缸盖气门阀座跳动电子检测仪的研究
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摘要
气缸盖是发动机的配气机构和燃油供给系统的重要组成部分。它的关键部位气门阀座和气门导管孔的加工精度直接影响着发动机的气密性、油耗、耐久性、扭矩大小和有效输出功率等性能指标。在气门阀座的各项检测参数中,气门阀座密封锥面相对导管孔中心线的跳动尤为重要。由于锥面密封带宽度很窄、气门导管孔很深而且内径很小,用普通测量方法很难对之进行精密检测,测量效率也很低。因此,为了满足用户“精确、高效”的检测要求,有必要为缸盖阀座跳动参数检测研制一种操作简单、高效、高精度、高可靠性的专用在线电子检测仪器。
文中对缸盖气门阀座跳动的测量原理进行了研究;在此基础上,给出了跳动检具的总体设计,建立了测量数学模型,包括实时方程数学模型和非实时方程数学模型;接着研究了量规上电感式位移传感器的信号处理系统,包括波形发生电路、放大电路、相敏检波电路和低通滤波电路;设计了以ADμC843单片机为核心的H型受限单极性可逆PWM驱动系统,实现了对检具旋转测量过程的控制。
在检具转动一圈的过程中,检具上的所有测点绕着导管孔中心线和阀座锥面扫描一周,与此同时传感器的信号被计算机与数据采集卡组成的数据采集系统进行整周取样。由计算机根据事先设定的测量方程进行计算处理,给出测量结果。
文中还讨论了统计测量的理论,给出(x|-)-R控制图等以供工艺人员进行工艺分析。
最后进行了测试验证。实验证明,该检测仪具有精度高、效率高、可靠性高的特点,完全可以满足生产线上快节奏高精度检测的需要。
The cylinder head is an important component of the engine valve train and fuel supply system. As the key part of the cylinder head, the processing precision of the valve seat and valve guide hole affects the gastightness, the fuel consumption, the durability, the effective torque output power and other performance indicators directly. For the parameters test of the valve seat, the relative run-out of conical surface of the valve seat to the centerline of guide hole is particularly important. The width of the cone seal is very narrow, and the valve guide hole is very deep and its diameter is too small, so it is difficult to be measured with common measurement methods, and the detection efficiency is very low. It is necessary to develop a kind of simple equipment which has high efficiency, strong reliability and high precision to meet the requirements of users.
Firstly, the paper designs the total solution and sets up the mathematics model of the measurement system including real-time equation and non-real-time equation on the basis of the research of the run-out measurement principle of the cylinder head valve seat. Secondly, the paper studies the signal processing system of inductive displacement sensor on the gauge including waveform generation circuit, amplifier circuit, phase sensitive detection circuit and low pass filter circuit. Lastly, taking ADμC843 MCU as the core, the project uses H-limited unipolar PWM driving system to control the rotation system.
In the process of detector’s rotation, all the measurement points scan a lap around the guide hole centerline and the conical surface of the valve seat. At the same time all the sensor signals are sampled by the data acquisition system composed of computer and DAQ. Then the computer deals with the sampled data and calculates the result according to the equation which the software pre-sets. The paper also introduces the theory of statistical measurement. The technologists can analyze the process with the (x|-)-R charts.
Finally, the performance test for the gauge has been done. The test data shows that the detector has good stability, good repeatability and high detection accuracy. The detector meets the needs of the fast-paced and high-precision detection for the production line.
