡质量受限时最小二乘法影响系数法的改进[J].西安交通大学学报,1998,32(11)：76-80.
[10]邓理博,程礼,李全通.转子动平衡影响系数法改进[J].机械科学与技术,2007(5)：631-634.
[11]唐善华.刚性转子动平衡测试原理与实现[J].煤矿机械,2007,(08).
[12]叶能安,余汝生.动平衡原理与动平衡机[M].武汉：华中工学院出版社,1985.
[13]申克公司.产品目录.上海：上海申克试验机有限公司出版,2009.
[14]Dyer S S,Jianjun shi.Robusl optimal influence-Coefficienl control of multiple-plane active rotor balancing systems[J].Transactions of the ASME-Joumal of dynamic Systems(Measurement and Control),2002,124,(1):41-46.
[15]邓旺群,唐广,高德平.转子动力特性及动平衡研究综述[J].燃气涡轮试验与研究,2008,(02)：57-62.
[16]伍良生,张云禧,周大帅,朱美玲.以DSP为核心的高速主轴在线动平衡控制器的设计[J]现代制造工程,2008,(08)：12-15.
[17]李顶根.新型立式动平衡机的研制与工件动不平衡量的测量[D]华中科技大学,2004.
[18]Benneff P.Virtual Instrument What they are,where they are at[J].Electronic Products,1993,(7): 37-39.
[19]王洪,彭熙伟,李古宏,侯增广.基于FFT的车轮动平衡检测技术[J]北京理工大学学报,2002,(03)：300-302.
[20]任海军,蒋和生.小波分析在摩托车曲轴总成动平衡检测中的应用[J].机械,2008,(08)：62-65.
[21]曹树谦.高维复杂转子系统非线性动力学的若干现代问题研究[D].天津大学,2003.
[22]Pashkov E.N,Nesterenko V.P.Transienls of rotation system with autobalancer filled with liquid[J].ModernTechniques and technology,2001,77-78.
[23]Watkins J, Lee K, Hernandez C. Adaptive Auto-Balancing Control of Magnetic Bearings for an Optical Chopper. Proceedings of the American Control Conference,2001,2:1298-1303.
[24]Chung J,Jang I.Dynamic Response and Stability Analysis of an Automatic Ball Balancer for a Flexible Rotor[J].Sound and Vibration,2003,259(1):31-43.
[25]David B.Miller,Ann Arbor,Mich.Testing armature balance:Correction methods[J].Electrical Manufacturing,1990,4(2):15-17.
[26]S.ZHOU.Optimal One-plane Active Balancing of Rigid Rotor During Accelerantion[J].Journal of Sound and Vibration,2002,249(1):196-205.
[27]John F.Shirtle,Max B.Mendel.Predicting dynamic imbalance in rotors[J].Probabilistic Eng ineering Mechanics,1996,25(9):31-35.
[28]Jong-Soo Kim,Soo-Hun LeeThe.stability of active balancing control using influence co efficients for a variable rotor system[J]. Manuf Technol,2003,(22):562-567.
[29]Y.Kang,Y.P.Chang,M.H.TSENG,et al.A Modified Approach Based On Influence Coefficient Method For Balancing Crank-Shafts[J].Journal of Sound and vibration,2000,234(2):277-296.
[30]Dyer S W, Ni J. Adaptive Influence Coefficient Control of Single-Plane Active Balancing Systems for Rotating Machinery. American Society of Mechanical Engineers, Manufacturing Engineering Division,1999,10:747-775.
[31]陈文勇,王秋晓,王世耕.一种动平衡测试系统测试方法的研究[J].机械研究与应用,2003,(02)：36-38.
[32]陈华,王宝瑞,罗锋.动平衡测量中微弱振动信号采集的实现[J]仪表技术与传感器,2008,(07)：99-102.
[33]何兵.汽车双联传动轴动平衡测试系统研究[D].重庆大学,2005.
[34]胡益飞.动平衡机半自动化系统的研制[J].电机设计与加工,2005(11)：60-62.
[35]张国.组态王DDE通信[J].试验技术与试验机,2005,(03).
[36]毛君,刘克铭,徐广明.基于C8051F020单片机的串口通信应用[J].煤矿机械,2005,(05)：79-81.
[37]舒红宇,张仪栋,谢凌飞.基于C8051F020单片机与MXA2500GL传感器的振动信号分布式检测方法[J].仪表技术与传感器,2005,(10)：46-58.
[38]苏维嘉,李书新.基于C8051F的动平衡测试系统[J].单片机开发与应用,2008(20)：159-160.
[39]陈怀超,丛培田.基于开关电容的自动跟踪滤波器的设计及研究[J].仪表技术与传感器,2003,(10)：38-39.
[40]陶利民,李岳,温熙森.基于开关电容技术的信号跟踪滤波方法及其在转子动平衡中的应用[J].中国机械工程,2007,(04)：427-430.
[41]陶利民,肖定邦,温熙森.用于动平衡测试的MDAC窄带跟踪滤波器[J].国防科技大学学报,2006,(02)102-116.
[42]黄凤娟.用锁相环CD4046实现电动机转速测量的研究[J].重庆科技学院学报(自然科学版),2007,(01)：49-52.
[43]廖冬初,廖想,蔡华锋,程诚.基于铣削去重的刹车盘平衡机控制系统研究[J].计算技术与自动化,2009,(04)：45-48.
[44]刘健,潘双夏.两工位全自动动平衡机气动系统设计.液压与气动,2004(9)：43-46.
[45]吕云飞.火车轮对动平衡数控校正系统的研究[D].华中科技大学,2001.
[46]田洪伟.汽车制动鼓自动平衡去重检测系统设计[D].长春工业大学,2004.
[47]杨克己.动平衡数控去重系统及其关键技术的研究[J].机电工程,2005(5)：4-8.
[48]陈卓.PLC与上位计算机通讯监控系统的研究与应用[D].重庆大学,2004.
[49]李莉.转子不平衡量自动钻削校正系统研究[D].上海交通大学,2008.
[50]松下MINAS A4系列伺服电机驱动器使用说明书