盾构机刀盘同步驱动系统自适应均载控制研究
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摘要
盾构机是用于基础设施建设及资源开发的重大技术装备,目前其核心技术主要由少数发达国家垄断。由于核心技术的缺失,我国进口的几百台盾构机已经花费200多亿元资金,一台进口盾构机的价格高达几千万元,而且使用寿命有限。因此,开展盾构机的理论研究,掌握其核心技术意义重大,体现了我国装备制造业的发展需求。盾构机掘进过程中,复杂多变的地质环境及多场耦合作用所引起的掘进界面载荷剧烈波动,极易造成主驱动系统中的驱动扭矩失衡,甚至导致驱动轴等关键部件非正常损坏。因此,主驱动系统的同步控制是关系到盾构机安全可靠运行的核心技术之一。本课题就盾构机主驱动同步控制这一科学问题,为解决现有控制方法同步性能较差的问题,以提出顺应掘进环境变化,保证切削过程安全,实现驱动扭矩快速均衡的主驱动系统同步控制策略为目标开展研究。
盾构机掘进过程中,影响驱动扭矩分布均衡的主要因素包括掘进界面的载荷波动、传动机构的非线性因素及控制系统的同步性能等几个方面。本文研究工作即围绕上述影响因素开展。
分析复杂地质条件下刀盘负载波动特性,研究地质情况、盾构埋深、掘进速度及刀盘转速对载荷波动的影响,可以为进一步确定载荷波动大小对主驱动系统均载性能的影响程度提供基础。现有的针对盾构机主驱动系统均载特性的研究中,对外部激励如载荷波动及驱动同步性能的影响关注较少,不能更好地反映整个系统的均载特性,因此需要分析弯扭耦合作用下的主驱动系统载荷传递规律,建立考虑齿轮传动机构非线性因素、驱动源及变载荷影响的齿轮传动系统动力学模型,并在此基础上分析系统均载特性。
盾构机主驱动系统中机械传动机构非线性与驱动电机同步性能的交互作用,最终影响了主驱动系统驱动扭矩的均衡性能,因此有必要将齿轮传动系统与多电机同步控制系统作为一个有机整体,建立盾构机主驱动系统的机电耦合数学模型,解决由于系统多变量、强耦合特性为研究载荷波动、齿轮传动非线性及驱动同步性能对系统均载性能影响中所带来的困难。
分析盾构机主驱动系统现有控制方法的同步性能,提出一种实现系统闭环控制的环形耦合控制结构；并且针对实际运行中驱动电机输出转矩值偏离给定值的现象,利用历史数据通过对有限时段电机电流的期望估计预测各电机电流值偏移趋势,调整各电机转矩给定值,从而改善系统同步性能,达到自适应均载的目的。通过以工程实例为基础的仿真分析,及以模拟实验平台为基础的实验研究,验证所提出理论和方法的正确性和有效性。
通过机理分析和仿真分析可知,盾构在软土混合地质中掘进时,刀盘扭矩随着泥质粘土含量的增大而降低；除了地质参数以外,刀盘扭矩波动程度随埋深的增加呈线性增长,随掘进速度的增大呈近似线性增长,随刀盘转速的增大呈幂指数形式降低。从载荷波动及冗余驱动同步性能影响的角度分析了系统均载特性,研究发现刀盘载荷波动率、传动系统非线性因素等影响了各齿轮均载系数曲线的幅值,而各齿轮均载系数曲线的分散程度则主要受齿轮驱动转矩同步性能影响,这表明驱动电机的同步性能是影响系统均载的关键性因素。
将齿轮传动系统与冗余电机同步控制系统作为一个有机整体,提出了盾构机主驱动系统的机电耦合模型,并以工程实测数据为基础的仿真验证了模型的有效性。通过仿真分析揭示了断轴事故原因：现有的主驱动系统同步控制策略不能实时补偿系统同步误差,顺应载荷突变的能力较差,刀盘载荷剧变会导致驱动轴扭矩瞬间失衡,进而造成断轴事故的发生。在此基础上,提出一种自适应均载控制策略,并通过机理分析和与现有控制方法的对比仿真,证明了所提出控制策略的有效性。仿真结果表明,载荷突变时系统同步误差瞬时增大,且随着载荷变化率的增加呈上升趋势；相对于现有的控制策略,本文提出的自适应均载控制策略使系统同步误差大幅降低,因而可以有效地顺应载荷突变,减少断轴事故的发生。
刀盘模拟驱动实验可以更真实地反映在现场因素作用下,不同的控制策略对驱动扭矩同步性能的影响,进一步验证通过数字仿真得到的结论。基于转矩主从控制策略的实验结果与仿真结果相符,验证了仿真模型的有效性及实验研究的可行性。采用本文提出的自适应均载控制策略时,驱动扭矩同步性能明显优于转矩主从控制策略,即本文所提出控制策略是有效的。
Shield machine is the Major technical equipment badly in need in national infrastructure construction, resource development and national defense construction. At present, the core technology of shield machine is mainly monopolized by a few developed countries. Due to the lack of core technology, China's imports of hundreds of shield machine with limited service life has spent more than200billion yuan of funds. Therefore, it is of great significance to carry out theoretical studies of the shield machine and master its core technology, which reflects the development needs of China's equipment manufacturing industry.The service conditions of shield machine is extremely complex. The driving interface load fluctuation caused by geological environment changes and multi field coupling of stress field, temperature field, seepage field in operation process, may lead into imbalance of redundant drive motors output torque in main driving system, even leading to the abnormal damage of drive shaft and other key components. Therefore, the shield machine driving synchronous control is one of the key technologies of shield machine. This article is in view of the shield machine main driving synchronous control, achieving the system's adaptive load sharing, in order to adapt to the boring environment changes and improve the driving safety and efficiency.
The main factors to affect the equilibrium distribution of drive torque include load fluctuations, the nonlinear factors of the transmission mechanism and the synchronization performance of the control system. The study is carried out around the above factors.