文中对缸盖气门阀座跳动的测量原理进行了研究;在此基础上,给出了跳动检具的总体设计,建立了测量数学模型,包括实时方程数学模型和非实时方程数学模型;接着研究了量规上电感式位移传感器的信号处理系统,包括波形发生电路、放大电路、相敏检波电路和低通滤波电路;设计了以ADμC843单片机为核心的H型受限单极性可逆PWM驱动系统,实现了对检具旋转测量过程的控制。
在检具转动一圈的过程中,检具上的所有测点绕着导管孔中心线和阀座锥面扫描一周,与此同时传感器的信号被计算机与数据采集卡组成的数据采集系统进行整周取样。由计算机根据事先设定的测量方程进行计算处理,给出测量结果。
文中还讨论了统计测量的理论,给出(x|-)-R控制图等以供工艺人员进行工艺分析。
最后进行了测试验证。实验证明,该检测仪具有精度高、效率高、可靠性高的特点,完全可以满足生产线上快节奏高精度检测的需要。
The cylinder head is an important component of the engine valve train and fuel supply system. As the key part of the cylinder head, the processing precision of the valve seat and valve guide hole affects the gastightness, the fuel consumption, the durability, the effective torque output power and other performance indicators directly. For the parameters test of the valve seat, the relative run-out of conical surface of the valve seat to the centerline of guide hole is particularly important. The width of the cone seal is very narrow, and the valve guide hole is very deep and its diameter is too small, so it is difficult to be measured with common measurement methods, and the detection efficiency is very low. It is necessary to develop a kind of simple equipment which has high efficiency, strong reliability and high precision to meet the requirements of users.
Firstly, the paper designs the total solution and sets up the mathematics model of the measurement system including real-time equation and non-real-time equation on the basis of the research of the run-out measurement principle of the cylinder head valve seat. Secondly, the paper studies the signal processing system of inductive displacement sensor on the gauge including waveform generation circuit, amplifier circuit, phase sensitive detection circuit and low pass filter circuit. Lastly, taking ADμC843 MCU as the core, the project uses H-limited unipolar PWM driving system to control the rotation system.
In the process of detector’s rotation, all the measurement points scan a lap around the guide hole centerline and the conical surface of the valve seat. At the same time all the sensor signals are sampled by the data acquisition system composed of computer and DAQ. Then the computer deals with the sampled data and calculates the result according to the equation which the software pre-sets. The paper also introduces the theory of statistical measurement. The technologists can analyze the process with the (x|-)-R charts.
Finally, the performance test for the gauge has been done. The test data shows that the detector has good stability, good repeatability and high detection accuracy. The detector meets the needs of the fast-paced and high-precision detection for the production line.
引文
1 http://www.motorlink.cn/html/exhibition/10000122c50bf23420090729215526625.html
2王植槐等.汽车制造检测技术.北京理工大学出版社. 2000:1~25
3魏登山.发动机装配过程中在线检测讨论.检测测量. 2008(6):34~35
4云丽平.气缸盖气门阀座和导管孔的几种精加工工艺分析.吉林大学硕士论文. 2005:1~24
5朱正德.进、排气门与缸盖阀座间的密封性检测.检测. 2002,40(7):58~65
6朱正德.汽车零部件及总成先进检测技术的应用理念.汽车工艺与材料. 2008(5):15~16
7罗建政.现代汽车检测技术的发展状况.中国电子商务. 2009(11):172~172
8麦汇彭.在汽车生产中检测技术发展的现状.汽车工艺与材料. 1998(4): 1~4
9 Gao Yan, Dou Li-hua, Gao Qi, Zhou Ning. Computer network control system in automatic automobile detection. Journal of Beijing Institute of Technology. 2001,10(4):406~411
10谭永良,邸彦召,丛明等.面向汽车制造业的柔性气密泄露检测设备的研究.工艺与设备. 2008:1~1
11刘继伟.发动机气缸气密性的检测.鸡西大学学报. 2007,7(2):1~2
12 Ceccarelli, Riccardo. Model-based adaptive observers for intake leakage detection in diesel engines. Proceedings of the American Control Conference. 2009:1128~1133
13 Delgado IrebertR, Proctor, MargaretP. Continued investigation of leakage and power loss test results for competing turbine engine seals. Collection of Technical Papers - AIAA/ASME/SAE/ASEE 42nd Joint Propulsion Conference. 2006.6:4335~4348
