直接驱动数控转台永磁环形力矩电机及其控制策略的研究
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摘要
数控转台是多轴联动数控机床的重要部件之一。传统驱动方式的数控转台因为机械传动链的存在而引起弹性变形、摩擦和反向间隙等一系列问题。直接驱动数控转台不仅有效地解决了上述问题,而且具有转矩高、响应速度快和定位精度高等性能优势。近年来,直接驱动数控转台部件是多轴联动高档数控机床领域研究的热点。本论文就是以直接驱动数控转台永磁环形力矩电机及其控制策略为研究对象,针对其关键技术问题展开工作的。
针对直接驱动数控转台对驱动电机低转矩波动和高转矩密度的要求,在多极分数槽电机设计理论的基础上,研究并设计了一种基于极槽数相近结构的不等齿顶宽间隔绕组外转子型永磁环形力矩电机。极槽数相近结构不仅可以提高绕组短距系数,而且极数和槽数的合理配比能够有效地削弱齿槽转矩。间隔绕组和不等齿顶宽结构可使定子齿磁链和绕组因数最大化,从而有效地提高了电机的转矩密度。另外,分析了不等齿顶宽间隔绕组结构对谐波转矩和齿槽转矩的影响。
为了进一步提高转台电机输出转矩的能力,配合直接驱动数控转台机械结构的特殊要求,研究了一种双同步串联联接的双转子永磁环形力矩电机。这一新型双转子转台电机结构具有较好的散热能力,一定程度上解决了大转矩转台电机的散热问题,有效地提高了电机的转矩密度。这种双转子转台电机结构还解决了传统双驱动方式下两台独立电机之间的同步驱动和功率分配问题。
利用双转子永磁环形力矩电机的结构特点,进一步研究了双转子电机齿槽转矩的生成规律。在此基础上,分析了基于移相技术和内外电机槽口宽度配合方法削弱双转子电机齿槽转矩的原理,利用解析计算方法推导出等齿顶宽和不等齿顶宽结构的最佳移相角度计算公式。而且,进一步研究了基于移相技术的双转子永磁环形力矩电机的数学模型。
在控制策略方面,主要针对永磁环形力矩电机伺服系统对周期性输入信号的跟踪问题,设计了一种插入型的重复控制器。在此基础上,为了提高控制系统对参数变化和负载扰动不确定性的鲁棒性,研究了将重复控制和μ(结构奇异值)理论相结合的控制方法,利用线性分式变换(LFT)将鲁棒重复控制问题转换成H∞最优控制问题,采用D-K迭代法设计鲁棒重复控制器,从而实现了系统的稳定性和鲁棒性,提高了伺服系统的跟踪精度。
最后,将不等齿顶宽间隔绕组结构的外转子永磁环形力矩电机做成样机,采用合理的机械结构设计制造了直接驱动数控转台。进而,对样机进行了空载转矩波动实验,负载转矩性能实验。并以数字信号处理器TMS320LF2407A为核心构建了转台实验系统平台。在空载、转动惯量变化和负载扰动的情况下,进行了位置跟踪实验,从而验证了电机结构设计方案和控制策略的合理性及正确性。
Numerical control (NC) table is one of the most important assemblies in multiaxial linkage NC machine. It is acknowledged that the elastic distortion, friction, backlash , and any other problems resulting from mechanical drive chain are shown on the traditional drive NC table. The direct drive NC table not only resolves the above problems but also has many advantages, such as high torque, quick response ability, high position precision, and so on. In recent years, the direct drive NC table assembly is the research hot spot in multiaxial linkage high-grade NC machine field. Therefore, taking permanent magnet (PM) ring torque motor and its control strategy used in direct drive NC table as subjects, the key technologie of subjects is dicussed in this dissertation.
