高性能注塑机关键技术的研究
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摘要
二十一世纪是科技的世纪,随着材料技术的发展,伺服电机的性能得到了很大的提高,为注塑机的高速、高精度提供了可能。先进控制技术的进一步发展和完善,为实现电机和泵联接的注塑机驱动系统伺服控制提供了理论依据。微控制器,特别是芯片技术的提高以及专用DSP的出现为算法控制技术的实现提供了可能。
节能、高速、高精度、低噪声是高性能注塑机控制系统的发展方向。然而,高速度和高精度、低噪声往往是两个互相矛盾的方向。控制方法的优化对解决节能以及高速、高精度有重要的意义,因此有必要对注塑机的控制方法进行研究。注塑机节能液压系统,正在从过去的流量比例和压力比例的双控制走向负载敏感自适应控制,走向变频调速控制、伺服控制及伺服闭环控制。高端的节能动力驱动系统是高性能注塑机不可缺少的系统。
针对上述问题,本论文首先采用模糊预测的方法对注塑机驱动电机—异步电机的转速控制进行了研究；其次,利用内模控制的方法对注塑机驱动电机—永磁同步伺服电机的电流调节器进行了深入的研究；第三,将模糊控制用于电机和变量泵的协调控制；第四,针对高速度、高精度和低噪声之间的矛盾,对不同的电机和变量柱塞泵之间的联接方式进行了研究；最后分析了注塑机伺服电机变量泵驱动系统节能的原理并和阀控系统节能进行了比较。
论文主要内容包含以下几个方面：
1)异步电机转速控制器的设计。在异步电机的控制中,电阻、电抗等参数对转速控制产生较大的误差影响,从而影响控制精度和动态响应速度。基于感应电机的数学模型,将模糊逻辑系统引入预测控制。针对异步电机的强耦合特性,提出模糊预测控制的方法,并用模糊预测控制的方法设计了高性能的转速控制器。
2)基于磁场定向的控制原理,提出了永磁同步电机电流调节器的内模控制(IMC)设计。在永磁同步伺服电机的矢量控制中,电机的调速范围很宽时,电阻、电抗等参数对d,q轴电流的控制产生较大的误差影响,从而影响控制精度和动态响应速度。用矩阵奇异值分析了IMC电流调节器的鲁棒性,并将其应用于永磁同步电机转子磁场定向的矢量控制中。对电流调节器的传递函数进行了仿真并用DSP实现电机矢量控制的运行实验,实验表明,用IMC电流调节器实现的电机调速,能够获得良好的跟踪性能和较高的稳态精度,从而提高了电机的控制能力并验证了IMC电流调节器的在宽调速时对电机参数依赖性小的良好性能。
3)从模糊控制的理论出发,提出了将模糊控制方法用于伺服电机和变量泵的协调控制。解决了注塑机变频调速时出现的低速特性差,动态响应慢,调速精度不易保证等问题。用模糊内模协调控制的方法解决了转速波动的问题。
4)针对高速度、高精度和低噪声之间的矛盾,对电机和变量柱塞泵之间的联接方式进行了研究。说明联轴器对伺服电机泵系统的响应和噪声有重大的影响。
5)分析了伺服电机加变量泵系统节能的原理,通过实验对伺服电机加变量泵系统和比例阀控系统进行了比较。
The 21st century is a technological century, with the development of material technology, servo motor performance has been improved for injection molding machines high-speed, high-precision. The advance control technology for the further development and for the implementation of motor and pump join moulding machine driven system servo control provides the theoretical basis. The development of microcontroller, especially the development of chip technology, and the appearance of specialties DSP, has made the implementation of control algorithms possible.
Energy-saving,high-speed,high-precision, low-noise is high-performance injection machine control system direction of development. However, high speed and high-precision is often contradictory against low noise. Control method optimization is meaningful in solving the energy-saving and high-speed, high-precision. It is necessary for injection molding machine control methods to be studied. Injection molding machines energy-saving hydraulic systems, from flow and pressure in the proportion of dual control in the past towards load sensitive adaptive control, then frequency converter speed control, servo control and servo close control. Advanced energy-saving power-driven system is very necessary in high-performance injection molding machines.
