喷射沉积管坯控制系统及其液位控制研究
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摘要
喷射沉积技术是制备快速凝固高性能材料的新型金属近成形技术,沉积坯件具有成分均匀、组织细化、致密度高、含氧量低、偏析程度小等特征。该技术在欧美、日本等国家已经进入工业化生产阶段,国内对该技术的研究基本还处于实验室材料研究或中试阶段,对喷射沉积自动控制及智能控制方面的研究已经展开,但离工业化生产尚有一段距离。
本文对喷射沉积制备大规格管坯工业化生产特点进行了分析,研究了喷射沉积管坯设备的构造及其工作原理,构建了由系统管理层、控制层、设备层组成的三层递阶控制结构。针对喷射沉积的工艺要求,结合项目特点,对喷射沉积控制系统进行了配置,完成了相关控制程序和组态监控程序的设计、开发和调试。
研究了基于PID算法的漏包移液和液位精确控制结构和方法,建立了漏包液位控制系统的仿真模型;针对PID控制策略,研究了自适应遗传算法,即基于模糊逻辑的遗传算法的PID控制参数整定方法,并通过Matlab平台仿真优化得出PID的控制参数。
研究结论应用在实际液位控制系统中,得到了很好的验证,生产现场采集数据表明,PID调节时间约为30秒,换包过程中最大波动量不超过10毫米,稳态误差为±3毫米,系统的响应较快、超调小、液位稳定并具有较高的控制精度。
Spray deposition is a new kind of near-net shape metal forming technology which is used to manufacture rapid solidification advanced materials with the characteristics of uniform composition, high density, low oxygen tension and small degree of segregation. This technology has been coming into industrial scale production in Europe, American and Japan, while domestic research in spray deposition technology is still basically staying at a laboratory or experimental stage. Domestic research in automatic control and intelligent control of spray deposition process has already been launched, but there is still a certain distance to industrial scale production.
The characteristics of utilizing spray deposition technology to manufacture large dimension tubular product was analyzed in the present thesis, the structure of spray deposition device of tubular preform and its main operational principle were studied on, and the three layer hierarchical control structure consist of the management system layer, control system layer, and field device layer was constructed. To meet the demands of the technics of the Spray Deposition, the configuration of the control system of the Spray Deposition was provided, and the design, development and debug of the control program and the monitor program were finished.
The structure and control strategy of the exactly level control based on PID method were put forward in the thesis, the detailed mathematical model of the tundish level control system was established. The self-adaptive genetic algorithm, which based on the fuzzy logic, is studied to optimize the PID parameters based on the platform MATLAB.
The result of the research has been applied in the real control system and has good performance. According to the data collected from the field, the time of PID regulating is about 30 seconds, level undulating quantity is less than 10 millimeters, steady state error is±3 millimeters. The system is characterized with fast response, small overshoot, steady level and good control precise.
本文对喷射沉积制备大规格管坯工业化生产特点进行了分析,研究了喷射沉积管坯设备的构造及其工作原理,构建了由系统管理层、控制层、设备层组成的三层递阶控制结构。针对喷射沉积的工艺要求,结合项目特点,对喷射沉积控制系统进行了配置,完成了相关控制程序和组态监控程序的设计、开发和调试。
研究了基于PID算法的漏包移液和液位精确控制结构和方法,建立了漏包液位控制系统的仿真模型;针对PID控制策略,研究了自适应遗传算法,即基于模糊逻辑的遗传算法的PID控制参数整定方法,并通过Matlab平台仿真优化得出PID的控制参数。
研究结论应用在实际液位控制系统中,得到了很好的验证,生产现场采集数据表明,PID调节时间约为30秒,换包过程中最大波动量不超过10毫米,稳态误差为±3毫米,系统的响应较快、超调小、液位稳定并具有较高的控制精度。
Spray deposition is a new kind of near-net shape metal forming technology which is used to manufacture rapid solidification advanced materials with the characteristics of uniform composition, high density, low oxygen tension and small degree of segregation. This technology has been coming into industrial scale production in Europe, American and Japan, while domestic research in spray deposition technology is still basically staying at a laboratory or experimental stage. Domestic research in automatic control and intelligent control of spray deposition process has already been launched, but there is still a certain distance to industrial scale production.
