对称布局的增力型曲柄压力机的创新设计与力学性能研究
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摘要
基于曲柄-连杆-滑块机构的普通机械压力机,属于一级增力型压力机,至今仍在工业领域大量应用。该类压力机具有机结构平衡性极差,体积笨重,噪声极大,摩擦损失大,力学性能曲线不合理,不便于自动控制等突出缺点。此外,由于增力机构仅是一次型的,在需要大的公称压力的场合,这类压力机难以胜任,使得人们不得不选择容易造成环境污染的液压传动压力机,或结构甚为复杂的摩擦-螺旋传动压力机。
针对传统曲柄压力机的上述缺点,根据科学美学的对称性理念,以及串联组合增力机构的设计方法,分别设计了对称布局的一级、二级、三级增力的曲柄压力机。新进行的主要研究工作如下:
(1)对传统曲柄压力机机构进行了数学建模和详细的运动学和动力学分析,从理论上分析指出了其力学性能的不足之处。
(2)对创新设计的对称布局一级增力曲柄压力机,在介绍工作原理的基础上,通过数学建模及力学性能曲线的对比,说明其相对于传统理论的非对称布局压力进的优越之处。
(3)为了在输入转矩相同的条件下,得到相对更大的输出压力,利用曲柄连杆机构与铰杆机构进行串联组合,分别设计了对称布局的二级与三级增力压力机。在要求的工作行程较小的条件下,采用串联组合增力机构,相对与传统的一级增力压力机,可显著缩小输入转矩。
(4)利用上述增力机构,将动力元件由普通交流电动机置换为伺服电动机,结合运用“电子飞轮”储能技术,形成便于进行自动控制的机电一体化数控压力机。数控压力机在结构上更为紧凑,能源利用率高,可任意设置行程,并可编程设计伺服电机的角速度曲线,而使压力机工作结构的动力学性能的到显著改善。
(5)介绍数控步冲压力机的基本原理,结合串联组合增力机构形成的新型数控步冲机,能有效克服伺服电动机功率与输出转矩小的缺点。
(6)利用MATLAB GUI面向对象设计,建立了各类冲压机构详细的数学模型,并设计了程序界面。用户只需按照界面上的提示,输入机构的相应参数,即可得到所需压力机的运动曲线和力学曲线图,极大地缩短了开发和选用压力机的周期。
Based on the crank– linkage - slider general mechanical press, belong to one step force-amplifier press, which is still a large number of industrial applications in Industry. Structure of such presses have lots of remarkable shortcomings, such as poor balance, bulky size, noise greatly, big friction loss, mechanical properties of curves unreasonable, and not facilitate the automatic control. Besides, because of force-amplifier is one step, this kind of press could not be competent for the occasion of big nominal force. So people have to select the hydraulic press, which is easy to cause environmental pollution, or the complex structure of the screw press.
For the above-mentioned disadvantage of traditional crank press , according to the symmetry of the scientific concept of aesthetics, as well as the design approach of the series combination of force-amplifier , one-step , two-step, and three-step force-amplifier crank press have been designed separately in a symmetrical layout. Major new research in the following:
(1) Mathematical modeling have been made for the traditional crank press ,than a detailed analysis of kinematics and dynamics have been carried out for it, And the inadequacies of the mechanical properties have been pointed out from theoretical analysis .
(2) On the basis of introducing the working principle, compare the mathematical modeling and mechanical properties of curves of the innovative design of the symmetrical one step force-amplifier crank press to the traditional non-symmetrical layout crank press, and point out the advantages.
(3) To get relatively greater stress with the same input torque, two-step and three-step force-amplifier crank press have been designed separately in a symmetrical layout through the method of series combinations with slider-crank mechanism and the toggle mechanism. At the smaller work stroke conditions, the use of tandem combination of force-amplifier significantly reduce the input torque compared to the traditional one-step force-amplifier mechanical press.
(4) Appling above-mentioned force-amplifier mechanical press, change the power components from ordinary alternation current motor to sever motor, combined with the use of energy storage technology by“Electronic Flywheel”, making the Mechatronics CNC presses which facilitate the automatic control. CNC press has a more compact structure and high energy efficiency. Moreover its dynamic performance of working part can be improved by designing the angular velocity curve of servo motor.
(5) Introduce the basic principles of NC-step press. And overcome the disadvantage that the servo motor torque and output power are too small by innovating new NC-step press combining the force-amplifier.
