基于DSPACE的单机架可逆轧机硬件在回路仿真系统的研究
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摘要
轧机控制系统的调试是轧机设计中不可或缺的手段。它的设计是基于控制对象数学模型的，这种方案设计出的控制系统直接应用在轧机上，效果不好，到现场以后还需要反复的加以调试修改甚至重新设计，这样就增加了调试的周期和成本，因此能否使仿真和测试实际应用效果两者更加接近，缩短调试周期，降低成本，提高效率就成了关键。本文尝试借助DSPACE硬件在回路仿真平台来实现对轧机控制系统的实时测试。平台中控制系统部分采用实物控制器，并借助DSPACE实时仿真计算机实时运行控制对象模型来虚拟出一台轧机，实现对轧机控制系统实时的闭环测试。
首先建立了完整的单机架可逆轧机数学模型，主要包括了液压压下系统、速度系统和张力系统三部分。液压压下系统中在考虑了电液伺服阀的非线性和不对称性、伺服油缸和轧机辊系机架变形的基础上建立了一个简化的二自由度的轧机压下系统模型适用于实时系统的快速计算；建立了电流速度双闭环的速度调节系统模型；结合带钢的前后滑值、实际轧制速度等情况，建立了单机架开卷取张力系统模型。最终将三个系统通过轧制力模型耦合在一起离线仿真，并分别对模型进行了仿真验证。
接下来详细介绍了DSPACE软硬件系统及硬件在回路仿真技术，分析了轧机硬件在回路仿真平台的原理及逻辑上的可行性和可实施性，并设计了轧机硬件在回路仿真的平台，总结了轧机硬件在回路仿真的设计步骤。
最后以燕山大学300实验轧机为对象搭建了轧机控制系统的硬件在回路仿真平台。通过进行仿真实验，验证了实验平台的可行性、轧机控制系统的有效性以及模型的正确性。这种方法可以为以后新建轧机控制系统提供一种更接近实际的调试方案。
The simulation debugging of the mill's control system is an experiment，which isestablished on the control system model. It is a necessary method in the design of mills.Such a control system designed by the program is applied directly to a mill, whose effectis not very good. When used in factory, it needs repeatedly debugging and modifying, oreven redesigning, which increases the cost of debugging. Therefore, whether the effect ofthe simulation and practical application can be more similar, it is critical to shorten thedebugging cycle, reduce costs and improve efficiency. In this paper, the DSPACEhardware in-the-loop simulation platform is made use of to achieve test on mill controlsystem. The practical controller is applied to the control system in the platform. Controlobject model with the help of the DSPACE real-time simulation computer’s real-timerunning designs a real-time mill closed-loop simulation system.
First, this paper formulates a complete single-stand reversing mill mathematicalmodel. And it consists of the hydraulic pressure system, the speed system and tensionsystem. A simplified 2-DOF (degree-of-freedom) mill pressure system model isestablished on the basis of the nonlinearity and asymmetry of the electro-hydraulic servovalve, servo cylinder and mill deformation. Meanwhile, the current speed double closedloop speed regulation system model is also set up. Besides, taking into account theforward and backward slid values and the actual rolling speed of the strip steel, onesingle-stand unwrapping and coiling-up system tension model is built in this paper. Finally,offline simulation is developed after the three systems are coupled together by the rollingforce model.
Second, this paper gives a detailed account of DSPACE hardware and softwaresystems, and also hardware-in-loop simulating technology. At the same time, the principleof the mill hardware-in-the-loop simulation platform is presented by the logical andpractical analysis. Moreover, the text summarizes the normal procedures of thehardware-in-loop simulation.
Finally, this paper takes Yanshan University laboratory mill as the subject, hardware in-the-loop simulation platform is built, and meanwhile it proves the feasibility of theexperimental platform, which provides a more practical debug scenario to new-built millcontrol systems in future.