The characteristics of utilizing spray deposition technology to manufacture large dimension tubular product was analyzed in the present thesis, the structure of spray deposition device of tubular preform and its main operational principle were studied on, and the three layer hierarchical control structure consist of the management system layer, control system layer, and field device layer was constructed. To meet the demands of the technics of the Spray Deposition, the configuration of the control system of the Spray Deposition was provided, and the design, development and debug of the control program and the monitor program were finished.
The structure and control strategy of the exactly level control based on PID method were put forward in the thesis, the detailed mathematical model of the tundish level control system was established. The self-adaptive genetic algorithm, which based on the fuzzy logic, is studied to optimize the PID parameters based on the platform MATLAB.
The result of the research has been applied in the real control system and has good performance. According to the data collected from the field, the time of PID regulating is about 30 seconds, level undulating quantity is less than 10 millimeters, steady state error is±3 millimeters. The system is characterized with fast response, small overshoot, steady level and good control precise.
引文
[1] A. G. Leatham, R. G. Brooks, J. S. Coombs,The past, present and future developments of Osprey perform process, proc. 1st Int. Conf. On spray forming,Osprey Metals,Neath,1990:1-12
[2] Mathur P, Annavarapu S, Apclian D, et al,Process control modeling and application of spray casting [J],JOM, 1989, 41(10):23
[3] Singer A. R. E.,Recent developments in the spray forming of metals: part2 [J],Metal Powder Rep, 1986, 31(2):109
[4] Willians B. Metal performs and powders by osprey process [J]. Metal Powder Rep., 1986, 26(2):223
[5] Lawley A, Leatham A G,Spray forming commercial products: principles and practice[J], Material Science Forum, 1999, 299-300(6): 407-415
[6] Ogata J, Lavernia E. J., Grant N. J., et al,Structure and properties of a rapidly solidified superalloy produced by liquid dynamic compaction [J], Rapid Solidification, 1986, 2(1):21-26
[7] Singer, A. R. E.,The Principles of Spray Rolling of Metals[J], Met. Mater, 1970, 4:246cbx
[8] Grant, P. S. Spray forming. Progress in Materials Science, 1995, 39(5): 497-545
[9] Alan Leatham. Spray Forming Technology[J]. Advanced materials & processes, 1996,21(8):27-31