Analyze the cutter torque ripple characteristics in complex geological conditions, study the impact of geology, shield depth, the driving speed and the cutter speed on load fluctuations, which can further determine its impact on the main drive system load sharing performance. Establish the load transfer model of main driving system with the multi-structural constraints of cutter structure, main bearings, supports, and the coupling of bending and torsion. Gear transmission system dynamics model is established considering the nonlinear factors of gear transmission, drive source and variable load effect.
Establish the mathematical model of main driving system considering the nonlinear factors of gear transmission and the multi-motor parameter dispersion, based on multi-motor control system model and gear transmission system model. The validity of the model is verified through the simulation analysis method.
Research the system synchronization performance using the existing main drive system control method, and a new ring-coupled synchronous control structure is proposed, which is closed-loop to the synchronization index, and can effectively improve the synchronization performance. A control parameter adaptive method is proposed which make motors have good dynamic and static performance. Put forward an algorithm to predict the current value trend of offset using historical data, and adjust the motor torque given value according to the predictive value, further improving the synchronization performance. Based on the actual engineering data simulation, verify the validity of the proposed control method. Design and set up the experiment platform with the gear transmission system and multi-motor drive system. The comparison of the synchronous performance of the two kinds of control strategies under the same load case is given to verify the proposed control strategy is effective.
The research results show that the cutterhead torque decreases as the the muddy clay content increases, the degree of the cutterhead torque fluctuations increases linearly with the shield, increases nearly linear with the driving speed growth, and reduces in exponential form with the cutterhead speed growth. The oscillation amplitude of Gear load sharing coefficient suffer a big effect from load fluctuation rate, gear nonlinear factors and rotation speed of cutterhead, and the dispersion degree of gear load sharing coefficient curves is impacted by synchronous performance of driving torque, that is the load sharing coefficient of gear transmission in shield machine is influenced mainly by multi-driving synchronous performance.
Put forward the electromechanical coupling model of shield machine main driving system based on a gear transmission system with a multi-motor synchronous control system as an organic whole. The validity of the model is verified through the simulation analysis based on real engineering data. The cause of the broken shaft accident is revealed that the existing synchronous control methods of cutterhead motor-drive system are open-loop control for the synchronization control targets without real-time synchronization error compensation, which have led to the synchronization performance of the existing main driving system is not ideal. When overloaded and load fluctuations, the drive shaft torque is not balanced, and even could lead to the safety shaft fracture or drive components of non-normal damage.The validity of the new control strategy is proved through mechanism analysis, and the simulation based on the actual engineering data verifies the superiority of the proposed control method. The simulation results show that system synchronization error transiently increases in load mutation, and increases with the increase of it. The new strategy can make the system synchronization error greatly reduced, thus it can effectively adapt to load mutation, and reduce shaft broken accident.