To satisfy the drive motor requirements of low torque ripple and high torque density, used in the NC table, the similar pole and slot number outer-rotor PM ring torque motor with unequal teeth tips width and alternate winding is researched and designed based on the design theory of multipolar fractional-slot motor. The structure of similar pole and slot number can increase the winding pitch coefficient, and reduce cogging torque ripple effectively with the reasonable combination of pole number and slot number. The alternate winding and unequal teeth tips width structure optimize the stator teeth flux linkage and winding coefficient, as a result, the torque density is increased. Furthermore, the influences of unequal teeth tips width and alternate winding structure on the harmonic torque and cogging torque are analyzed.
In order to increase the output torque ability of table motor further, combining the special requirements of direct drive NC table mechanical structure, the dual-synchronous dual-rotor PM ring torque motor with series connection structure is researched. The new dual-rotor table motor structure with better ability of heat dissipation, resolves the heat dissipation problem of high torque table motor to some extent and increases the torque density. And it also resolves the synchronous control and power distribution problems between the two independent motors of traditional double-drive mode.
Based on dual-rotor PM ring torque motor structure characteristics, the generating rule of dual-rotor motor cogging torque is researched further. On the basis of this analysis, the reduction principle of dual-rotor motor cogging torque with phase-shifting technology is studied, and the reduction principle of cogging torque by combination of inner and outer slot notch width is also analysed. The optimal phase-shifting angle calculation formulas both in equal teeth tips motor and unequal teeth tips motor are obtained by analytic calculation method. And the dual-rotor PM ring torque methmatical model is also established.
In the aspect of control strategy, aiming at the periodic input signal tracking problem of the PM ring torque motor, a plug-in type repetitive controller is designed. On this basis, in order to improve the robustness against load disturbances and parameter variations, the control method of repetitive control combining withμ(structured singular value) theory is researched. The robust repetitive control problem is transformed into H∞optimal control problem using linear fractional transformation(LFT). The D-K iteration is used to design the robust repetitive controller, which realized the stability, the robustness and improved the tracking precision of the servo system.
In the end, the outer-rotor PM ring torque motor with unequal teeth tips width and alternate winding structure is produced, and the direct drive NC table combining reasonable mechanical structure design is also produced. Consequently, the many prototype experiments are completed, such as noload torque ripple experiment, load torque performance experiment. The table experiment system is established using digital signal processor TMS320LF2407A. The position tracking experiments are completed under the conditions of noload, load disturbance, and rotational inertia parameter variations repectively. All the experiments results prove that the motor design scheme and control strategy are reasonable and correct.
针对直接驱动数控转台对驱动电机低转矩波动和高转矩密度的要求,在多极分数槽电机设计理论的基础上,研究并设计了一种基于极槽数相近结构的不等齿顶宽间隔绕组外转子型永磁环形力矩电机。极槽数相近结构不仅可以提高绕组短距系数,而且极数和槽数的合理配比能够有效地削弱齿槽转矩。间隔绕组和不等齿顶宽结构可使定子齿磁链和绕组因数最大化,从而有效地提高了电机的转矩密度。另外,分析了不等齿顶宽间隔绕组结构对谐波转矩和齿槽转矩的影响。
为了进一步提高转台电机输出转矩的能力,配合直接驱动数控转台机械结构的特殊要求,研究了一种双同步串联联接的双转子永磁环形力矩电机。这一新型双转子转台电机结构具有较好的散热能力,一定程度上解决了大转矩转台电机的散热问题,有效地提高了电机的转矩密度。这种双转子转台电机结构还解决了传统双驱动方式下两台独立电机之间的同步驱动和功率分配问题。
利用双转子永磁环形力矩电机的结构特点,进一步研究了双转子电机齿槽转矩的生成规律。在此基础上,分析了基于移相技术和内外电机槽口宽度配合方法削弱双转子电机齿槽转矩的原理,利用解析计算方法推导出等齿顶宽和不等齿顶宽结构的最佳移相角度计算公式。而且,进一步研究了基于移相技术的双转子永磁环形力矩电机的数学模型。
在控制策略方面,主要针对永磁环形力矩电机伺服系统对周期性输入信号的跟踪问题,设计了一种插入型的重复控制器。在此基础上,为了提高控制系统对参数变化和负载扰动不确定性的鲁棒性,研究了将重复控制和μ(结构奇异值)理论相结合的控制方法,利用线性分式变换(LFT)将鲁棒重复控制问题转换成H∞最优控制问题,采用D-K迭代法设计鲁棒重复控制器,从而实现了系统的稳定性和鲁棒性,提高了伺服系统的跟踪精度。
最后,将不等齿顶宽间隔绕组结构的外转子永磁环形力矩电机做成样机,采用合理的机械结构设计制造了直接驱动数控转台。进而,对样机进行了空载转矩波动实验,负载转矩性能实验。并以数字信号处理器TMS320LF2407A为核心构建了转台实验系统平台。在空载、转动惯量变化和负载扰动的情况下,进行了位置跟踪实验,从而验证了电机结构设计方案和控制策略的合理性及正确性。