[10] A. Leatham, A. J. W. Ogilvy,Commercial-Scale application of spray formed materials[J],Mater. Synth. Process , 1997, 5(1):5-10
[11] 曲迎东, 崔成松, 陈善本, 等,智能控制技术在喷射成形工艺中的应用[J], 粉末冶金技术, 2002, 3(2):113-115
[12] 田世藩,喷射成形的发展及其产业化趋势,粉末冶金工业, 1999, 9(3): 41-48
[13] 熊柏清,喷射成形技术的产业化现状及应用发展方向,稀有金属, 1999, 23(6): 425-430
[14] 张永安, 熊柏清, 石力开,喷射成形技术产品的研究现状,材料导报, 2002, 16(3): 11-14
[15] 王军, 严彪, 徐政,喷射成形技术的产业化发展,江苏冶金, 2003, 31(1): 7-10
[16] 王文明, 潘复生, Lu Yun 等. 喷射成形技术的发展概况及展望,重庆大学学报, 2004, 27(1): 101-106
[17] 康福伟, 孙剑飞, 沈军,喷射成形工艺的发展及应用,稀有金属, 2004, 28(2): 402-407
[18] C. Spiegelhaller, J. Overgard, G. Oakes, et al., Spray forming of Larger Diameter Steel Products by the Osprey Process, Advances in P/M & Particulate Materials-1995, Vol. 2 [proc. Conf.]: 41-46
[19] 王伟,柴天佑,工业中应用的控制技术发展新动向,控制工程,2006,13(1): 1-5
[20] 熊柏清,喷射成形技术的产业化现状及应用发展方向,稀有金属, 1999, 23(6): 425-430
[21] 曲迎东, 崔成松, 陈善本, 等,智能控制技术在喷射成形工艺中的应用[J], 粉末冶金技术, 2002, 27(2):113-115
[22] 王建强, 常新春, 郝云彦, 等,喷射成形过程的实时监测与智能控制技术[J],材料工程, 1998,11(2):47-49
[23] 陈振华, 严红革, 陈刚, 等,多层喷射沉积的装置和原理[J],湖南大学学报, 2001, 28(5):20-18
[24] 康智涛, 陈振华, 严红革, 等,多层喷射沉积工艺中可编程调节器的应用[J],粉末冶金技术, 2000, 18(2):98-101
[25] 傅定发, 袁武华, 康智涛等,可编程控制器在多层喷射沉积制备管坯工艺中的应用[J],中南工业大学学报, 2000, 31(2):160-162
[26] 康智涛,多层喷射共沉积制备大尺寸 SiC 颗粒增强铝基复合材料的工艺、设备及过程原理研究[D],长沙,中南工业大学, 2001,23(3):23-27
[27] 刘锴,周海,深入浅出西门子 S7-300 PLC,北京,北京航空航天大学出版社,2004:25-30
[28] 西门子有限公司,深入浅出西门子 WinCC V6,北京,北京航空航天大学出版社,2004
[29] 薛定宇, 陈阳全,基于 MATLAB/Simulink 的系统仿真技术与应用,北京,清华大学出版社,2002
[30] 韩京清, 袁露林,跟踪微分器的离散形式,系统科学与数学, 1999, 19(3): 268-273
[31] 刘金昆,先进 PID 控制 MATLAB 仿真,北京,电子工业出版社,2004
[32] 王永富,柴天佑,自适应模糊控制理论的研究综述,控制工程,2006,13(3): 193-195
[33] 恽为民,席裕庚. 遗传算法的运行机理分析. 控制理论与应用,1996,13(3):289-297
[34] John J. Grefenstette,Optimization of Control Parameters for Genetic Algorithms[J], IEEE Trans. Sys. Man, and Cyber,1986, 16(1):122-128
[35] B.M.Kim, Y.b.Kim, C.H.Oh,A Study on the Convergence of Genetic Algorithms[J], Computers Ind. Eng, 1997, 33(3):581-588
[36] 席裕庚,柴天佑,恽为民,遗传算法综述,控制理论与应用,1996,13(6):1-5
[37] 张筱磊,赵培庆,基于模糊逻辑的遗传算法研究,计算技术与自动化,2006,25(1):55-57
[38] 邢宝, 王晓勇,喷射成形中漏包液位 PID 控制的建模与仿真,南京航空航天大学第七界研究生学术会议论文集
[2] Mathur P, Annavarapu S, Apclian D, et al,Process control modeling and application of spray casting [J],JOM, 1989, 41(10):23
[3] Singer A. R. E.,Recent developments in the spray forming of metals: part2 [J],Metal Powder Rep, 1986, 31(2):109
[4] Willians B. Metal performs and powders by osprey process [J]. Metal Powder Rep., 1986, 26(2):223
[5] Lawley A, Leatham A G,Spray forming commercial products: principles and practice[J], Material Science Forum, 1999, 299-300(6): 407-415