14 Lin Wei-Chih, Wu Shi-Min, Mo Chi-Nen. The design of automatic leakage inspection system for CRT optical engine. International Display Manufacturing Conference and Exhibition, IDMC'05. 2005:826~827
15 Jin Yonglong, Xu Nanping, Wu Shiying, Cang Daqiang. Study and application of test technique for air leakage determination on sintering machine. 2003,38(3):1~3
16 Lev-On Miriam, Taback Hal Epperson, David Siegell. Methods forquantification of mass emissions from leaking process equipment when using optical imaging for leak detection. Environmental Progress. 2006,25(4):49~55
17乔梅波,都利勇,王忠财.发动机气门与气门座气密性检测.内燃机与动力装置. 2009.2:52~55
18张新国,张巍.自制气门座跳动检具的设计.经验借鉴. 2003.5:69~69
19李书福,夏金海.气缸盖气门环带跳动检具[P].中国. 200510061165.0.2007.4
20周世荣.气缸盖进、排气阀座锥面跳动测量专用测量[P]. 200720188293.6.2007.11
21谈秀菊.内燃机气缸盖冷却水腔的优化分析研究.天津大学硕士学位论文. 2005:1~35
22谭正三.内燃机构造.机械出版社. 1996:1~80
23 Shojaefard M.H., Ghaffarpour M.R., Noorpoor A.R. Alizadehnia S. Thermomechanical analysis of an engine cylinder head. Proceedings of the Institution of Mechanical Engineers. Journal of Automobile Engineering. 2006,220(5):627~636
24 Tung VincentT.C, Crocker MalcolmJ. Diesel engine noise and relationship to cylinder pressure. Proceedings-Society of Automotive Engineers. 1982:61一71
25 Zuo Zhengxing, Liao Ridong, Fa Lixia, Zou Wensheng. Investigation of mechanical stresses for cylinder head of high power diesel engine. Journal of Beijing Institute of Technology. 1998,7(2):190-195
26 Shi Xiuyong, Li Guoxiang, Hu Yuping. Study sealing performance between cylinder head and cylinder liner.Lubrication Engineering. 2006(5):111~114
27陆瑞松等.内燃机的传热与热负荷.国防工业出版社. 1985: 1~95
28汪恺,唐保宁.形位公差原理和应用(第二版).机械工业出版社. 1991: 1~26
29陈立杰,张玉,张镭.径向全跳动误差的理论研究.宇航计测技术. 2002,22(4):21~25.
30李海国.曲轴径向圆跳动误差的试验研究.山东机械. 2001(4):57~60.
31黄燕,徐年富.端面圆跳动的测量.机械制造与研究. 2005,34(5):37~38
32向胜梅.非连续回转面径向跳动测量数据处理系统研究.长春理工大学硕士学位. 2008:1~36
33 Kaiser M.J, Morin T.L. Centers, out-of-roundness measures, and mathematical programming. Computers and Industrial Engineering. 2006,26(1):35~54
34李玉梅,郑风琴.圆度误差的最小二乘评定的新计算方法.大连水产学院学报, 1995,10(4):27~32
35 Manbir S Sodhi , Khalil Tiliouine. Surface roundness monitoring usingcomputer vision [J ] . Mach Tools Manufact. 1996,36(7): 817～828
36 Wei Gao, Satoshi kiyono. High-accuracy roundness measurement by a new error separation method[J ]. Precision engineering. 1997,21:123～133
37强锡富.传感器(第三版).机械工业出版社. 2001:52~70
38 Graham Miller, Patrick Gaydecki. Detection and Imaging of Surface Corrosion on Steel Reinforcing Bars Using A Phase-Sensitive Inductive Sensor Intended for Use with Concrete. NDT&E International. 2003, (36): 19~26
39 K. Diaz de Lezana, A. Garcia-Arribas, J.M. Barandiaran, J. Gutierrez. Comparative Study of Alternative Circuit Configurations for Inductive Sensors. Sensors and Actuators. 2002, 91: 226–229
40 S.C. Saxen, S.B. Lal Seksena. Inductive Ratio Transducer Instrument System for Displacement Measurement. Meas. Sci. Technol. 1990,8: 475~480
41 D. de Cos, A. Garc?′a-Arribas, J.M. Barandiarán. Simplified Electronic Interfaces for Sensors Based on Inductance Changes. Sensors and Actuators. 2004,112: 302~307
42张国雄,金篆芷.测控电路.机械工业出版社. 2001:10~120
43蔡惟铮,杨春玲.集成电子技术.高等教育出版社. 2004:231~233
44童诗白,华成英.模拟电子技术基础(第三版).高等教育出版社. 2001:354~354
45李刚,林凌,粟田禾.易学易用高性能SoC单片机ADuC841.西安电子科技大学出版社. 2006:1~80
46陈国呈. PWM变频调速技术.机械工业出版社. 1998:15~97
47 H.R. Bolton, Y.D. Liu, N.M. Mallison. Investigation into a class of brushless DC motor with quasisquare voltages and currents[J]. IEEE Proceedings. 1986,133(2):669~674.