首先建立了完整的单机架可逆轧机数学模型，主要包括了液压压下系统、速度系统和张力系统三部分。液压压下系统中在考虑了电液伺服阀的非线性和不对称性、伺服油缸和轧机辊系机架变形的基础上建立了一个简化的二自由度的轧机压下系统模型适用于实时系统的快速计算；建立了电流速度双闭环的速度调节系统模型；结合带钢的前后滑值、实际轧制速度等情况，建立了单机架开卷取张力系统模型。最终将三个系统通过轧制力模型耦合在一起离线仿真，并分别对模型进行了仿真验证。
接下来详细介绍了DSPACE软硬件系统及硬件在回路仿真技术，分析了轧机硬件在回路仿真平台的原理及逻辑上的可行性和可实施性，并设计了轧机硬件在回路仿真的平台，总结了轧机硬件在回路仿真的设计步骤。
最后以燕山大学300实验轧机为对象搭建了轧机控制系统的硬件在回路仿真平台。通过进行仿真实验，验证了实验平台的可行性、轧机控制系统的有效性以及模型的正确性。这种方法可以为以后新建轧机控制系统提供一种更接近实际的调试方案。
The simulation debugging of the mill's control system is an experiment，which isestablished on the control system model. It is a necessary method in the design of mills.Such a control system designed by the program is applied directly to a mill, whose effectis not very good. When used in factory, it needs repeatedly debugging and modifying, oreven redesigning, which increases the cost of debugging. Therefore, whether the effect ofthe simulation and practical application can be more similar, it is critical to shorten thedebugging cycle, reduce costs and improve efficiency. In this paper, the DSPACEhardware in-the-loop simulation platform is made use of to achieve test on mill controlsystem. The practical controller is applied to the control system in the platform. Controlobject model with the help of the DSPACE real-time simulation computer’s real-timerunning designs a real-time mill closed-loop simulation system.
First, this paper formulates a complete single-stand reversing mill mathematicalmodel. And it consists of the hydraulic pressure system, the speed system and tensionsystem. A simplified 2-DOF (degree-of-freedom) mill pressure system model isestablished on the basis of the nonlinearity and asymmetry of the electro-hydraulic servovalve, servo cylinder and mill deformation. Meanwhile, the current speed double closedloop speed regulation system model is also set up. Besides, taking into account theforward and backward slid values and the actual rolling speed of the strip steel, onesingle-stand unwrapping and coiling-up system tension model is built in this paper. Finally,offline simulation is developed after the three systems are coupled together by the rollingforce model.
Second, this paper gives a detailed account of DSPACE hardware and softwaresystems, and also hardware-in-loop simulating technology. At the same time, the principleof the mill hardware-in-the-loop simulation platform is presented by the logical andpractical analysis. Moreover, the text summarizes the normal procedures of thehardware-in-loop simulation.
Finally, this paper takes Yanshan University laboratory mill as the subject, hardware in-the-loop simulation platform is built, and meanwhile it proves the feasibility of theexperimental platform, which provides a more practical debug scenario to new-built millcontrol systems in future.
引文
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[2]赫培峰,崔建江,潘峰.计算机仿真技术[M].北京:机械工业出版社, 2009: 35-48.
[3]张大勇.电力机车用大功率交流传动系统的优化设计[D].长沙：中南大学交通信息工程及控制学科硕士学位论文, 2007: 6-7.
[4]郭齐胜,董志明,单家元,等.系统仿真[M].北京:国防工业出版社, 2006: 142.
[5]单家元,孟秀云,等.半实物仿真系统[M].北京:国防工业出版社, 2008: 4.
[6]朱辉,王丽清,程昌圻,柴油机电控单元硬件在回路仿真系统研究[J].内燃机学报, 1998,16(4): 389-398.
[7]李长文,张宏波,赵长禄,等. ECU硬件在回路柴油机控制仿真平台研究[J].北京理工大学学报, 2004, 24(5): 407-410.
[8]李彬轩,吴锋,何文华,等.柴油机ECU硬件在回路仿真系统的设计[J].浙江大学学报(工学版), 2002,36(2): 177-182.
[9]于世涛,谭文春,等.高压共轨电控系统嵌入式实时软件系统[J].上海交通大学学报,2006,35(2),45-48.
[10]丁威介,柴油机电控单元硬件在回路仿真系统设计[D].北京：北京交通大学电力牵引与传动控制专业硕士学位论文, 2010: 8-9.