[6] Ogata J, Lavernia E. J., Grant N. J., et al,Structure and properties of a rapidly solidified superalloy produced by liquid dynamic compaction [J], Rapid Solidification, 1986, 2(1):21-26
[7] Singer, A. R. E.,The Principles of Spray Rolling of Metals[J], Met. Mater, 1970, 4:246cbx
[8] Grant, P. S. Spray forming. Progress in Materials Science, 1995, 39(5): 497-545
[9] Alan Leatham. Spray Forming Technology[J]. Advanced materials & processes, 1996,21(8):27-31
[10] A. Leatham, A. J. W. Ogilvy,Commercial-Scale application of spray formed materials[J],Mater. Synth. Process , 1997, 5(1):5-10
[11] 曲迎东, 崔成松, 陈善本, 等,智能控制技术在喷射成形工艺中的应用[J], 粉末冶金技术, 2002, 3(2):113-115
[12] 田世藩,喷射成形的发展及其产业化趋势,粉末冶金工业, 1999, 9(3): 41-48
[13] 熊柏清,喷射成形技术的产业化现状及应用发展方向,稀有金属, 1999, 23(6): 425-430
[14] 张永安, 熊柏清, 石力开,喷射成形技术产品的研究现状,材料导报, 2002, 16(3): 11-14
[15] 王军, 严彪, 徐政,喷射成形技术的产业化发展,江苏冶金, 2003, 31(1): 7-10
[16] 王文明, 潘复生, Lu Yun 等. 喷射成形技术的发展概况及展望,重庆大学学报, 2004, 27(1): 101-106
[17] 康福伟, 孙剑飞, 沈军,喷射成形工艺的发展及应用,稀有金属, 2004, 28(2): 402-407
[18] C. Spiegelhaller, J. Overgard, G. Oakes, et al., Spray forming of Larger Diameter Steel Products by the Osprey Process, Advances in P/M & Particulate Materials-1995, Vol. 2 [proc. Conf.]: 41-46
[19] 王伟,柴天佑,工业中应用的控制技术发展新动向,控制工程,2006,13(1): 1-5
[20] 熊柏清,喷射成形技术的产业化现状及应用发展方向,稀有金属, 1999, 23(6): 425-430
[21] 曲迎东, 崔成松, 陈善本, 等,智能控制技术在喷射成形工艺中的应用[J], 粉末冶金技术, 2002, 27(2):113-115
[22] 王建强, 常新春, 郝云彦, 等,喷射成形过程的实时监测与智能控制技术[J],材料工程, 1998,11(2):47-49
[23] 陈振华, 严红革, 陈刚, 等,多层喷射沉积的装置和原理[J],湖南大学学报, 2001, 28(5):20-18
[24] 康智涛, 陈振华, 严红革, 等,多层喷射沉积工艺中可编程调节器的应用[J],粉末冶金技术, 2000, 18(2):98-101
[25] 傅定发, 袁武华, 康智涛等,可编程控制器在多层喷射沉积制备管坯工艺中的应用[J],中南工业大学学报, 2000, 31(2):160-162
[26] 康智涛,多层喷射共沉积制备大尺寸 SiC 颗粒增强铝基复合材料的工艺、设备及过程原理研究[D],长沙,中南工业大学, 2001,23(3):23-27
[27] 刘锴,周海,深入浅出西门子 S7-300 PLC,北京,北京航空航天大学出版社,2004:25-30
[28] 西门子有限公司,深入浅出西门子 WinCC V6,北京,北京航空航天大学出版社,2004
[29] 薛定宇, 陈阳全,基于 MATLAB/Simulink 的系统仿真技术与应用,北京,清华大学出版社,2002
[30] 韩京清, 袁露林,跟踪微分器的离散形式,系统科学与数学, 1999, 19(3): 268-273
[31] 刘金昆,先进 PID 控制 MATLAB 仿真,北京,电子工业出版社,2004
[32] 王永富,柴天佑,自适应模糊控制理论的研究综述,控制工程,2006,13(3): 193-195
[33] 恽为民,席裕庚. 遗传算法的运行机理分析. 控制理论与应用,1996,13(3):289-297
[34] John J. Grefenstette,Optimization of Control Parameters for Genetic Algorithms[J], IEEE Trans. Sys. Man, and Cyber,1986, 16(1):122-128
[35] B.M.Kim, Y.b.Kim, C.H.Oh,A Study on the Convergence of Genetic Algorithms[J], Computers Ind. Eng, 1997, 33(3):581-588
[36] 席裕庚,柴天佑,恽为民,遗传算法综述,控制理论与应用,1996,13(6):1-5
[37] 张筱磊,赵培庆,基于模糊逻辑的遗传算法研究,计算技术与自动化,2006,25(1):55-57
[38] 邢宝, 王晓勇,喷射成形中漏包液位 PID 控制的建模与仿真,南京航空航天大学第七界研究生学术会议论文集