48双诺公司. AC1558使用手册.
49陆丽峰.三色电子柱量仪的研制.哈尔滨工业大学硕士论文. 2006:10~29
50殷建军,余忠华,吴昭同.面向SPC的高精度位移检测系统.仪器仪表学报. 2005, 26(5): 492~496
51 T.Kourti, J.F.McGregor. Multivariate SPC Methods For Process and Product Monitoring. Journal of Quality Technology. 1996,28(4):409~428
52 Flott, Leslie W. X-bar and R Charts. Metal Finishing. 1991,3: 29~31
54朱正德.测量能力指数C_g的本质及其实际应用.工具技术.2000,11(34):37~39
53尚有林,李保安.(x|-)-R控制图在工序质量控制中的应用.洛阳工学院学报.2001,22(2):33~35
2王植槐等.汽车制造检测技术.北京理工大学出版社. 2000:1~25
3魏登山.发动机装配过程中在线检测讨论.检测测量. 2008(6):34~35
4云丽平.气缸盖气门阀座和导管孔的几种精加工工艺分析.吉林大学硕士论文. 2005:1~24
5朱正德.进、排气门与缸盖阀座间的密封性检测.检测. 2002,40(7):58~65
6朱正德.汽车零部件及总成先进检测技术的应用理念.汽车工艺与材料. 2008(5):15~16
7罗建政.现代汽车检测技术的发展状况.中国电子商务. 2009(11):172~172
8麦汇彭.在汽车生产中检测技术发展的现状.汽车工艺与材料. 1998(4): 1~4
9 Gao Yan, Dou Li-hua, Gao Qi, Zhou Ning. Computer network control system in automatic automobile detection. Journal of Beijing Institute of Technology. 2001,10(4):406~411
10谭永良,邸彦召,丛明等.面向汽车制造业的柔性气密泄露检测设备的研究.工艺与设备. 2008:1~1
11刘继伟.发动机气缸气密性的检测.鸡西大学学报. 2007,7(2):1~2
12 Ceccarelli, Riccardo. Model-based adaptive observers for intake leakage detection in diesel engines. Proceedings of the American Control Conference. 2009:1128~1133
13 Delgado IrebertR, Proctor, MargaretP. Continued investigation of leakage and power loss test results for competing turbine engine seals. Collection of Technical Papers - AIAA/ASME/SAE/ASEE 42nd Joint Propulsion Conference. 2006.6:4335~4348
14 Lin Wei-Chih, Wu Shi-Min, Mo Chi-Nen. The design of automatic leakage inspection system for CRT optical engine. International Display Manufacturing Conference and Exhibition, IDMC'05. 2005:826~827
15 Jin Yonglong, Xu Nanping, Wu Shiying, Cang Daqiang. Study and application of test technique for air leakage determination on sintering machine. 2003,38(3):1~3
16 Lev-On Miriam, Taback Hal Epperson, David Siegell. Methods forquantification of mass emissions from leaking process equipment when using optical imaging for leak detection. Environmental Progress. 2006,25(4):49~55
17乔梅波,都利勇,王忠财.发动机气门与气门座气密性检测.内燃机与动力装置. 2009.2:52~55
18张新国,张巍.自制气门座跳动检具的设计.经验借鉴. 2003.5:69~69
19李书福,夏金海.气缸盖气门环带跳动检具[P].中国. 200510061165.0.2007.4
20周世荣.气缸盖进、排气阀座锥面跳动测量专用测量[P]. 200720188293.6.2007.11
21谈秀菊.内燃机气缸盖冷却水腔的优化分析研究.天津大学硕士学位论文. 2005:1~35
22谭正三.内燃机构造.机械出版社. 1996:1~80
