重型数控车床静压推力轴承油膜控制研究
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摘要
静压推力轴承的性能优劣直接影响重型数控加工设备的加工质量和运行效率。如何提高静压推力轴承的刚度是目前非常迫切的任务之一。本文以油膜刚度作为研究内容,突出工程应用的特色,将理论、实验及应用密切结合起来,开发一种重型高刚度静压推力轴承主动控制系统。
基于有限元分析数据,以重型数控车床C5116E-NC工作台为研究对象,分析了工件重量、工件高度、切削力对油膜位移的影响。研究结果表明在给定的切削力条件下,工件重量的变化影响倾覆力矩的分配形式,随着工件重量的减轻,油膜位移逐渐增大,特别是当工件重量小于最大工件重量的1/2时,使用最大切削力,则局部油膜压力无法建立;随着工件高度的增加,倾覆力矩增加,油膜位移增大。该研究定量给出了工件重量与颠覆力矩产生的油膜位移。基于Christensen随机粗糙表面模型,建立了稳态和摄动随机雷诺方程,考虑转动惯量和油液可压缩性研究了表面粗糙度对油膜性能的影响。研究结果表明,表面粗糙度对承载性能的影响可忽略,对稳态流量、动态刚度的影响显著。该项研究为静压推力轴承刚度的提高提供了前提条件。
基于油膜特性影响因素分析,提出油腔流量分组控制的主动控制方案,选择电液位置伺服系统作为可控油腔流量调节机构,采用四组可控油腔调节和控制油膜,实现工作台的期望位姿;建立了电液伺服变量机构的数学模型及可控油腔流量模型。为确保模型的准确性,设计二维互不相关系统辨识激励信号,将四通道系统简化成四个单通道系统进行参数辨识。该研究为静压推力轴承油膜主动控制系统的设计与实现奠定了理论基础。
将静压推力轴承油膜控制模型等效为工作台位姿控制模型,并对油膜控制的运动学及逆运动学进行了建模和求解。基于非线性时变的油膜控制系统对控制策略的要求,设计了自适应模糊PID复合控制作为静压推力轴承油膜控制策略,并采用模糊推理完成“切换”以实现了控制性能的明显改善,用描述函数法分析了推力轴承模糊控制系统稳定性;建立油膜控制策略仿真模型,进行了推力轴承工作台位姿仿真分析,结果表明,采用模糊PID复合控制,具有更快的动态响应特性,比常规模糊控制具有更小的超调、更高的稳态精度。该研究为静压推力轴承油膜主动控制策略的实现奠定了基础。
基于xPC快速原型化技术,设计了油膜控制半物理仿真实验系统,实现油膜厚度位置闭环控制。采用闭环辨识法辨识了单通道油膜控制伺服系统(试验台)的模型,实验结果证明了参数辨识模型的合理性。分别对常规PID控制器、模糊控制器、模糊复合控制器建立单通道油膜控制半物理仿真模型,进行油膜控制策略半实物仿真实验,半实物仿真结果表明,复合控制器具有快速的上升时间,更好地提高了系统的抗干扰能力,且对被控对象参数变化有很强的适应能力。该研究为静压推力轴承油膜主动控制系统的研制提供了可靠的依据。
The performance of hydrostatic thrust bearing will directly impact the machining quality and operational efficiency of the heavy NC machining equipments. How to improve the stiffness of hydrostatic thrust bearing is one of the most urgent missions now. The oil film stiffness is the main research content and engineering application is the final goal in this dissertation, which combine closely the theory, experiment and application to develop a kind of active control system on hydrostatic thrust bearing to enhance bearing stiffness.
The effects of workpiece weight, height and cutting force upon oil film displacement are analyzed based on finite element analysis data for worktable of heavy NC lathe C5116E-NC. The research results show that variation of workpiece weight impact on overturning moment distribution for given cutting force, oil film displacement will increase gradually as workpiece weight decreases, especially when workpiece weight is less than half of the maximum workpiece weight, local oil film pressure will not be built; the overturning moment and oil film displacement will increase as workpiece height increases. The oil film displacement produced by workpiece weight and overturning moment is given quantitatively in this study. Based on Christensen model, the Reynolds equations on steady-state and perturbed-state are built. The effect of surface roughness on oil film characteristics is analyzed taking into account the effect of fluid inertia and compressibility. The research results show that bearing surface roughness provide a neglected effect upon the load-carrying and a significant effect upon the steady lubricant flow rate, dynamic stiffness and damping coefficients. This work provides precondition of improving the hydrostatic thrust bearing stiffness.
