尾桨叶梁成型设备关键技术研究
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摘要
叶梁(树酯基复合材料)热压成型过程中,存在着许多复杂的环节,其中两大关键技术对产品质量造成很大的影响,即温度和压力控制。对它们进行完善的计算机控制和仿真是成型过程安全可靠、产品质量合格的保障。
在温度系统中,通过系统需求分析,首先从热学性能、可加工性和机械性能三个方面对热压模具的材料进行了选择,确定热压模具的材料为模具钢(5CrMnMo),然后根据项目需求和现有的技术条件,确定了温控系统的加热/制冷方案。最后根据热压设备几个关键部位处对隔热材料的不同需求,选择了聚四氟乙烯作为隔热材料。同时对温度控制系统的硬件电路进行了设计和配置。
利用ANSYS分析了叶梁热压后的温度分布情况,分析结果表明叶梁温差为6.398℃,与实际测量一致,但是距离要求温差在2%以内的要求相差太大。本课题要求温度均匀一致,这样大的温差显然不符合要求。之后对影响热压面温度均匀性的原因进行分析。首先分析了热压模具和周围环境之间的热损失对热压面稳态温度均匀性的影响,给出了在热压头侧面加隔热材料和调节加热功率的解决方案;其次从热压头材料的热扩散率的角度出发,分析了热扩散率对热压面动态温度均匀性的影响,并分别从保持现有热压头结构不变和改变热压头结构两个方面,给出了增大热压模具热扩散率的解决方案。最后采用在叶梁两端温度较低的区域并联两个管排式结构加热器来解决温度分布不均匀的问题。方案选定好后,采用ANSYS软件进行改进实验,有规律的改变管路在模具内的分布进行瞬态温度场分析,得到的分析结果温差为0.187℃,满足温差要求。
在压力控制系统的设计上,本课题设计了热压系统的液压回路包括前后回路、出口节流调速回路、主蓄能器回路、增压蓄能器回路和增压控制回路,继而对压力控制系统做了总体设计,采用工控机与可编程控制器(PLC)构成的两级控制模式,负责热压机的动作顺序控制和压力的控制。建立了压力控制系统的数学模型,利用MATLAB的SIMULINK工具箱对其进行了仿真,建模、仿真和分析,得到了系统在常规PID控制器作用下对不同控制信号的响应曲线和特性参数,定量地分析了系统的动态指标。得到了阶跃信号下的响应曲线。在参数为Kp=10,Ki=0.8,Kd=0.3的PID控制下,系统的速度响应能较好地跟随控制信号,建压时间可以满足要求。
In molding process of resinous matrix composites by hot-pressing, many complicated physical and chemical changes exist and many intricate factors affect quality of the products. The most important element is temperature and pressure. Computer control system for its formation process is the guarantee of high quality of final products, and it also makes the whole process much reliable.
The scheme of system is investigated. According to the diathermancy and the mechanical ability, the material of hot-pressing block is decided. The conduction oil as heat element and the circulating-oil cooling as cooling method are employed in temperature system by comparing several heat/cooling projects. The heat insulation material is selected.
Using ANSYS simulate the distribution of temperate. The result shows that the temperature difference is 6.398"C.But the range is out of the demanding. Then I am analysis the impact on the distribution of temperate. First the thermal loss between the mould and surrounding environments is explained and the solution is given. Secondly, considering diffusion rate of material, the analysis of this is given. Finally, parallel two tubes in temperature lower region to solve the temperature distribution non-uniformity problem. The plan is carried on by ANSYS software to improve the temperature non-uniformity problem, through the changing of pipeline and then obtains the result that the temperature difference is 0.187℃, so satisfied the request.
Then, the blue print of injection system of pressing, which includes hydraulic circle design, control scheme design, hardware choose, software structure design, is presented. The fact that the injection process is a process with high speed and high pressure requires the control valves and sensors to have rapid response and fine precision, sampling plate to has high Sampling frequency, control software to has better real-time property. In this paper, the principle of injection system of pressing machine based on electro-hydraulic proportional control is introduced in detail. In order to get a in-depth and visual understanding of the performance of real-time controlled injection system, MTALB and its SIMULINK toolbox is used to build model, simulation and analyze for velocity control system and pressure control system of injection process. As result, response curves and dynamic characteristic parameters, which roundly represent the system performance, are obtained under various control signals during common PID control.
