大型回转双驱动系统关键参数测量与同步性研究
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摘要
作为大型回转双驱动典型设备,翻车机是电力、化工、冶金、港口等行业不可或缺的原料储运重要装备,具有结构庞大、承载物重、运转低频、启制动频繁和机械重心经常性偏移等特点。工作过程中常常出现传动系统齿断、载荷平台塑性形变等机械故障,由此导致生产断续,甚至造成整条生产线瘫痪,给企业带来巨大经济损失。因此,研究翻车机,特别是双驱动三车翻车机传动系统中关键参数测量与控制同步已成为大型回转机械装备制造行业和测控领域的热点课题。
本文从双驱动三车翻车机的机械结构、承载方式与工作原理入手,综合运用数学、机械学、动力工程学,以及先进测控理论与方法,分析其运行特性,研究关键参数的测量方法和控制同步策略的实施。
基于计算机图形学,引入矩阵算子,采用坐标转换的方法,研究了翻车机转体翻转过程中的力矩动态分布,推导出传动系统静载力矩方程。运用流质转动惯量学,分析了翻卸过程中流质时变特性,建立了卸载过程流质时变产生的动态转矩数学模型,实现关键参数历时动态计算,为翻车过程的优化控制奠定了基础。
给出了一种基于相关相位差与广义预测软测量频率跟踪相结合的转矩测量新方法,实现采样频率与被测信号时变的跟踪,有效地解决了系统运行频率时变、物料流质堆放分布不均、载荷平台弹性波动、平台与车体耦合不紧密等干扰,提高了转矩测量精度。
研究了翻车机传动系统断齿和承载平台塑性变形特点,给出了大型回转翻车机双驱动不一致导致断齿和承载平台塑性变形的结论及其论据,并在机械方面提出末级传动中引入自适应柔性传动,依据磨损转换原理,将大齿圈的磨损完全转移到滚轮。引入粗调、微调的概念和方法,确保小齿轮和大齿圈两转动副始终保持正确的啮合状态,使得断齿和形变现象减至最少。提出滚轮磨损的测量方案,实现系统传动精度的自动补偿。
研究了广义预测控制的实时快速性特点,设计了基于广义预测的双驱动控制同步子系统,在两驱动子系统通道间加入一模糊控制器,基于协调控制原理,以两子系统相应状态的差值达到最小为目标,采用同步误差非等分共反馈模糊校正的控制方案,使两同步子系统的输出保持一致,提高了系统对同步误差的响应速度,有效地降低了两驱动子系统的同步误差,保证了翻车机双驱动一致性,解决了双驱动不一致导致机械故障频发的问题,确保其工作稳定可靠。本文提出的控制同步策略为大型回转设备中多子系统的同步精度提供了有利的保证,同时也对其他的控制同步系统开拓了思路。
As a large rotary equipment which has dual drive at both ends, car dumper is an important material transport equipment which is necessary in electric power, chemical industry, metallurgy and port etc. It has characteristics such as large structure, heavy duty, low frequency operation, stop-and-go and recurrent excursion of machine barycentre. During working process, such mechanical failure as teeth breakdown of transmission system and plastic deformation of load flat appears frequently, which result in the break of production, even the paralysis of whole product line, so tremendous economic loss is inevitable for corporations. Therefore, researches on car dumper, especially key parameter measurement and synchronization control of dual drive triple-car dumper have become hot subjects in large machinery manufacturing and measurement control field.
This paper starts with machine structure, loading mode and operating principle of dual drive triple-car dumper, utilizes interrelated theory and method of mathematics, mechanics, dynamics and advanced measurement control, analyzes its dynamic working characteristic, researches measurement method of key parameters and implementation of synchronization control.
By application of coordinate conversion and computer graph software, moment dynamic distribution during whole tumbling process is researched and dead-load moment equation of transmission system is deduced. By using fluidity rotary inertia theory, fluidity time-varying performance during dumping is analyzed and dynamic torque mathematical model is established, which provide basis for optimization control of dumping progress.
A new torque measurement method based on correlation phase and generalized forecast soft measurement difference frequency tracing is presented to realize time-varying tracing of sampling frequency and measured signal, which solves such interference effectively as frequency time-varying during the system operation, uneven distribution of material, elasticity fluctuation of load flat and untight coupling between flat and bodywork, so measure accuracy of torque is improved.
The teeth breakdown of transmission system and plastic deformation of load flat of car dumper is researched. The conclusion and argument about above phenomena caused by inconsistency of dual drive is given. Self adapting flexible drive is introduced into the final stage of transmission system. The abrasion of big gear ring is transformed fully to roller wheel based on the abrasion transfer principle. The conception and means of coarse adjustment and delicate adjustment is imported to guarantee exactitude engagement of pinion wheel and big gear ring, which minimize the occurrence of teeth breakdown and deformation. The scheme of roller abrasion and gear mesh measurement is put forward to achieve automation compensation of system driving precision.
Real-time and rapidity of generalized predictive control is researched and a dual drive synchronization control system of car dumper based on generalized predictive control is designed. A fuzzy controller is added between two channels of dual drive subsystem. Based on coordinated control principle and achieving the goal of difference minimum of corresponding state of two subsystem, a fuzzy correction control program using in-phase error non-uniform common feedback is adopted to make the output of two synchronous subsystem consistent basically, which increase response speed of system to synchronous error, reduce synchronous error of dual drive subsystems effectively, ensure the consistency of car dumper dual drive, solve the recurrent mechanical failure caused by inconsistency of dual drive and enhance the steady reliable operation of car dumpers. The synchronization control strategy presented by this paper provides favorable guarantee for synchronization precision of multi subsystem in large rotary equipments and at the same time explores new ideas for other synchronization control systems.