[11]孙娜,于梅,袁爱进.基于LabVIEW的纯实时仿真方法及应用[J].控制工程, 2007: 14(6),55-58.
[12]程健庆.军用系统建模与仿真技术发展与展望[J].指挥控制与仿真, 2007(4): 35-37.
[13] DSPACE User Guide. Implementation Guide[M]．DSPACE Inc．2003: 90-98.
[14]张晓华,薛定宇.系统建模与仿真[M].北京:清华大学出版社, 2006: 31-32.
[15]王益群,陈春明,张伟,等.虚拟轧制技术研究进展的评述[J].机械工程学报, 2010, 46(2):35-38.
[16] Frank Feldmann. Application of Fuzzy Logic Technology to Tandem Mill Transitional GaugeVariation[J]. Iron and Steel Engineer, 1998, (6): 40-43.
[17] GUO Remn-Min. Analysis of dynamic behaviors of tandem cold mills using generalized dynamicand control equations[C]. Conference Record - IAS Annual Meeting (IEEE Industry ApplicationsSociety), Glasgow, 1999, 1: 571-580.
[18] ZIAEI, Shahyar. Virtual rolling mills: Bar and structural mill design and optimization usingcomputer simulations[J]. AISE Steel Technology, 2000, 77(9): 44-45.
[19] Sansai K, Yildiz.Fraser Forbes, J.Huang Biao. Dynamic modelling and simulation of a hot stripfinishing mill [J]. Applied Mathematical modeling, 2009, 33(7): 3208-3225.
[20] Jepsen, O.N.,Kneppe, G.System. Simulation and mill modeling illustrated by the example ofchatter in tandem cold rolling mills[J]. MPT Metallurgical Plant and Technology International,1996, 19(6): 80-86.
[21] Eugenio, Brosa.Luca Lemma. Numerical and experimental analysis of the dynamic effects incompact cluster mills for cold rolling[J]. Journal of Materials Processing Technology, 2009,209(5): 2436-2445.
[22]张伟,王益群,高英杰.板带轧机液压压下系统的建模与仿真[J].液压与气动. 2004, 23(1):40-43.
[23]高英杰.轧机AGC系统动态模型的研究[J].燕山大学学报, 1998, 22(3): 259-262.
[24]潘学军.冷连轧过程仿真软件包的研制[J].系统仿真学报, 1998, 10(4): 20-24.
[25]方一鸣.冷连轧机速度系统建模仿真及鲁棒控制研究[D].秦皇岛：燕山大学机械电子工程学科博士学位论文, 2003; 4.
[26]铁鸣,柴天佑.冷连轧仿真系统虚拟对象级的设计要点[J].东北大学学报, 2007,6(28).51-53.
[27]崔建江,陈大力,潘峰,等.基于高层体系结构的冷轧机仿真系统设计[J].系统仿真学报,2009, 1(12) : 55-59.
[28]王益群,张伟,高英杰,等.虚拟冷连轧数字仿真研究[J].中国机械工程, 2003,2(12): 68-70.
[29]郑申白,韩冬,方敏.中板轧机的仿真探讨杨[J].河南冶金, 2007,8(4): 35-47.
[30]彭光辉.模块化连轧过程动态仿真开发[J].河北理工大学学报:自然科学版, 2009,5(2):33-35.
[31]陈连生,王淑华,赵晶,等.宽带钢热连轧精轧机组板形控制仿真系统[C]. 2006年河北省轧钢技术与学术年, 2006:48-50
[32]赵丽娟,胡建华.冷连轧机板形与板厚控制系统的建模与仿真[J].机械与电子, 2007,4( 10):45-48.
[33]彭艳,孙建亮,刘宏民.基于板形板厚控制的轧机系统动态建模及仿真研究进展[J].燕山大学学报, 2010, 34(1): 5-12.
[34]王为人,孙一康,王正林.冷连轧机液压APC系统半实物仿真[J].冶金设备, 2004, 10(5): 5-7.
[35]王正林,童朝南,孙一康,等.带钢热连轧AGC系统实时仿真[J].北京科技大学学报, 2005,10(5): 600-603.
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