粉末成形液压机自适应鲁棒运动控制
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摘要
在粉末冶金零件成形生产中,压坯产品的质量取决于粉末成形工艺的完成度,这依赖于成形液压机的运动控制性能。然而控制粉末成形液压机运动的电液系统是一种具有参数不确定性的非线性系统,且整个运动控制系统在粉末致密化加压成形过程中还受到了负载压制力的强非线性干扰。针对以上难题,研究中建立了负载压制力的非线性模型,将其与电液系统的动力学模型相结合,基于此包含负载动力学的控制设计模型利用自适应鲁棒控制理论设计了粉末成形液压机的压制运动控制器。理论上,该控制器保证了鲁棒瞬态性能和稳态跟踪精度。实验结果表明,所设计的电液控制器可以实现对铁基粉末成形圆柱体压坯单向变速压制工艺压制运动曲线的精确跟踪控制,并表现出良好的控制性能。
High-performance pressing motion control of powder compaction press for improving the quality of green compacts was considered. With the aim to realize precise motion trajectory tracking control,physical modeling of the compacting force in powder densification process was developed and validated by iron-based powder compressibility test. A control oriented model was constructed to describe the system dynamics of the electro-hydraulic system of the powder compaction press by using the solenoid valves.Then a motion controller based on adaptive robust control( ARC) method was synthesized by backstepping design with Lyapunov function. The controller took into consideration of the effect of parameter variations with the strongly nonlinear disturbance of compacting force coming from the powder press molding process and various hydraulic parameters as well as the effect of hard-to-model nonlinearities and uncertainties. The stability, tracking transient and final tracking accuracy of the system can be guaranteed by the controller. Experimental study was also carried out through a 1 000 k N powder compaction press prototype. The pressing motion control of the prototype machine in the iron-based powder forming cylinder compact process was used as a case study. The analysis and experimental results showed that the proposed control method achieved satisfying control performance for the powder compaction press,validating the effectiveness of the proposed control approach in practical applications.In powder forming process the tracking errors were reduced almost down to the measurement resolution level( ± 0. 04 mm). Furthermore,the dimensional accuracy in the height direction and the density uniformity of the compacts were improved.
High-performance pressing motion control of powder compaction press for improving the quality of green compacts was considered. With the aim to realize precise motion trajectory tracking control,physical modeling of the compacting force in powder densification process was developed and validated by iron-based powder compressibility test. A control oriented model was constructed to describe the system dynamics of the electro-hydraulic system of the powder compaction press by using the solenoid valves.Then a motion controller based on adaptive robust control( ARC) method was synthesized by backstepping design with Lyapunov function. The controller took into consideration of the effect of parameter variations with the strongly nonlinear disturbance of compacting force coming from the powder press molding process and various hydraulic parameters as well as the effect of hard-to-model nonlinearities and uncertainties. The stability, tracking transient and final tracking accuracy of the system can be guaranteed by the controller. Experimental study was also carried out through a 1 000 k N powder compaction press prototype. The pressing motion control of the prototype machine in the iron-based powder forming cylinder compact process was used as a case study. The analysis and experimental results showed that the proposed control method achieved satisfying control performance for the powder compaction press,validating the effectiveness of the proposed control approach in practical applications.In powder forming process the tracking errors were reduced almost down to the measurement resolution level( ± 0. 04 mm). Furthermore,the dimensional accuracy in the height direction and the density uniformity of the compacts were improved.
引文
1周照耀,李元元.金属粉末成形力学建模与计算机模拟[M].广州:华南理工大学出版社,2011.
2 邓佳,曹树平,罗小辉,等.二氧化铀粉末成型系统电液位置-压力复合控制仿真[J].机械制造与自动化,2013(6):84-89.Deng Jia,Cao Shuping,Luo Xiaohui,el al.Simulation of electro-hydraulic position and force compound control system for compacting UO2powder[J].Machine Building and Automation,2013(6):84-89.(in Chinese)
3 熊晓红,卢怀亮,黄树槐.智能型粉末成形液压机的研究[J].华中理工大学学报,1998,26(8):38-40.Xiong Xiaohong,Lu Huailiang,Huang Shuhuai.Research on intelligent powder compaction press[J].Journal of Huazhong University of Science and Technology,1998,26(8):38-40.(in Chinese)
4 俞建卫,徐蕾,吴士鹏.基于遗传算法优化的模糊PID在粉末液压机伺服系统的应用研究[J].组合机床与自动化加工技术,2013(8):58-61.Yu Jianwei,Xu Lei,Wu Shipeng.Study on fuzzy-PID control based on genetic algorithm used in powder hydraulic machine’s servo system[J].Modular Machine Tool&Automatic Manufacturing Technique,2013(8):58-61.(in Chinese)
5 崔明光,管国栋,张金,等.自适应PID在粉末冶金液压机速度控制中的应用[C]∥第十二届全国塑性工程学术年会第四届全球华人塑性加工技术研讨会论文集,2011:214-217.Cui Mingguang,Guan Guodong,Zhang Jin,el al.Application of adaptive PID method in speed control of powder metallurgy hydraulic press[C]∥Proceedings of the 12th Conference on Forming Technology,2011:214-217.(in Chinese)
6 于韶辉.干粉自动成型液压机双闭环模糊控制系统的研究[D].哈尔滨:哈尔滨工业大学,2004.Yu Shaohui.Research on double feedback fuzzy control of automatic forming hydraulic press for dry powder[D].Harbin:Harbin Institute of Technology,2004.(in Chinese)
7 高俊,颜国义,彭根运,等.基于迭代学习的粉末成形压机控制策略仿真[J].流体传动与控制,2013(1):25-28.Gao Jun,Yan Guoyi,Peng Genyun,el al.Simulation of power metallurgic forming machine based on the iterative learning control strategy[J].Fluid Power Transmission and Control,2013(1):25-28.(in Chinese)
8 Yao B,Tomizuka M.Smooth robust adaptive sliding mode control of manipulators with guaranteed transient performance[J].ASME Journal of Dynamic Systems,Measurement,and Control,1996,118(4):764-775.