本文从双驱动三车翻车机的机械结构、承载方式与工作原理入手,综合运用数学、机械学、动力工程学,以及先进测控理论与方法,分析其运行特性,研究关键参数的测量方法和控制同步策略的实施。
基于计算机图形学,引入矩阵算子,采用坐标转换的方法,研究了翻车机转体翻转过程中的力矩动态分布,推导出传动系统静载力矩方程。运用流质转动惯量学,分析了翻卸过程中流质时变特性,建立了卸载过程流质时变产生的动态转矩数学模型,实现关键参数历时动态计算,为翻车过程的优化控制奠定了基础。
给出了一种基于相关相位差与广义预测软测量频率跟踪相结合的转矩测量新方法,实现采样频率与被测信号时变的跟踪,有效地解决了系统运行频率时变、物料流质堆放分布不均、载荷平台弹性波动、平台与车体耦合不紧密等干扰,提高了转矩测量精度。
研究了翻车机传动系统断齿和承载平台塑性变形特点,给出了大型回转翻车机双驱动不一致导致断齿和承载平台塑性变形的结论及其论据,并在机械方面提出末级传动中引入自适应柔性传动,依据磨损转换原理,将大齿圈的磨损完全转移到滚轮。引入粗调、微调的概念和方法,确保小齿轮和大齿圈两转动副始终保持正确的啮合状态,使得断齿和形变现象减至最少。提出滚轮磨损的测量方案,实现系统传动精度的自动补偿。
研究了广义预测控制的实时快速性特点,设计了基于广义预测的双驱动控制同步子系统,在两驱动子系统通道间加入一模糊控制器,基于协调控制原理,以两子系统相应状态的差值达到最小为目标,采用同步误差非等分共反馈模糊校正的控制方案,使两同步子系统的输出保持一致,提高了系统对同步误差的响应速度,有效地降低了两驱动子系统的同步误差,保证了翻车机双驱动一致性,解决了双驱动不一致导致机械故障频发的问题,确保其工作稳定可靠。本文提出的控制同步策略为大型回转设备中多子系统的同步精度提供了有利的保证,同时也对其他的控制同步系统开拓了思路。
As a large rotary equipment which has dual drive at both ends, car dumper is an important material transport equipment which is necessary in electric power, chemical industry, metallurgy and port etc. It has characteristics such as large structure, heavy duty, low frequency operation, stop-and-go and recurrent excursion of machine barycentre. During working process, such mechanical failure as teeth breakdown of transmission system and plastic deformation of load flat appears frequently, which result in the break of production, even the paralysis of whole product line, so tremendous economic loss is inevitable for corporations. Therefore, researches on car dumper, especially key parameter measurement and synchronization control of dual drive triple-car dumper have become hot subjects in large machinery manufacturing and measurement control field.
This paper starts with machine structure, loading mode and operating principle of dual drive triple-car dumper, utilizes interrelated theory and method of mathematics, mechanics, dynamics and advanced measurement control, analyzes its dynamic working characteristic, researches measurement method of key parameters and implementation of synchronization control.
By application of coordinate conversion and computer graph software, moment dynamic distribution during whole tumbling process is researched and dead-load moment equation of transmission system is deduced. By using fluidity rotary inertia theory, fluidity time-varying performance during dumping is analyzed and dynamic torque mathematical model is established, which provide basis for optimization control of dumping progress.
A new torque measurement method based on correlation phase and generalized forecast soft measurement difference frequency tracing is presented to realize time-varying tracing of sampling frequency and measured signal, which solves such interference effectively as frequency time-varying during the system operation, uneven distribution of material, elasticity fluctuation of load flat and untight coupling between flat and bodywork, so measure accuracy of torque is improved.
The teeth breakdown of transmission system and plastic deformation of load flat of car dumper is researched. The conclusion and argument about above phenomena caused by inconsistency of dual drive is given. Self adapting flexible drive is introduced into the final stage of transmission system. The abrasion of big gear ring is transformed fully to roller wheel based on the abrasion transfer principle. The conception and means of coarse adjustment and delicate adjustment is imported to guarantee exactitude engagement of pinion wheel and big gear ring, which minimize the occurrence of teeth breakdown and deformation. The scheme of roller abrasion and gear mesh measurement is put forward to achieve automation compensation of system driving precision.
Real-time and rapidity of generalized predictive control is researched and a dual drive synchronization control system of car dumper based on generalized predictive control is designed. A fuzzy controller is added between two channels of dual drive subsystem. Based on coordinated control principle and achieving the goal of difference minimum of corresponding state of two subsystem, a fuzzy correction control program using in-phase error non-uniform common feedback is adopted to make the output of two synchronous subsystem consistent basically, which increase response speed of system to synchronous error, reduce synchronous error of dual drive subsystems effectively, ensure the consistency of car dumper dual drive, solve the recurrent mechanical failure caused by inconsistency of dual drive and enhance the steady reliable operation of car dumpers. The synchronization control strategy presented by this paper provides favorable guarantee for synchronization precision of multi subsystem in large rotary equipments and at the same time explores new ideas for other synchronization control systems.
引文
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