(6) Using MATLAB GUI , set up various types of presses’detailed mathematical model, and design the program interface. Accordance to the tips on the program interface, people just need enter the corresponding parameters of the press you choose. Than you will get the kinematical curves and mechanical properties curves. So it is greatly shortening the development and selection of press cycle.
针对传统曲柄压力机的上述缺点,根据科学美学的对称性理念,以及串联组合增力机构的设计方法,分别设计了对称布局的一级、二级、三级增力的曲柄压力机。新进行的主要研究工作如下:
(1)对传统曲柄压力机机构进行了数学建模和详细的运动学和动力学分析,从理论上分析指出了其力学性能的不足之处。
(2)对创新设计的对称布局一级增力曲柄压力机,在介绍工作原理的基础上,通过数学建模及力学性能曲线的对比,说明其相对于传统理论的非对称布局压力进的优越之处。
(3)为了在输入转矩相同的条件下,得到相对更大的输出压力,利用曲柄连杆机构与铰杆机构进行串联组合,分别设计了对称布局的二级与三级增力压力机。在要求的工作行程较小的条件下,采用串联组合增力机构,相对与传统的一级增力压力机,可显著缩小输入转矩。
(4)利用上述增力机构,将动力元件由普通交流电动机置换为伺服电动机,结合运用“电子飞轮”储能技术,形成便于进行自动控制的机电一体化数控压力机。数控压力机在结构上更为紧凑,能源利用率高,可任意设置行程,并可编程设计伺服电机的角速度曲线,而使压力机工作结构的动力学性能的到显著改善。
(5)介绍数控步冲压力机的基本原理,结合串联组合增力机构形成的新型数控步冲机,能有效克服伺服电动机功率与输出转矩小的缺点。
(6)利用MATLAB GUI面向对象设计,建立了各类冲压机构详细的数学模型,并设计了程序界面。用户只需按照界面上的提示,输入机构的相应参数,即可得到所需压力机的运动曲线和力学曲线图,极大地缩短了开发和选用压力机的周期。
Based on the crank– linkage - slider general mechanical press, belong to one step force-amplifier press, which is still a large number of industrial applications in Industry. Structure of such presses have lots of remarkable shortcomings, such as poor balance, bulky size, noise greatly, big friction loss, mechanical properties of curves unreasonable, and not facilitate the automatic control. Besides, because of force-amplifier is one step, this kind of press could not be competent for the occasion of big nominal force. So people have to select the hydraulic press, which is easy to cause environmental pollution, or the complex structure of the screw press.
For the above-mentioned disadvantage of traditional crank press , according to the symmetry of the scientific concept of aesthetics, as well as the design approach of the series combination of force-amplifier , one-step , two-step, and three-step force-amplifier crank press have been designed separately in a symmetrical layout. Major new research in the following:
(1) Mathematical modeling have been made for the traditional crank press ,than a detailed analysis of kinematics and dynamics have been carried out for it, And the inadequacies of the mechanical properties have been pointed out from theoretical analysis .
(2) On the basis of introducing the working principle, compare the mathematical modeling and mechanical properties of curves of the innovative design of the symmetrical one step force-amplifier crank press to the traditional non-symmetrical layout crank press, and point out the advantages.
(3) To get relatively greater stress with the same input torque, two-step and three-step force-amplifier crank press have been designed separately in a symmetrical layout through the method of series combinations with slider-crank mechanism and the toggle mechanism. At the smaller work stroke conditions, the use of tandem combination of force-amplifier significantly reduce the input torque compared to the traditional one-step force-amplifier mechanical press.
(4) Appling above-mentioned force-amplifier mechanical press, change the power components from ordinary alternation current motor to sever motor, combined with the use of energy storage technology by“Electronic Flywheel”, making the Mechatronics CNC presses which facilitate the automatic control. CNC press has a more compact structure and high energy efficiency. Moreover its dynamic performance of working part can be improved by designing the angular velocity curve of servo motor.
(5) Introduce the basic principles of NC-step press. And overcome the disadvantage that the servo motor torque and output power are too small by innovating new NC-step press combining the force-amplifier.
(6) Using MATLAB GUI , set up various types of presses’detailed mathematical model, and design the program interface. Accordance to the tips on the program interface, people just need enter the corresponding parameters of the press you choose. Than you will get the kinematical curves and mechanical properties curves. So it is greatly shortening the development and selection of press cycle.