9 Yao B.High performance adaptive robust control of nonlinear systems:a general frame work and new schemes[C]∥Decision and Control.Proceedings of the 36th IEEE Conference on Decision and Control,San Diego,CA:IEEE,1997:2489-2494.
10 Yao B,Bu F,Chiu G T.Non-linear adaptive robust control of electro-hydraulic systems driven by double-rod actuators[J].International Journal of Control,2001,74(8):761-775.
11 Yao B,Bu F,Reedy J,et al.Adaptive robust motion control of single-rod hydraulic actuators:theory and experiments[J].IEEE/ASME Transactions on Mechatronics,2000,5(1):79-91.
12 Yao B,Chang J.Advanced motion control:from classical PID to nonlinear adaptive robust control[C]∥11th IEEE International Workshop on Advanced Motion Control,2010:815-829.
13 Troxel N A,Yao B.Hydraulic cylinder velocity control with energy recovery:a comparative simulation study[C]∥ASME 2011Dynamic Systems and Control Conference and Bath/ASME Symposium on Fluid Power and Motion Control,2011:169-176.
14 Paul Beiss.粉末冶金零件的粉末成形压机、模架及成形能力发展趋向[J].粉末冶金工业,2011,21(5):12-20.Paul Beiss.Trends in powder presses,tooling and shaping capabilities for PM parts[J].Powder Metallurgy Industry,2011,21 (5):12-20.(in Chinese)
15 董林峰.粉末金属成形中的缺陷预测与成形过程的计算机仿真[D].上海:上海交通大学,2001.Dong Linfeng.Defects prediction during metal powder compaction and computer simulation of compaction process[D].Shanghai:Shanghai Jiao Tong University,2001.(in Chinese)
16 汪俊,李从心,阮雪榆.基于实验参数修正的粉末金属压制过程数学模型[J].上海交通大学学报,2000,34(3):322-325.Wang Jun,Li Congxin,Ruan Xueyu.Mathematical model of powdered metal compacting process based on modified experimental parameters[J].Journal of Shanhai Jiao Tong University,2000,34(3):322-325.(in Chinese)
17 Skonecki S,Kulig R,ysiak G.Models of pressure compaction and their application for wheat meal[J].International Agrophysics,2014,28(1):125-130.
18 俞建卫,刘岳,焦明华,等.粉末冶金压制成形受力情况的研究[J].粉末冶金工业,2012,22(2):49-54.Yu Jianwei,Liu Yue,Jiao Minghua,et al.Study on force in powder metallurgy molding[J].Powder Metallurgy Industry,2012,22 (2):49-54.(in Chinese)
19 Alleyne A.Nonlinear force control of an electro-hydraulic actuator[C]∥Japan/USA Symposium on Flexible Automation,1996,1:193-200.
20 Sopchak N D,Misiolek W Z.Density gradients in multilayer compacted iron powder parts[J].Materials and Manufacturing Processes,2000,15(1):65-79.
21 吴成义,张丽英.粉末成形力学原理[M].北京:冶金工业出版社,2003.