在温度系统中,通过系统需求分析,首先从热学性能、可加工性和机械性能三个方面对热压模具的材料进行了选择,确定热压模具的材料为模具钢(5CrMnMo),然后根据项目需求和现有的技术条件,确定了温控系统的加热/制冷方案。最后根据热压设备几个关键部位处对隔热材料的不同需求,选择了聚四氟乙烯作为隔热材料。同时对温度控制系统的硬件电路进行了设计和配置。
利用ANSYS分析了叶梁热压后的温度分布情况,分析结果表明叶梁温差为6.398℃,与实际测量一致,但是距离要求温差在2%以内的要求相差太大。本课题要求温度均匀一致,这样大的温差显然不符合要求。之后对影响热压面温度均匀性的原因进行分析。首先分析了热压模具和周围环境之间的热损失对热压面稳态温度均匀性的影响,给出了在热压头侧面加隔热材料和调节加热功率的解决方案;其次从热压头材料的热扩散率的角度出发,分析了热扩散率对热压面动态温度均匀性的影响,并分别从保持现有热压头结构不变和改变热压头结构两个方面,给出了增大热压模具热扩散率的解决方案。最后采用在叶梁两端温度较低的区域并联两个管排式结构加热器来解决温度分布不均匀的问题。方案选定好后,采用ANSYS软件进行改进实验,有规律的改变管路在模具内的分布进行瞬态温度场分析,得到的分析结果温差为0.187℃,满足温差要求。
在压力控制系统的设计上,本课题设计了热压系统的液压回路包括前后回路、出口节流调速回路、主蓄能器回路、增压蓄能器回路和增压控制回路,继而对压力控制系统做了总体设计,采用工控机与可编程控制器(PLC)构成的两级控制模式,负责热压机的动作顺序控制和压力的控制。建立了压力控制系统的数学模型,利用MATLAB的SIMULINK工具箱对其进行了仿真,建模、仿真和分析,得到了系统在常规PID控制器作用下对不同控制信号的响应曲线和特性参数,定量地分析了系统的动态指标。得到了阶跃信号下的响应曲线。在参数为Kp=10,Ki=0.8,Kd=0.3的PID控制下,系统的速度响应能较好地跟随控制信号,建压时间可以满足要求。
In molding process of resinous matrix composites by hot-pressing, many complicated physical and chemical changes exist and many intricate factors affect quality of the products. The most important element is temperature and pressure. Computer control system for its formation process is the guarantee of high quality of final products, and it also makes the whole process much reliable.
The scheme of system is investigated. According to the diathermancy and the mechanical ability, the material of hot-pressing block is decided. The conduction oil as heat element and the circulating-oil cooling as cooling method are employed in temperature system by comparing several heat/cooling projects. The heat insulation material is selected.
Using ANSYS simulate the distribution of temperate. The result shows that the temperature difference is 6.398"C.But the range is out of the demanding. Then I am analysis the impact on the distribution of temperate. First the thermal loss between the mould and surrounding environments is explained and the solution is given. Secondly, considering diffusion rate of material, the analysis of this is given. Finally, parallel two tubes in temperature lower region to solve the temperature distribution non-uniformity problem. The plan is carried on by ANSYS software to improve the temperature non-uniformity problem, through the changing of pipeline and then obtains the result that the temperature difference is 0.187℃, so satisfied the request.
Then, the blue print of injection system of pressing, which includes hydraulic circle design, control scheme design, hardware choose, software structure design, is presented. The fact that the injection process is a process with high speed and high pressure requires the control valves and sensors to have rapid response and fine precision, sampling plate to has high Sampling frequency, control software to has better real-time property. In this paper, the principle of injection system of pressing machine based on electro-hydraulic proportional control is introduced in detail. In order to get a in-depth and visual understanding of the performance of real-time controlled injection system, MTALB and its SIMULINK toolbox is used to build model, simulation and analyze for velocity control system and pressure control system of injection process. As result, response curves and dynamic characteristic parameters, which roundly represent the system performance, are obtained under various control signals during common PID control.
引文
[1]李顺林,复合材料工作手册,北京:航空工业出版所,1988,1,48-52
[2]翁祖棋,中国玻璃钢大全,北京:国防工业出版社,1992,6,80-92
[3]董永棋,我国树酯基复合材料成型工艺的发展方向,纤维复合材料,2003,6,32-34
[4]庞博,复合材料成型过程表征的计算机系统研究,硕士论文,北京航空航天大学,2004
[5]http://www.Jo-mt.de
[6]http://www,evgroup,com
[7]K.Vande Velde,P.Kiekens.Thermoplastic polymers:overview of several properties and their consequences in flax fibre reinforced composites.Polymer Testing,2003,20:885-893
[8]Tianhong Cui,Jing Wang.Polymer-Based Wide-Bandwidth and High-Sensitivity Micromachined Electron Tunneling Accelerometers Using Hot Embossing.和 URNAL OF MICROELECTROMECHANICAL SYSTEMS,2005,14(5)332-337.
[9]Shen J X,Li Wei Pan,Li Wei Lin.Microplastic embossing process:experimental and theoretical characterizations.Sensors and Actuators,2002,97-98(2002):428-433.