Based on analysis of effect factors on oil film property, an active control scheme on flow group of controlled chamber is proposed. The electro-hydraulic position servo system is selected as flow adjusting mechanism, which can regulate and control the oil film thickness of four groups controlled chambers to realize desired pose of the worktable. Mathematical models of electro-hydraulic servo variable flow mechanism and flow models of controlled chambers are built. A kind of second-dimension mutually non-correlative exciting signals is designed, which can simplify four-channel system into four single-channel systems for parameter identification. This work provides theoretical basis for designing and realizing oil film active control system of hydrostatic thrust bearing.
Oil film control model of hydrostatic thrust bearing is equivalent to worktable pose control model; kinematics and inverse kinematics of oil film control are modeled and solved. Based on requirements for control strategy of non-line time-varying oil film system, a self-adaptive fuzzy PID hybrid controller is designed, a fuzzy switching mode is employed to improve obviously the control performance, and the fuzzy control system stability is analyzed using the describing function method. Oil film control strategy simulation model is built and worktable pose simulation is analyzed. The simulation results show that the rapidity of dynamic response and more little overshoot and more highly steady-state precision are attained for fuzzy PID hybrid controller. This work provides basis for realizing oil film active control strategy of hydrostatic thrust bearing.
Hardware-in-loop simulation experiment system is developed to realize oil film position close-loop control based on xPC rapid control prototype technique. The model of single channel oil film control system (servo test bench) is identified by close-loop identification method, and reasonability of model is proved by experiment result. Hardware-in-loop simulation experiment of PID controller, fuzzy controller and fuzzy hybrid controller are carried out, and results show that hybrid controller provides quickly rising time and strongly anti-disturbance ability and adaptability for parameters change of plant controlled. This work provides reliable basis for developing oil film active control system of hydrostatic thrust bearing.
基于有限元分析数据,以重型数控车床C5116E-NC工作台为研究对象,分析了工件重量、工件高度、切削力对油膜位移的影响。研究结果表明在给定的切削力条件下,工件重量的变化影响倾覆力矩的分配形式,随着工件重量的减轻,油膜位移逐渐增大,特别是当工件重量小于最大工件重量的1/2时,使用最大切削力,则局部油膜压力无法建立;随着工件高度的增加,倾覆力矩增加,油膜位移增大。该研究定量给出了工件重量与颠覆力矩产生的油膜位移。基于Christensen随机粗糙表面模型,建立了稳态和摄动随机雷诺方程,考虑转动惯量和油液可压缩性研究了表面粗糙度对油膜性能的影响。研究结果表明,表面粗糙度对承载性能的影响可忽略,对稳态流量、动态刚度的影响显著。该项研究为静压推力轴承刚度的提高提供了前提条件。
基于油膜特性影响因素分析,提出油腔流量分组控制的主动控制方案,选择电液位置伺服系统作为可控油腔流量调节机构,采用四组可控油腔调节和控制油膜,实现工作台的期望位姿;建立了电液伺服变量机构的数学模型及可控油腔流量模型。为确保模型的准确性,设计二维互不相关系统辨识激励信号,将四通道系统简化成四个单通道系统进行参数辨识。该研究为静压推力轴承油膜主动控制系统的设计与实现奠定了理论基础。
将静压推力轴承油膜控制模型等效为工作台位姿控制模型,并对油膜控制的运动学及逆运动学进行了建模和求解。基于非线性时变的油膜控制系统对控制策略的要求,设计了自适应模糊PID复合控制作为静压推力轴承油膜控制策略,并采用模糊推理完成“切换”以实现了控制性能的明显改善,用描述函数法分析了推力轴承模糊控制系统稳定性;建立油膜控制策略仿真模型,进行了推力轴承工作台位姿仿真分析,结果表明,采用模糊PID复合控制,具有更快的动态响应特性,比常规模糊控制具有更小的超调、更高的稳态精度。该研究为静压推力轴承油膜主动控制策略的实现奠定了基础。
基于xPC快速原型化技术,设计了油膜控制半物理仿真实验系统,实现油膜厚度位置闭环控制。采用闭环辨识法辨识了单通道油膜控制伺服系统(试验台)的模型,实验结果证明了参数辨识模型的合理性。分别对常规PID控制器、模糊控制器、模糊复合控制器建立单通道油膜控制半物理仿真模型,进行油膜控制策略半实物仿真实验,半实物仿真结果表明,复合控制器具有快速的上升时间,更好地提高了系统的抗干扰能力,且对被控对象参数变化有很强的适应能力。该研究为静压推力轴承油膜主动控制系统的研制提供了可靠的依据。
The performance of hydrostatic thrust bearing will directly impact the machining quality and operational efficiency of the heavy NC machining equipments. How to improve the stiffness of hydrostatic thrust bearing is one of the most urgent missions now. The oil film stiffness is the main research content and engineering application is the final goal in this dissertation, which combine closely the theory, experiment and application to develop a kind of active control system on hydrostatic thrust bearing to enhance bearing stiffness.