Numerical control (NC) table is one of the most important assemblies in multiaxial linkage NC machine. It is acknowledged that the elastic distortion, friction, backlash , and any other problems resulting from mechanical drive chain are shown on the traditional drive NC table. The direct drive NC table not only resolves the above problems but also has many advantages, such as high torque, quick response ability, high position precision, and so on. In recent years, the direct drive NC table assembly is the research hot spot in multiaxial linkage high-grade NC machine field. Therefore, taking permanent magnet (PM) ring torque motor and its control strategy used in direct drive NC table as subjects, the key technologie of subjects is dicussed in this dissertation.
To satisfy the drive motor requirements of low torque ripple and high torque density, used in the NC table, the similar pole and slot number outer-rotor PM ring torque motor with unequal teeth tips width and alternate winding is researched and designed based on the design theory of multipolar fractional-slot motor. The structure of similar pole and slot number can increase the winding pitch coefficient, and reduce cogging torque ripple effectively with the reasonable combination of pole number and slot number. The alternate winding and unequal teeth tips width structure optimize the stator teeth flux linkage and winding coefficient, as a result, the torque density is increased. Furthermore, the influences of unequal teeth tips width and alternate winding structure on the harmonic torque and cogging torque are analyzed.
In order to increase the output torque ability of table motor further, combining the special requirements of direct drive NC table mechanical structure, the dual-synchronous dual-rotor PM ring torque motor with series connection structure is researched. The new dual-rotor table motor structure with better ability of heat dissipation, resolves the heat dissipation problem of high torque table motor to some extent and increases the torque density. And it also resolves the synchronous control and power distribution problems between the two independent motors of traditional double-drive mode.
Based on dual-rotor PM ring torque motor structure characteristics, the generating rule of dual-rotor motor cogging torque is researched further. On the basis of this analysis, the reduction principle of dual-rotor motor cogging torque with phase-shifting technology is studied, and the reduction principle of cogging torque by combination of inner and outer slot notch width is also analysed. The optimal phase-shifting angle calculation formulas both in equal teeth tips motor and unequal teeth tips motor are obtained by analytic calculation method. And the dual-rotor PM ring torque methmatical model is also established.
In the aspect of control strategy, aiming at the periodic input signal tracking problem of the PM ring torque motor, a plug-in type repetitive controller is designed. On this basis, in order to improve the robustness against load disturbances and parameter variations, the control method of repetitive control combining withμ(structured singular value) theory is researched. The robust repetitive control problem is transformed into H∞optimal control problem using linear fractional transformation(LFT). The D-K iteration is used to design the robust repetitive controller, which realized the stability, the robustness and improved the tracking precision of the servo system.
In the end, the outer-rotor PM ring torque motor with unequal teeth tips width and alternate winding structure is produced, and the direct drive NC table combining reasonable mechanical structure design is also produced. Consequently, the many prototype experiments are completed, such as noload torque ripple experiment, load torque performance experiment. The table experiment system is established using digital signal processor TMS320LF2407A. The position tracking experiments are completed under the conditions of noload, load disturbance, and rotational inertia parameter variations repectively. All the experiments results prove that the motor design scheme and control strategy are reasonable and correct.
引文
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