Focusing on the problems above, the first this thesis taking the advantages of the fuzzy prodictive control theory, analyzes the speed controller of induction motor for the injection molding machine; Secondly, using the internal model control methods, the author deeply researched the current regulator of Permanent magnet synchronous motor; Thirdly, fuzzy control is used for motor and variables pump co-ordination control; Fourthly, to the conflicts of high-speed, and high-precision against low noise, the different joint ways of the motor and variable pump is studied; Finally energy-saving principles of servo motors variable pump-driven system for the injection molding machine are studied; The experiment has been done to compare it with valve-control systems.
The main points of this papers are as follows:
1)A speed controller is designed for induction motor. In the contol of induction motor, great errors will be produced in speed control due to the parameters of the resistance and reactance. Based on the model of induction motor, a fuzzy predictive control method for the nonlinear discrete systems is presented by introducing fuzzy logic system into predictive control strategy, a high performance speed controller is designed using fuzzy predictive control method.
2) Based on the conventional theory of rotor oriented vector control for permanent magnet synchronous machine, the internal mode control approach is applied to the current regulation of indirect rotor flux oriented control of permanent magnet synchronous machine. In the vector contol of permanent magnet synchronous machine, great errors will be produced in current control of the axis of d and q due to the parameters of the resistance and reactance in a wider speed range. The design methodology of current regulator is presented and its dynamic and robust characteristics is analyzed using matrix singular values. Finally, the simulating and experimental results indicate that the system utilizing internal mode control current regulator has better tracking performance and higher steady precision, and improves the motor control effect, it also verifies the good performance of the IMC (internal model current control) in the indirect rotor flux oriented control of permanent magnet synchronous machine, especially less dependence to the motor parameters on the wide range of speed.
3) Based on the fuzzy control theory, it is proposed that fuzzy control method is used in servo motor and variables pump co-ordination control. The problem of low-speed features, slow dynamic response, and precision being not easily assured are solved when variable frequency speed-control of the injection molding machine. The shortage of speed fluctuations is solved by fuzzy internal-model-co-ordinating control.
4) To the conflicts between high-speed, high-precision and low-noise, the different joint ways of the motor and variable pump are researched. The result shows the coupling has a significant impact on servo motor pump system's response and noise.
5) Energy-saving principle for the servo motor with variable pump system is studied. Based on them, comparison between servo motor with variable pump system and proportional valve system is done though experiment.
节能、高速、高精度、低噪声是高性能注塑机控制系统的发展方向。然而,高速度和高精度、低噪声往往是两个互相矛盾的方向。控制方法的优化对解决节能以及高速、高精度有重要的意义,因此有必要对注塑机的控制方法进行研究。注塑机节能液压系统,正在从过去的流量比例和压力比例的双控制走向负载敏感自适应控制,走向变频调速控制、伺服控制及伺服闭环控制。高端的节能动力驱动系统是高性能注塑机不可缺少的系统。
针对上述问题,本论文首先采用模糊预测的方法对注塑机驱动电机—异步电机的转速控制进行了研究；其次,利用内模控制的方法对注塑机驱动电机—永磁同步伺服电机的电流调节器进行了深入的研究；第三,将模糊控制用于电机和变量泵的协调控制；第四,针对高速度、高精度和低噪声之间的矛盾,对不同的电机和变量柱塞泵之间的联接方式进行了研究；最后分析了注塑机伺服电机变量泵驱动系统节能的原理并和阀控系统节能进行了比较。
论文主要内容包含以下几个方面：
1)异步电机转速控制器的设计。在异步电机的控制中,电阻、电抗等参数对转速控制产生较大的误差影响,从而影响控制精度和动态响应速度。基于感应电机的数学模型,将模糊逻辑系统引入预测控制。针对异步电机的强耦合特性,提出模糊预测控制的方法,并用模糊预测控制的方法设计了高性能的转速控制器。
2)基于磁场定向的控制原理,提出了永磁同步电机电流调节器的内模控制(IMC)设计。在永磁同步伺服电机的矢量控制中,电机的调速范围很宽时,电阻、电抗等参数对d,q轴电流的控制产生较大的误差影响,从而影响控制精度和动态响应速度。用矩阵奇异值分析了IMC电流调节器的鲁棒性,并将其应用于永磁同步电机转子磁场定向的矢量控制中。对电流调节器的传递函数进行了仿真并用DSP实现电机矢量控制的运行实验,实验表明,用IMC电流调节器实现的电机调速,能够获得良好的跟踪性能和较高的稳态精度,从而提高了电机的控制能力并验证了IMC电流调节器的在宽调速时对电机参数依赖性小的良好性能。
3)从模糊控制的理论出发,提出了将模糊控制方法用于伺服电机和变量泵的协调控制。解决了注塑机变频调速时出现的低速特性差,动态响应慢,调速精度不易保证等问题。用模糊内模协调控制的方法解决了转速波动的问题。
4)针对高速度、高精度和低噪声之间的矛盾,对电机和变量柱塞泵之间的联接方式进行了研究。说明联轴器对伺服电机泵系统的响应和噪声有重大的影响。
5)分析了伺服电机加变量泵系统节能的原理,通过实验对伺服电机加变量泵系统和比例阀控系统进行了比较。
