液压锻造操作机多学科协同仿真研究
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摘要
锻造操作机是现代锻造系统的重要设备，是实现锻造工艺的可重复性、提高锻件精度必不可少的装置。本文针对液压锻造操作机自动化、程序化的发展趋势，结合国内液压锻造操作机的开发、研究以及控制现状，运用虚拟样机技术这一近年来快速发展的先进技术开展锻造操作机液压控制系统的研究，重点研究集多学科领域的锻造操作机协同仿真模型，用于锻造操作机液压控制系统的分析优化，对于提高锻造操作机的工作效率和自动化水平具有重要的理论意义和研究价值。本文主要完成的工作和研究内容如下：
(1)针对锻造操作机动作多、结构复杂的特点，对锻造操作机各执行机构进行了运动学特性分析，建立了夹钳末端与执行元件之间的数学模型，结合锻造操作机具体结构参数对夹钳平行升降逆解近似公式的精度进行了分析，提出了一种锻造操作机夹钳平行升降位移的高次方程逆解解算方法，为锻造操作机高精度控制提供了重要的数学依据，并建立了锻造操作机机械系统多体动力学模型。
(2)针对锻造操作机液压系统复杂的特点，对液压系统中关键元件如电磁卸荷溢流阀、非线性比例换向阀、蓄能器、执行元件、管道等进行了建模仿真，在此基础上建立了锻造操作机液压系统模型，并进行了封装，为锻造操作机控制特性研究奠定了理论基础。
(3)对锻造操作机多学科模型间的参数耦合关系进行了分析，建立了锻造操作机多学科模型间数据交换和通讯的接口，采用基于软件接口的方法，搭建了锻造操作机多学科协同仿真模型。
(4)对锻造操作机液压系统进行了实验测试，对实验压力产生异常变化的原因进行了分析，分析结论对于锻造操作机的结构优化设计、提高操作机的工作可靠性具有重要意义，并采用定量方法对锻造操作机多学科协同仿真模型进行了实验验证，验证了模型的准确性，为其应用研究奠定了基础。
(5)基于虚拟样机技术研究了锻造操作机的单项动作控制特性、复合动作控制特性以及控制方式，提出了一种锻造操作机自补偿绝对位置控制方式，有利于提高锻造操作机的控制精度，研究结果为锻造操作机液压控制系统的设计优化提供了参考价值。
Forging manipulator is one of important equipments in modern forging system,which can achieve repeatability of forging process and improve the precision of forging.According to the automatic and programmable developing trend of hydraulic forgingmanipulator, combining development, research and control status quo in domestic, thispaper focused on research and developing a multidisciplinary system model of forgingmanipulator based on the virtual prototyping that rapidly developed technology in recentyears. The model, which is used in analyzing and optimizing hydraulic control system,can improve the work efficiency and automation level of forging manipulator and it isgreat valuable for academic research. This paper mainly completed works and researchcontents as follows:
(1)According to the actions and structure characteristics of complex, the kinematiccharacteristics of forging manipulator mechanisms were analyzed and the mathematicalmodel between tongs terminal and actuator was built. Combined with the structureparameters of forging manipulator, the approximation formula accuracy of tongs parallellifting action was analyzed, and a method of reducing the calculation error was proposed,which uses higher equation of approximation formula and provides an importantmathematical basis for the realization high precision control in forging manipulator. Andthe mult-body dynamics model of forging manipulator was built.
(2)According to the hydraulic system characteristics of complex, the model of keycomponents such as electromagnetic unloading relief valve, the proportion of non-linearvalve, accumulators, actuators and pipes etc were built and simulated. Then, thehydraulic system model of forging manipulator was built. which lay the theoreticalfoundation for researching the control characteristics of forging manipulator.
(3)According to the characteristics of forging manipulator models, the principle ofparameters coupling in multidisciplinary field models was analyzed, and the interfaces ofdata exchange and communication were created. Then the collaborative simulation modelof forging manipulator was built.
(4)The experimental test for hydraulic system of forging manipulator was finished,and the experimental abnormal pressure changes were analyzed. The conclusion hadgreat significance for structure optimization and improvement of working reliability offorging manipulator. Using quantitative methods, the collaborative simulation model offorging manipulator was experimentally verified, which validated that the model hadhigh accuracy and lay a foundation for application research.