引文
[1]李作有.曲柄压力机译文集[M].北京:机械工业出版社,1990
[2]中国机械工程学会塑性工程学会.锻压手册[M].北京:机械工业出版社,2007
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[4]成刚虎.模切机施压机构的运动特性分析与优化设计[J].西安理工大学学报.2006, 22 (3) 249-252
[5]钟康民.铰杆增力式离心离合器的工作原理与设计[J].制造技术与机床,2000(03),13-15.
[6]苏东宁.铰杆增力机构中滑柱力学模型及计算公式的改善[J].济南大学学报,2003,17(1),35-37.
[7]申永胜.机械原理教程[M].北京:清华大学出版社,1999,276-280.
[8]林文焕.机床夹具设计[M].北京:国防工业出版社,1987,107-156.
[9] Edward G? Hoffman. Jig and Fixture Design (Fourth Edition). Albany, USA: Delmar Publishers. 1996. 171-200.
[10]唐中一,于今.顾庆详编著.复合传动与控制[M].重庆:重庆大学出版社,2004.
[11]曹华,钟康民.对称型齿条-齿轮-铰杆机构在液压传动中的应用.新技术新工艺,2004(10):43-44.
[12] Zhong Kangmin, Guo Peiquan. Orthogonal reinforcement mechanism. and hydraulic drive. In: Proceedings of tenth world congress on the theory of machines and mechanisms(Vol5)[J]. Oulu, Finland: Oulu University Press,1999,2037-2042
[13]钟康民.简论对称性美学思想指导下的机械设计创新.机械设计,2004(专辑):94-95,56.
[14]机床设计手册(3.部件、机构及总体设计),机械工业出版社,1986.
[15]陆雯,钟康民.气动肌腱与铰杆增力机构的三种组合系统及其比较[J].机械设计,2005,(2).
[16]侯伟丽.21世纪中国绿色发展问题研究[J].南都学坛(人文社会科学报),2004,24(3):106-110
[17]黄德中.工程机械的绿色设计[J].水利电力机械,2004,26,4:32-34
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[19] Shivpuri R.s.Yossifon. A servo motor driven multi-action Press for sheet metal Forming[J].International journal of Machinery tool Manufacture,1991,31:345-359.
[20] Shivpuri R.s.Yossifon. Analysis and comparison of selected rotary linkage drives for mechanical Press[J]. Intenationa1 Journa1 of Machinery tool Manufacture,1993,2:175-189.
[21]魏良模,朱新榕,孙友松,魏航变速驱动曲柄压力机运动分析[J]锻压装备与制造技术,2004,3:32一34.
[22]徐大任.AC伺服冲压机及其应用[J].机械工人,2005 (4).
[23]何德誉.曲柄压力机[J].北京:机械工业出版社,1981.
[24]商思岳.台湾锻压机床行业研究与借鉴[J].锻压装备与制造技术,2005,3:25-27.
[25]张俊,魏红根.数控技术发展趋势——智能化数控系统[J]制造技术与机床,2000,4:7-9.
[26]陈正中.高速精密压力机特点及其发展趋势.锻压机械,1998,21, 3: 8-9
[27]陈新.机械结构动态设计理论与方法及应用.北京:机械工业出版社,1997.
[28]赵匀.机构数值分析与综合[M].北京:机械工业出版社,2005.
[29] Robert L. Noton. An Introduction to the Synthesis and Analysis of Mechanisms and Machines[M].2002
[30]华大年.连杆机构设计与应用创新[M].北极:机械工业出版社,2007.
[31]陈志嵩,钟康民.铰杆——杠杆串联组合机构分析及其应用[J].机械设计.
[32] ZhiSong Chen, Kangmin Zhong . Innovative interpretation and patterns of toggle - levers tandem combinations force amplifier. ICFDM2008 be held during September 23-26, 2008 in Tianjin, China.
[33]二代龙震工作室.Pro/ENGINEER Wildfire 3.0基础设计[M].北京:电子工业出版社,2007.
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[2]中国机械工程学会塑性工程学会.锻压手册[M].北京:机械工业出版社,2007
[3]卢险峰.板材的冲裁力学研究及应用[J].江西工业大学应用科学学报.1992, 10 (8) 221-225.
[4]成刚虎.模切机施压机构的运动特性分析与优化设计[J].西安理工大学学报.2006, 22 (3) 249-252
[5]钟康民.铰杆增力式离心离合器的工作原理与设计[J].制造技术与机床,2000(03),13-15.