The experimental table for main driving system can realize the comparison experiment of different synchronous control strategies, with monitoring of motor speed, torque and current data. The experimental results coincide with the simulation results, which can prove the validity of the the model and the experimental method, and the effectiveness of the new control strategy.
盾构机掘进过程中,影响驱动扭矩分布均衡的主要因素包括掘进界面的载荷波动、传动机构的非线性因素及控制系统的同步性能等几个方面。本文研究工作即围绕上述影响因素开展。
分析复杂地质条件下刀盘负载波动特性,研究地质情况、盾构埋深、掘进速度及刀盘转速对载荷波动的影响,可以为进一步确定载荷波动大小对主驱动系统均载性能的影响程度提供基础。现有的针对盾构机主驱动系统均载特性的研究中,对外部激励如载荷波动及驱动同步性能的影响关注较少,不能更好地反映整个系统的均载特性,因此需要分析弯扭耦合作用下的主驱动系统载荷传递规律,建立考虑齿轮传动机构非线性因素、驱动源及变载荷影响的齿轮传动系统动力学模型,并在此基础上分析系统均载特性。
盾构机主驱动系统中机械传动机构非线性与驱动电机同步性能的交互作用,最终影响了主驱动系统驱动扭矩的均衡性能,因此有必要将齿轮传动系统与多电机同步控制系统作为一个有机整体,建立盾构机主驱动系统的机电耦合数学模型,解决由于系统多变量、强耦合特性为研究载荷波动、齿轮传动非线性及驱动同步性能对系统均载性能影响中所带来的困难。
分析盾构机主驱动系统现有控制方法的同步性能,提出一种实现系统闭环控制的环形耦合控制结构；并且针对实际运行中驱动电机输出转矩值偏离给定值的现象,利用历史数据通过对有限时段电机电流的期望估计预测各电机电流值偏移趋势,调整各电机转矩给定值,从而改善系统同步性能,达到自适应均载的目的。通过以工程实例为基础的仿真分析,及以模拟实验平台为基础的实验研究,验证所提出理论和方法的正确性和有效性。
通过机理分析和仿真分析可知,盾构在软土混合地质中掘进时,刀盘扭矩随着泥质粘土含量的增大而降低；除了地质参数以外,刀盘扭矩波动程度随埋深的增加呈线性增长,随掘进速度的增大呈近似线性增长,随刀盘转速的增大呈幂指数形式降低。从载荷波动及冗余驱动同步性能影响的角度分析了系统均载特性,研究发现刀盘载荷波动率、传动系统非线性因素等影响了各齿轮均载系数曲线的幅值,而各齿轮均载系数曲线的分散程度则主要受齿轮驱动转矩同步性能影响,这表明驱动电机的同步性能是影响系统均载的关键性因素。
将齿轮传动系统与冗余电机同步控制系统作为一个有机整体,提出了盾构机主驱动系统的机电耦合模型,并以工程实测数据为基础的仿真验证了模型的有效性。通过仿真分析揭示了断轴事故原因：现有的主驱动系统同步控制策略不能实时补偿系统同步误差,顺应载荷突变的能力较差,刀盘载荷剧变会导致驱动轴扭矩瞬间失衡,进而造成断轴事故的发生。在此基础上,提出一种自适应均载控制策略,并通过机理分析和与现有控制方法的对比仿真,证明了所提出控制策略的有效性。仿真结果表明,载荷突变时系统同步误差瞬时增大,且随着载荷变化率的增加呈上升趋势；相对于现有的控制策略,本文提出的自适应均载控制策略使系统同步误差大幅降低,因而可以有效地顺应载荷突变,减少断轴事故的发生。
刀盘模拟驱动实验可以更真实地反映在现场因素作用下,不同的控制策略对驱动扭矩同步性能的影响,进一步验证通过数字仿真得到的结论。基于转矩主从控制策略的实验结果与仿真结果相符,验证了仿真模型的有效性及实验研究的可行性。采用本文提出的自适应均载控制策略时,驱动扭矩同步性能明显优于转矩主从控制策略,即本文所提出控制策略是有效的。
Shield machine is the Major technical equipment badly in need in national infrastructure construction, resource development and national defense construction. At present, the core technology of shield machine is mainly monopolized by a few developed countries. Due to the lack of core technology, China's imports of hundreds of shield machine with limited service life has spent more than200billion yuan of funds. Therefore, it is of great significance to carry out theoretical studies of the shield machine and master its core technology, which reflects the development needs of China's equipment manufacturing industry.The service conditions of shield machine is extremely complex. The driving interface load fluctuation caused by geological environment changes and multi field coupling of stress field, temperature field, seepage field in operation process, may lead into imbalance of redundant drive motors output torque in main driving system, even leading to the abnormal damage of drive shaft and other key components. Therefore, the shield machine driving synchronous control is one of the key technologies of shield machine. This article is in view of the shield machine main driving synchronous control, achieving the system's adaptive load sharing, in order to adapt to the boring environment changes and improve the driving safety and efficiency.