(5)The control characteristics of single action, compound action and control mode offorging manipulator were researched based on virtual prototyping, and aself-compensating absolute position control mode of forging manipulator was proposed,which can improve the position control accuracy. The results provided a theoreticalreference for forging manipulator hydraulic control system design and optimization.
(1)针对锻造操作机动作多、结构复杂的特点，对锻造操作机各执行机构进行了运动学特性分析，建立了夹钳末端与执行元件之间的数学模型，结合锻造操作机具体结构参数对夹钳平行升降逆解近似公式的精度进行了分析，提出了一种锻造操作机夹钳平行升降位移的高次方程逆解解算方法，为锻造操作机高精度控制提供了重要的数学依据，并建立了锻造操作机机械系统多体动力学模型。
(2)针对锻造操作机液压系统复杂的特点，对液压系统中关键元件如电磁卸荷溢流阀、非线性比例换向阀、蓄能器、执行元件、管道等进行了建模仿真，在此基础上建立了锻造操作机液压系统模型，并进行了封装，为锻造操作机控制特性研究奠定了理论基础。
(3)对锻造操作机多学科模型间的参数耦合关系进行了分析，建立了锻造操作机多学科模型间数据交换和通讯的接口，采用基于软件接口的方法，搭建了锻造操作机多学科协同仿真模型。
(4)对锻造操作机液压系统进行了实验测试，对实验压力产生异常变化的原因进行了分析，分析结论对于锻造操作机的结构优化设计、提高操作机的工作可靠性具有重要意义，并采用定量方法对锻造操作机多学科协同仿真模型进行了实验验证，验证了模型的准确性，为其应用研究奠定了基础。
(5)基于虚拟样机技术研究了锻造操作机的单项动作控制特性、复合动作控制特性以及控制方式，提出了一种锻造操作机自补偿绝对位置控制方式，有利于提高锻造操作机的控制精度，研究结果为锻造操作机液压控制系统的设计优化提供了参考价值。
Forging manipulator is one of important equipments in modern forging system,which can achieve repeatability of forging process and improve the precision of forging.According to the automatic and programmable developing trend of hydraulic forgingmanipulator, combining development, research and control status quo in domestic, thispaper focused on research and developing a multidisciplinary system model of forgingmanipulator based on the virtual prototyping that rapidly developed technology in recentyears. The model, which is used in analyzing and optimizing hydraulic control system,can improve the work efficiency and automation level of forging manipulator and it isgreat valuable for academic research. This paper mainly completed works and researchcontents as follows:
(1)According to the actions and structure characteristics of complex, the kinematiccharacteristics of forging manipulator mechanisms were analyzed and the mathematicalmodel between tongs terminal and actuator was built. Combined with the structureparameters of forging manipulator, the approximation formula accuracy of tongs parallellifting action was analyzed, and a method of reducing the calculation error was proposed,which uses higher equation of approximation formula and provides an importantmathematical basis for the realization high precision control in forging manipulator. Andthe mult-body dynamics model of forging manipulator was built.
(2)According to the hydraulic system characteristics of complex, the model of keycomponents such as electromagnetic unloading relief valve, the proportion of non-linearvalve, accumulators, actuators and pipes etc were built and simulated. Then, thehydraulic system model of forging manipulator was built. which lay the theoreticalfoundation for researching the control characteristics of forging manipulator.
(3)According to the characteristics of forging manipulator models, the principle ofparameters coupling in multidisciplinary field models was analyzed, and the interfaces ofdata exchange and communication were created. Then the collaborative simulation modelof forging manipulator was built.
(4)The experimental test for hydraulic system of forging manipulator was finished,and the experimental abnormal pressure changes were analyzed. The conclusion hadgreat significance for structure optimization and improvement of working reliability offorging manipulator. Using quantitative methods, the collaborative simulation model offorging manipulator was experimentally verified, which validated that the model hadhigh accuracy and lay a foundation for application research.
(5)The control characteristics of single action, compound action and control mode offorging manipulator were researched based on virtual prototyping, and aself-compensating absolute position control mode of forging manipulator was proposed,which can improve the position control accuracy. The results provided a theoreticalreference for forging manipulator hydraulic control system design and optimization.
引文
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