摘要
电磁制动器在国外已普遍应用于拖挂式车辆制动系统中,作为关系汽车安全的关键部件之一,其性能的好坏将直接影响汽车整车的安全性能。当前,汽车技术的发展对电磁制动器的设计提出了高性能、低成本和短周期的要求,迫切需要借助计算机辅助设计技术为电磁制动器的设计提供支撑。
本文针对电磁制动器设计的关键技术进行研究,以建立电磁制动器集成设计平台为目标,主要开展了以下几个方面的研究内容:
对汽车列车制动力匹配技术进行了研究,确定了牵引车和房车的制动力分配系数,依据相关标准运用制动器与整车性能相匹配的理论,建立了房车所需制动力矩的数学模型,用以对制动器进行选型设计,并给出了集成设计平台中整车匹配模块的算法流程图。
通过对鼓式电磁制动器力学性能的分析和研究,提出了一种实用的鼓式制动器制动效能因数的计算方法,并给出了相关的计算公式。基于鼓式电磁制动器结构参数对制动效能因数的敏感性分析,以制动效能为优化目标,建立了制动器优化设计数学模型,确定了鼓式电磁制动器优化设计的主要结构参数。通过分析优化设计的约束条件,给出了基于Matlab的Fmincon函数的程序优化算法和实现方法。建立了基于ADAMS的电磁制动器虚拟样机模型,通过试验和仿真,比较优化前后制动器的性能,验证了优化设计方法的有效性及虚拟样机模型的正确性。
从研究电磁制动器的工作机理出发,分析了电磁体制动时的工作姿态及其表面磨损的情况,为实现电磁体表面均匀磨损和抗旋转趋势,提出了电磁体的优化设计方案。基于电磁体表面内侧开槽的非对称设计构想,计算了理论开槽面积。利用三维电磁场分析软件Maxwell 3D对非对称结构电磁体进行了仿真分析,以仿真结果对理论分析及设计作出了合理修正,从而得到了最佳的开槽结构。通过将对称结构和自制非对称结构的电磁体做耐久性磨损试验对比,验证了非对称结构电磁体的磨损均匀性明显提高及电磁体优化设计的合理性。
通过对稳健优化设计原理与方法的研究,将基于损失模型的稳健设计方法应用于制动器的设计,将影响制动器输出特性的因素划分为可控因素和噪声因素,并应用传统优化思想,确定了各因素的中心值及波动。通过正交试验,计算出试验结果,进行直观分析或方差分析,获取每个因素对试验结果影响的重要程度,最终得出了各因素对产品质量的贡献率;将基于响应面模型的稳健设计方法应用于电磁体的设计,通过试验获得电磁体相关数据,并运用回归的方法建立了响应面模型。将传统的稳健设计方法与现代计算方法相结合,运用Matlab中相关的优化函数,获得了电磁体稳健点以及电磁体所应具有的输出特性。
通过分析电磁制动器设计过程及其影响因素,研究并分析了电磁制动器集成设计平台的内涵,提出了基于集成设计平台的电磁制动器设计过程,建立了集成设计平台的运作体系和系统体系,分析了集成设计平台的体系结构特征;通过分析电磁制动器设计过程中的基本数据元素和模型,建立了由组织、过程和产品三个视图组成的多视图集成数据模型,提出了基于数据库的主模型数据一致性管理方法,实现了平台的数据集成;提出了基于组件技术思想建立集成设计平台应用集成的方法,给出了组件形式化定义及集成设计平台中应用组件接口,提出了集成平台中组件的分类方法和原则,给出了组件互操作的实现方案,并详细论述了相关应用软件的集成方法。最后,通过集成设计平台的开发及相关功能模块的建立,验证了研究成果的可行性、有效性和实用性。
Electromagnetic brake has been widely used in the tractor/trailer braking system abroad, as one of critical parts in automobile, the performance of it influences the safety performance of automobile directly. In nowadays, with the development of automobile, higher performance, lower cost, and shorter lifecycle have become new requirements for the designing of electromagnetic brake. Consequently, the computer aided design technology is an instant need to provide the technical support.
With a purpose to establish an integrated design environment for the designing of electromagnetic brake, the key technologies related are researched in this paper. The main contents and contributions of the paper are summarized as follows:
The matching technology between drum electromagnetic brake and vehicle is studied and the braking force distribution coefficient of the tractor and trailer is confirmed. According to the related standard, the mathematic model of the braking moment which the electromagnetic brake should provide has been ascertained using the matching theory. The matching technology of trailer train brake system has been introduced in the type selection and analysis of the brakes. The algorithm flow of the vehicle matching module of the intergated design environment has been given.
Based on the study and analysis of mechanical theory of electromagnetic brake, an applied formula of brake factor is provided in this paper. Based on the analysis of sensibility about drum electromagnetic brake to brake factor, the structure parameters for optimization and mathematic model of the drum brake are ascertained taking the braking efficiency as optimum goal. The optimization algorithm of the structure parameters based on the tools of Matlab is also presented. The virtual prototype of electromagnetic brake is built using ADAMS. The effectiveness of optimum design method and the validity of virtual prototype are verified by comparing the braking performance around optimization.
Based on the study of the brake mechanism, the work posture and wear performance of the electromagnet are analyzed, and the optimum design plan of electromagnet is proposed to realize the even wear of the electromagnet surface and decrease the revolving tendency. Based on the unsymmetrical design of magnetic circuit by means of slotting inside, the theory slot area is calculated. As the complex shape of the magnetic circuit, by using the electromagnetic analysis software Maxwell 3D for the simulation analysis, the simulation results amend the theoretical analysis to achieve the best unsymmetrical structures. By wearing comparison of the symmetrical and unsymmetrical electromagnet, the testing result indicates that the unsymmetrical electromagnet obviously surpasses the symmetrical structure and optimum design plan is reasonable.
For the brake, based on going deep into analyze robust design on losing model, this paper founds mathematic model on brake, and separates all factors which can influent the quality of output into under-control factors and noise factors, then confirms the center values and fluctuations of each factor. Thereafter, via orthogonal test, works out the test results. At last, through intuitionist analyses or differential analyses, the significant degree of each factor in influent the test result and the contribute ratio of each factor in influent the quality of output can be known. For the electromagnet, based on going deep into analyze robust design on response surface model, this paper gets test results about electromagnet through orthogonal test, and gained response surface model with regressive method. Combining traditional robust design methods with modern calculate methods; this article gets robust points and output of electromagnet under correlative optimization functions in Matlab.
An analysis on the electromagnetic brake design process and its influence factors are given and it is followed by an intense study on the connotation of the integrated design environment; on the basis of which this paper demonstrates the electromagnetic brake design process in the integrated design environment. In addition, the operation architecture and the system architecture of the integrated design environment are further build with an analysis of the architecture features.
By analyzing the basic data elements and models of electromagnetic brake design process, this paper presents a multi-view integrated data model consisting of organization, process and product views. Meanwhile, a data consistency management method based on the databased master model is addressed. The method of the application integration based on component technology thought and the formalization definition of software components are presented. The component interface developing criterion is proposed as well. Taxonomic approach, principle of the component and implementation of component's interoperability are introduced. The technology of the integration of related software has also been discussed. At last, by applying the theories and methods studied above to practice, the research offers an integrated design environment of electromagnetic brake, the effectiveness and practicality of the research result are verified.
引文
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