2 邓佳,曹树平,罗小辉,等.二氧化铀粉末成型系统电液位置-压力复合控制仿真[J].机械制造与自动化,2013(6):84-89.Deng Jia,Cao Shuping,Luo Xiaohui,el al.Simulation of electro-hydraulic position and force compound control system for compacting UO2powder[J].Machine Building and Automation,2013(6):84-89.(in Chinese)
3 熊晓红,卢怀亮,黄树槐.智能型粉末成形液压机的研究[J].华中理工大学学报,1998,26(8):38-40.Xiong Xiaohong,Lu Huailiang,Huang Shuhuai.Research on intelligent powder compaction press[J].Journal of Huazhong University of Science and Technology,1998,26(8):38-40.(in Chinese)
4 俞建卫,徐蕾,吴士鹏.基于遗传算法优化的模糊PID在粉末液压机伺服系统的应用研究[J].组合机床与自动化加工技术,2013(8):58-61.Yu Jianwei,Xu Lei,Wu Shipeng.Study on fuzzy-PID control based on genetic algorithm used in powder hydraulic machine’s servo system[J].Modular Machine Tool&Automatic Manufacturing Technique,2013(8):58-61.(in Chinese)
5 崔明光,管国栋,张金,等.自适应PID在粉末冶金液压机速度控制中的应用[C]∥第十二届全国塑性工程学术年会第四届全球华人塑性加工技术研讨会论文集,2011:214-217.Cui Mingguang,Guan Guodong,Zhang Jin,el al.Application of adaptive PID method in speed control of powder metallurgy hydraulic press[C]∥Proceedings of the 12th Conference on Forming Technology,2011:214-217.(in Chinese)
6 于韶辉.干粉自动成型液压机双闭环模糊控制系统的研究[D].哈尔滨:哈尔滨工业大学,2004.Yu Shaohui.Research on double feedback fuzzy control of automatic forming hydraulic press for dry powder[D].Harbin:Harbin Institute of Technology,2004.(in Chinese)
7 高俊,颜国义,彭根运,等.基于迭代学习的粉末成形压机控制策略仿真[J].流体传动与控制,2013(1):25-28.Gao Jun,Yan Guoyi,Peng Genyun,el al.Simulation of power metallurgic forming machine based on the iterative learning control strategy[J].Fluid Power Transmission and Control,2013(1):25-28.(in Chinese)
8 Yao B,Tomizuka M.Smooth robust adaptive sliding mode control of manipulators with guaranteed transient performance[J].ASME Journal of Dynamic Systems,Measurement,and Control,1996,118(4):764-775.
9 Yao B.High performance adaptive robust control of nonlinear systems:a general frame work and new schemes[C]∥Decision and Control.Proceedings of the 36th IEEE Conference on Decision and Control,San Diego,CA:IEEE,1997:2489-2494.
10 Yao B,Bu F,Chiu G T.Non-linear adaptive robust control of electro-hydraulic systems driven by double-rod actuators[J].International Journal of Control,2001,74(8):761-775.
11 Yao B,Bu F,Reedy J,et al.Adaptive robust motion control of single-rod hydraulic actuators:theory and experiments[J].IEEE/ASME Transactions on Mechatronics,2000,5(1):79-91.
12 Yao B,Chang J.Advanced motion control:from classical PID to nonlinear adaptive robust control[C]∥11th IEEE International Workshop on Advanced Motion Control,2010:815-829.
13 Troxel N A,Yao B.Hydraulic cylinder velocity control with energy recovery:a comparative simulation study[C]∥ASME 2011Dynamic Systems and Control Conference and Bath/ASME Symposium on Fluid Power and Motion Control,2011:169-176.
14 Paul Beiss.粉末冶金零件的粉末成形压机、模架及成形能力发展趋向[J].粉末冶金工业,2011,21(5):12-20.Paul Beiss.Trends in powder presses,tooling and shaping capabilities for PM parts[J].Powder Metallurgy Industry,2011,21 (5):12-20.(in Chinese)
15 董林峰.粉末金属成形中的缺陷预测与成形过程的计算机仿真[D].上海:上海交通大学,2001.Dong Linfeng.Defects prediction during metal powder compaction and computer simulation of compaction process[D].Shanghai:Shanghai Jiao Tong University,2001.(in Chinese)
16 汪俊,李从心,阮雪榆.基于实验参数修正的粉末金属压制过程数学模型[J].上海交通大学学报,2000,34(3):322-325.Wang Jun,Li Congxin,Ruan Xueyu.Mathematical model of powdered metal compacting process based on modified experimental parameters[J].Journal of Shanhai Jiao Tong University,2000,34(3):322-325.(in Chinese)
17 Skonecki S,Kulig R,ysiak G.Models of pressure compaction and their application for wheat meal[J].International Agrophysics,2014,28(1):125-130.
18 俞建卫,刘岳,焦明华,等.粉末冶金压制成形受力情况的研究[J].粉末冶金工业,2012,22(2):49-54.Yu Jianwei,Liu Yue,Jiao Minghua,et al.Study on force in powder metallurgy molding[J].Powder Metallurgy Industry,2012,22 (2):49-54.(in Chinese)
19 Alleyne A.Nonlinear force control of an electro-hydraulic actuator[C]∥Japan/USA Symposium on Flexible Automation,1996,1:193-200.
20 Sopchak N D,Misiolek W Z.Density gradients in multilayer compacted iron powder parts[J].Materials and Manufacturing Processes,2000,15(1):65-79.
21 吴成义,张丽英.粉末成形力学原理[M].北京:冶金工业出版社,2003.