The 21st century is a technological century, with the development of material technology, servo motor performance has been improved for injection molding machines high-speed, high-precision. The advance control technology for the further development and for the implementation of motor and pump join moulding machine driven system servo control provides the theoretical basis. The development of microcontroller, especially the development of chip technology, and the appearance of specialties DSP, has made the implementation of control algorithms possible.
Energy-saving,high-speed,high-precision, low-noise is high-performance injection machine control system direction of development. However, high speed and high-precision is often contradictory against low noise. Control method optimization is meaningful in solving the energy-saving and high-speed, high-precision. It is necessary for injection molding machine control methods to be studied. Injection molding machines energy-saving hydraulic systems, from flow and pressure in the proportion of dual control in the past towards load sensitive adaptive control, then frequency converter speed control, servo control and servo close control. Advanced energy-saving power-driven system is very necessary in high-performance injection molding machines.
Focusing on the problems above, the first this thesis taking the advantages of the fuzzy prodictive control theory, analyzes the speed controller of induction motor for the injection molding machine; Secondly, using the internal model control methods, the author deeply researched the current regulator of Permanent magnet synchronous motor; Thirdly, fuzzy control is used for motor and variables pump co-ordination control; Fourthly, to the conflicts of high-speed, and high-precision against low noise, the different joint ways of the motor and variable pump is studied; Finally energy-saving principles of servo motors variable pump-driven system for the injection molding machine are studied; The experiment has been done to compare it with valve-control systems.
The main points of this papers are as follows:
1)A speed controller is designed for induction motor. In the contol of induction motor, great errors will be produced in speed control due to the parameters of the resistance and reactance. Based on the model of induction motor, a fuzzy predictive control method for the nonlinear discrete systems is presented by introducing fuzzy logic system into predictive control strategy, a high performance speed controller is designed using fuzzy predictive control method.
2) Based on the conventional theory of rotor oriented vector control for permanent magnet synchronous machine, the internal mode control approach is applied to the current regulation of indirect rotor flux oriented control of permanent magnet synchronous machine. In the vector contol of permanent magnet synchronous machine, great errors will be produced in current control of the axis of d and q due to the parameters of the resistance and reactance in a wider speed range. The design methodology of current regulator is presented and its dynamic and robust characteristics is analyzed using matrix singular values. Finally, the simulating and experimental results indicate that the system utilizing internal mode control current regulator has better tracking performance and higher steady precision, and improves the motor control effect, it also verifies the good performance of the IMC (internal model current control) in the indirect rotor flux oriented control of permanent magnet synchronous machine, especially less dependence to the motor parameters on the wide range of speed.
3) Based on the fuzzy control theory, it is proposed that fuzzy control method is used in servo motor and variables pump co-ordination control. The problem of low-speed features, slow dynamic response, and precision being not easily assured are solved when variable frequency speed-control of the injection molding machine. The shortage of speed fluctuations is solved by fuzzy internal-model-co-ordinating control.
4) To the conflicts between high-speed, high-precision and low-noise, the different joint ways of the motor and variable pump are researched. The result shows the coupling has a significant impact on servo motor pump system's response and noise.
5) Energy-saving principle for the servo motor with variable pump system is studied. Based on them, comparison between servo motor with variable pump system and proportional valve system is done though experiment.
引文
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