[10]Yi Je Juang.POLYMER PROCESSING AND RHEOLOGICAL ANALYSIS NEAR THE GLASS TRANSITION TEMPERATURE.DOCTORAL EXANMINATION AND DISSERTATION REPORT,The Ohio State University,2001.
[11]Marc J Madou,L James Lee,Kurt W,et al.Design and fabrication of polymer micro fluidic platforms for biomedical applications.ANTEC 2001:2534-2538.
[12]陈再枝,蓝德年编著,模具钢手册,北京:冶金工业出版社,2002
[13]姚志彪,半导体制冷装置的实验研究.流体机械,1996,(12):48-52.
[14]田洪芳,左岐,肖秀玲,王锐.智能温度变送器研制,自动化仪器与仪表,2000,(1):41-43.
[15]潘新民,王燕芳,微型计算机与传感器技术.北京:人民邮电出版社,1991.8,120-135
[16]唐介,电工学,北京:高等教育出版社,1999.4,30-40
[17]刘翔,复合材料结构温度场的有限元算法研究以及在面板坝中的应用:[硕士学位论文].北京:清华大学,2004
[18]朱伯芳,有限单元法原理与应用,北京:水利电力出版社,1979,20-25
[19]邵红艳,竺润祥,任茶仙结构温度场和温度应力的有限元分析[J]宁波大学学报,2003,16(1):77-78
[20]段凯,杨新华,杨文兵用ANSYS软件计算桥梁结构的温度应力[J]四川建筑,2005,31(3):82-83
[21]李维特,黄保海,毕仲波热应力理论分析及应用[M]北京:中国电力出版社,2004.59-272
[22]孔祥熙,有限单元法在传热学中的应用[J],北京:科学出版社,1998,30-35
[23]何燕,马连湘,滚动轮胎温度场的研究[J],青岛科技大学学报,2006,27(3):242-244
[24]杨世铭,陶文锉,传热学,北京:高等教育出版社,1999,50-55
[25]李龙,工善元,俞建勇,热压参数对玻璃纤维/聚丙烯喷气混纤纱复合材料性能影响[J].玻璃钢/复合材料,1998,1:20-21
[26]曾竟成:罗青,复合材料理化性能[M],北京:国防科技大学出版社,1998,17-62
[27]李崇俊,郑金煌,二维C/C复合材料高温力学、热物理性能研究[J],宇航材料工
[28]庄骏,张红,热管技术及其工程应用,北京:化学工业出版社,2000,30-45
[29]George R.Keller,液压系统分析(第一版),陈燕庆译,北京:国防工业出版社,1985,38-47
[30]李洪人,液压控制系统(第一版),北京:国防工业出版社,1981,35-40
[31]Herbert E.Merritt,液压控制系统(第一版),陈燕庆译.北京:科学技术出版社,1976,36-41
[32]路雨祥,胡大统,实用电液比例技术(第一版).北京:机械工业出版社,1993.112,80-96
[33]吴根茂,邱敏秀,土庆丰等,实用电液比例技术(第一版),杭州:浙江大学出版社,1993,40-45
[34]黎启柏.电液比例控制与数字控制系统.北京:机械工业出版社,1997,35-40
[35]周雪辉,朱永兴,PLC与上位机的串行通讯实现.上海水产大学学报,2004(2):189-192
[36]陈令,工业控制计算机的发展与前景,工业控制计算机,1998(5):17-18
[37]黄晓勇,陈超,windows工业控制应用探讨,工业控制计算机,1997(4):25-27
[38]沙志宏,傅建中,陈子辰,微流体芯片计算机数控热压机设计,组合机床与自动化加工技术,2004,1:40-41.
[39]梁宏斌,土永章,基于Windows的开放式数控系统实时问题研究.计算机集成制造系统-CIMS,2003,9(5):403407
[40]George R.Keller.液压系统分析(第一版).陈燕庆译.北京:国防工业出版社,1985,62-65
[41]A.J.Wilkinson,GE.Wilson,A.Connor,N.A.Smith.CIM and control of pressure die-cash in the automotive industry.Computing&Control Engineering Journal,1994,5(3)" 125-130
[42]王晓东,刘冲,马立群等,塑料微流控芯片微通道热压成型机的研制,制造技术与机床,2004,11:57-60
[43]陈翔彬,基于模糊PID的高速液压拉深机速度控制系统的研究:[硕士学位论文].武汉:华中科技大学,2002
[2]翁祖棋,中国玻璃钢大全,北京:国防工业出版社,1992,6,80-92
[3]董永棋,我国树酯基复合材料成型工艺的发展方向,纤维复合材料,2003,6,32-34
[4]庞博,复合材料成型过程表征的计算机系统研究,硕士论文,北京航空航天大学,2004
[5]http://www.Jo-mt.de
[6]http://www,evgroup,com
[7]K.Vande Velde,P.Kiekens.Thermoplastic polymers:overview of several properties and their consequences in flax fibre reinforced composites.Polymer Testing,2003,20:885-893
[8]Tianhong Cui,Jing Wang.Polymer-Based Wide-Bandwidth and High-Sensitivity Micromachined Electron Tunneling Accelerometers Using Hot Embossing.和 URNAL OF MICROELECTROMECHANICAL SYSTEMS,2005,14(5)332-337.