[6]苏东宁.铰杆增力机构中滑柱力学模型及计算公式的改善[J].济南大学学报,2003,17(1),35-37.
[7]申永胜.机械原理教程[M].北京:清华大学出版社,1999,276-280.
[8]林文焕.机床夹具设计[M].北京:国防工业出版社,1987,107-156.
[9] Edward G? Hoffman. Jig and Fixture Design (Fourth Edition). Albany, USA: Delmar Publishers. 1996. 171-200.
[10]唐中一,于今.顾庆详编著.复合传动与控制[M].重庆:重庆大学出版社,2004.
[11]曹华,钟康民.对称型齿条-齿轮-铰杆机构在液压传动中的应用.新技术新工艺,2004(10):43-44.
[12] Zhong Kangmin, Guo Peiquan. Orthogonal reinforcement mechanism. and hydraulic drive. In: Proceedings of tenth world congress on the theory of machines and mechanisms(Vol5)[J]. Oulu, Finland: Oulu University Press,1999,2037-2042
[13]钟康民.简论对称性美学思想指导下的机械设计创新.机械设计,2004(专辑):94-95,56.
[14]机床设计手册(3.部件、机构及总体设计),机械工业出版社,1986.
[15]陆雯,钟康民.气动肌腱与铰杆增力机构的三种组合系统及其比较[J].机械设计,2005,(2).
[16]侯伟丽.21世纪中国绿色发展问题研究[J].南都学坛(人文社会科学报),2004,24(3):106-110
[17]黄德中.工程机械的绿色设计[J].水利电力机械,2004,26,4:32-34
[18] R.F.Fung,KenWang chen. Dynamic Analysis and vibration Control of a Flexible slider-crank Mechanism using a PM synchronous servo Motor drive[J].Journal of Sound and Vibration,1998,214(4):605-637.
[19] Shivpuri R.s.Yossifon. A servo motor driven multi-action Press for sheet metal Forming[J].International journal of Machinery tool Manufacture,1991,31:345-359.
[20] Shivpuri R.s.Yossifon. Analysis and comparison of selected rotary linkage drives for mechanical Press[J]. Intenationa1 Journa1 of Machinery tool Manufacture,1993,2:175-189.
[21]魏良模,朱新榕,孙友松,魏航变速驱动曲柄压力机运动分析[J]锻压装备与制造技术,2004,3:32一34.
[22]徐大任.AC伺服冲压机及其应用[J].机械工人,2005 (4).
[23]何德誉.曲柄压力机[J].北京:机械工业出版社,1981.
[24]商思岳.台湾锻压机床行业研究与借鉴[J].锻压装备与制造技术,2005,3:25-27.
[25]张俊,魏红根.数控技术发展趋势——智能化数控系统[J]制造技术与机床,2000,4:7-9.
[26]陈正中.高速精密压力机特点及其发展趋势.锻压机械,1998,21, 3: 8-9
[27]陈新.机械结构动态设计理论与方法及应用.北京:机械工业出版社,1997.
[28]赵匀.机构数值分析与综合[M].北京:机械工业出版社,2005.
[29] Robert L. Noton. An Introduction to the Synthesis and Analysis of Mechanisms and Machines[M].2002
[30]华大年.连杆机构设计与应用创新[M].北极:机械工业出版社,2007.
[31]陈志嵩,钟康民.铰杆——杠杆串联组合机构分析及其应用[J].机械设计.
[32] ZhiSong Chen, Kangmin Zhong . Innovative interpretation and patterns of toggle - levers tandem combinations force amplifier. ICFDM2008 be held during September 23-26, 2008 in Tianjin, China.
[33]二代龙震工作室.Pro/ENGINEER Wildfire 3.0基础设计[M].北京:电子工业出版社,2007.
[34]钟日铭.Pro/ENGINEER Wildfire 3.0中文版装配设计与产品实例[M].北京:机械工业出版社,2007.
[35]二代龙震工作室.Pro/Mechanism/MECHANICA Wildfire 2.0机构/运动/结构/热力分析[M].北京:电子工业出版社,2007.
[36]高会生,李新叶,胡智奇.MATLAB原理与工程应用:With applications from mechanical, aerospace, electrical, and civil engineering[M].北京:电子工业出版社,2006.
[37]飞思科技产品研发中心. MATLAB 6.5辅助优化计算与设计[M].北京:电子工业出版社,2003.
[38]罗建军. MATLAB教程[M].北京:电子工业出版社,2005.
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