The main factors to affect the equilibrium distribution of drive torque include load fluctuations, the nonlinear factors of the transmission mechanism and the synchronization performance of the control system. The study is carried out around the above factors.
Analyze the cutter torque ripple characteristics in complex geological conditions, study the impact of geology, shield depth, the driving speed and the cutter speed on load fluctuations, which can further determine its impact on the main drive system load sharing performance. Establish the load transfer model of main driving system with the multi-structural constraints of cutter structure, main bearings, supports, and the coupling of bending and torsion. Gear transmission system dynamics model is established considering the nonlinear factors of gear transmission, drive source and variable load effect.
Establish the mathematical model of main driving system considering the nonlinear factors of gear transmission and the multi-motor parameter dispersion, based on multi-motor control system model and gear transmission system model. The validity of the model is verified through the simulation analysis method.
Research the system synchronization performance using the existing main drive system control method, and a new ring-coupled synchronous control structure is proposed, which is closed-loop to the synchronization index, and can effectively improve the synchronization performance. A control parameter adaptive method is proposed which make motors have good dynamic and static performance. Put forward an algorithm to predict the current value trend of offset using historical data, and adjust the motor torque given value according to the predictive value, further improving the synchronization performance. Based on the actual engineering data simulation, verify the validity of the proposed control method. Design and set up the experiment platform with the gear transmission system and multi-motor drive system. The comparison of the synchronous performance of the two kinds of control strategies under the same load case is given to verify the proposed control strategy is effective.
The research results show that the cutterhead torque decreases as the the muddy clay content increases, the degree of the cutterhead torque fluctuations increases linearly with the shield, increases nearly linear with the driving speed growth, and reduces in exponential form with the cutterhead speed growth. The oscillation amplitude of Gear load sharing coefficient suffer a big effect from load fluctuation rate, gear nonlinear factors and rotation speed of cutterhead, and the dispersion degree of gear load sharing coefficient curves is impacted by synchronous performance of driving torque, that is the load sharing coefficient of gear transmission in shield machine is influenced mainly by multi-driving synchronous performance.
Put forward the electromechanical coupling model of shield machine main driving system based on a gear transmission system with a multi-motor synchronous control system as an organic whole. The validity of the model is verified through the simulation analysis based on real engineering data. The cause of the broken shaft accident is revealed that the existing synchronous control methods of cutterhead motor-drive system are open-loop control for the synchronization control targets without real-time synchronization error compensation, which have led to the synchronization performance of the existing main driving system is not ideal. When overloaded and load fluctuations, the drive shaft torque is not balanced, and even could lead to the safety shaft fracture or drive components of non-normal damage.The validity of the new control strategy is proved through mechanism analysis, and the simulation based on the actual engineering data verifies the superiority of the proposed control method. The simulation results show that system synchronization error transiently increases in load mutation, and increases with the increase of it. The new strategy can make the system synchronization error greatly reduced, thus it can effectively adapt to load mutation, and reduce shaft broken accident.
The experimental table for main driving system can realize the comparison experiment of different synchronous control strategies, with monitoring of motor speed, torque and current data. The experimental results coincide with the simulation results, which can prove the validity of the the model and the experimental method, and the effectiveness of the new control strategy.
引文
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