[9]Shen J X,Li Wei Pan,Li Wei Lin.Microplastic embossing process:experimental and theoretical characterizations.Sensors and Actuators,2002,97-98(2002):428-433.
[10]Yi Je Juang.POLYMER PROCESSING AND RHEOLOGICAL ANALYSIS NEAR THE GLASS TRANSITION TEMPERATURE.DOCTORAL EXANMINATION AND DISSERTATION REPORT,The Ohio State University,2001.
[11]Marc J Madou,L James Lee,Kurt W,et al.Design and fabrication of polymer micro fluidic platforms for biomedical applications.ANTEC 2001:2534-2538.
[12]陈再枝,蓝德年编著,模具钢手册,北京:冶金工业出版社,2002
[13]姚志彪,半导体制冷装置的实验研究.流体机械,1996,(12):48-52.
[14]田洪芳,左岐,肖秀玲,王锐.智能温度变送器研制,自动化仪器与仪表,2000,(1):41-43.
[15]潘新民,王燕芳,微型计算机与传感器技术.北京:人民邮电出版社,1991.8,120-135
[16]唐介,电工学,北京:高等教育出版社,1999.4,30-40
[17]刘翔,复合材料结构温度场的有限元算法研究以及在面板坝中的应用:[硕士学位论文].北京:清华大学,2004
[18]朱伯芳,有限单元法原理与应用,北京:水利电力出版社,1979,20-25
[19]邵红艳,竺润祥,任茶仙结构温度场和温度应力的有限元分析[J]宁波大学学报,2003,16(1):77-78
[20]段凯,杨新华,杨文兵用ANSYS软件计算桥梁结构的温度应力[J]四川建筑,2005,31(3):82-83
[21]李维特,黄保海,毕仲波热应力理论分析及应用[M]北京:中国电力出版社,2004.59-272
[22]孔祥熙,有限单元法在传热学中的应用[J],北京:科学出版社,1998,30-35
[23]何燕,马连湘,滚动轮胎温度场的研究[J],青岛科技大学学报,2006,27(3):242-244
[24]杨世铭,陶文锉,传热学,北京:高等教育出版社,1999,50-55
[25]李龙,工善元,俞建勇,热压参数对玻璃纤维/聚丙烯喷气混纤纱复合材料性能影响[J].玻璃钢/复合材料,1998,1:20-21
[26]曾竟成:罗青,复合材料理化性能[M],北京:国防科技大学出版社,1998,17-62
[27]李崇俊,郑金煌,二维C/C复合材料高温力学、热物理性能研究[J],宇航材料工
[28]庄骏,张红,热管技术及其工程应用,北京:化学工业出版社,2000,30-45
[29]George R.Keller,液压系统分析(第一版),陈燕庆译,北京:国防工业出版社,1985,38-47
[30]李洪人,液压控制系统(第一版),北京:国防工业出版社,1981,35-40
[31]Herbert E.Merritt,液压控制系统(第一版),陈燕庆译.北京:科学技术出版社,1976,36-41
[32]路雨祥,胡大统,实用电液比例技术(第一版).北京:机械工业出版社,1993.112,80-96
[33]吴根茂,邱敏秀,土庆丰等,实用电液比例技术(第一版),杭州:浙江大学出版社,1993,40-45
[34]黎启柏.电液比例控制与数字控制系统.北京:机械工业出版社,1997,35-40
[35]周雪辉,朱永兴,PLC与上位机的串行通讯实现.上海水产大学学报,2004(2):189-192
[36]陈令,工业控制计算机的发展与前景,工业控制计算机,1998(5):17-18
[37]黄晓勇,陈超,windows工业控制应用探讨,工业控制计算机,1997(4):25-27
[38]沙志宏,傅建中,陈子辰,微流体芯片计算机数控热压机设计,组合机床与自动化加工技术,2004,1:40-41.
[39]梁宏斌,土永章,基于Windows的开放式数控系统实时问题研究.计算机集成制造系统-CIMS,2003,9(5):403407
[40]George R.Keller.液压系统分析(第一版).陈燕庆译.北京:国防工业出版社,1985,62-65
[41]A.J.Wilkinson,GE.Wilson,A.Connor,N.A.Smith.CIM and control of pressure die-cash in the automotive industry.Computing&Control Engineering Journal,1994,5(3)" 125-130
[42]王晓东,刘冲,马立群等,塑料微流控芯片微通道热压成型机的研制,制造技术与机床,2004,11:57-60
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