The effects of workpiece weight, height and cutting force upon oil film displacement are analyzed based on finite element analysis data for worktable of heavy NC lathe C5116E-NC. The research results show that variation of workpiece weight impact on overturning moment distribution for given cutting force, oil film displacement will increase gradually as workpiece weight decreases, especially when workpiece weight is less than half of the maximum workpiece weight, local oil film pressure will not be built; the overturning moment and oil film displacement will increase as workpiece height increases. The oil film displacement produced by workpiece weight and overturning moment is given quantitatively in this study. Based on Christensen model, the Reynolds equations on steady-state and perturbed-state are built. The effect of surface roughness on oil film characteristics is analyzed taking into account the effect of fluid inertia and compressibility. The research results show that bearing surface roughness provide a neglected effect upon the load-carrying and a significant effect upon the steady lubricant flow rate, dynamic stiffness and damping coefficients. This work provides precondition of improving the hydrostatic thrust bearing stiffness.
Based on analysis of effect factors on oil film property, an active control scheme on flow group of controlled chamber is proposed. The electro-hydraulic position servo system is selected as flow adjusting mechanism, which can regulate and control the oil film thickness of four groups controlled chambers to realize desired pose of the worktable. Mathematical models of electro-hydraulic servo variable flow mechanism and flow models of controlled chambers are built. A kind of second-dimension mutually non-correlative exciting signals is designed, which can simplify four-channel system into four single-channel systems for parameter identification. This work provides theoretical basis for designing and realizing oil film active control system of hydrostatic thrust bearing.
Oil film control model of hydrostatic thrust bearing is equivalent to worktable pose control model; kinematics and inverse kinematics of oil film control are modeled and solved. Based on requirements for control strategy of non-line time-varying oil film system, a self-adaptive fuzzy PID hybrid controller is designed, a fuzzy switching mode is employed to improve obviously the control performance, and the fuzzy control system stability is analyzed using the describing function method. Oil film control strategy simulation model is built and worktable pose simulation is analyzed. The simulation results show that the rapidity of dynamic response and more little overshoot and more highly steady-state precision are attained for fuzzy PID hybrid controller. This work provides basis for realizing oil film active control strategy of hydrostatic thrust bearing.
Hardware-in-loop simulation experiment system is developed to realize oil film position close-loop control based on xPC rapid control prototype technique. The model of single channel oil film control system (servo test bench) is identified by close-loop identification method, and reasonability of model is proved by experiment result. Hardware-in-loop simulation experiment of PID controller, fuzzy controller and fuzzy hybrid controller are carried out, and results show that hybrid controller provides quickly rising time and strongly anti-disturbance ability and adaptability for parameters change of plant controlled. This work provides reliable basis for developing oil film active control system of hydrostatic thrust bearing.
引文
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