23 Shojaefard M.H., Ghaffarpour M.R., Noorpoor A.R. Alizadehnia S. Thermomechanical analysis of an engine cylinder head. Proceedings of the Institution of Mechanical Engineers. Journal of Automobile Engineering. 2006,220(5):627~636
24 Tung VincentT.C, Crocker MalcolmJ. Diesel engine noise and relationship to cylinder pressure. Proceedings-Society of Automotive Engineers. 1982:61一71
25 Zuo Zhengxing, Liao Ridong, Fa Lixia, Zou Wensheng. Investigation of mechanical stresses for cylinder head of high power diesel engine. Journal of Beijing Institute of Technology. 1998,7(2):190-195
26 Shi Xiuyong, Li Guoxiang, Hu Yuping. Study sealing performance between cylinder head and cylinder liner.Lubrication Engineering. 2006(5):111~114
27陆瑞松等.内燃机的传热与热负荷.国防工业出版社. 1985: 1~95
28汪恺,唐保宁.形位公差原理和应用(第二版).机械工业出版社. 1991: 1~26
29陈立杰,张玉,张镭.径向全跳动误差的理论研究.宇航计测技术. 2002,22(4):21~25.
30李海国.曲轴径向圆跳动误差的试验研究.山东机械. 2001(4):57~60.
31黄燕,徐年富.端面圆跳动的测量.机械制造与研究. 2005,34(5):37~38
32向胜梅.非连续回转面径向跳动测量数据处理系统研究.长春理工大学硕士学位. 2008:1~36
33 Kaiser M.J, Morin T.L. Centers, out-of-roundness measures, and mathematical programming. Computers and Industrial Engineering. 2006,26(1):35~54
34李玉梅,郑风琴.圆度误差的最小二乘评定的新计算方法.大连水产学院学报, 1995,10(4):27~32
35 Manbir S Sodhi , Khalil Tiliouine. Surface roundness monitoring usingcomputer vision [J ] . Mach Tools Manufact. 1996,36(7): 817～828
36 Wei Gao, Satoshi kiyono. High-accuracy roundness measurement by a new error separation method[J ]. Precision engineering. 1997,21:123～133
37强锡富.传感器(第三版).机械工业出版社. 2001:52~70
38 Graham Miller, Patrick Gaydecki. Detection and Imaging of Surface Corrosion on Steel Reinforcing Bars Using A Phase-Sensitive Inductive Sensor Intended for Use with Concrete. NDT&E International. 2003, (36): 19~26
39 K. Diaz de Lezana, A. Garcia-Arribas, J.M. Barandiaran, J. Gutierrez. Comparative Study of Alternative Circuit Configurations for Inductive Sensors. Sensors and Actuators. 2002, 91: 226–229
40 S.C. Saxen, S.B. Lal Seksena. Inductive Ratio Transducer Instrument System for Displacement Measurement. Meas. Sci. Technol. 1990,8: 475~480
41 D. de Cos, A. Garc?′a-Arribas, J.M. Barandiarán. Simplified Electronic Interfaces for Sensors Based on Inductance Changes. Sensors and Actuators. 2004,112: 302~307
42张国雄,金篆芷.测控电路.机械工业出版社. 2001:10~120
43蔡惟铮,杨春玲.集成电子技术.高等教育出版社. 2004:231~233
44童诗白,华成英.模拟电子技术基础(第三版).高等教育出版社. 2001:354~354
45李刚,林凌,粟田禾.易学易用高性能SoC单片机ADuC841.西安电子科技大学出版社. 2006:1~80
46陈国呈. PWM变频调速技术.机械工业出版社. 1998:15~97
47 H.R. Bolton, Y.D. Liu, N.M. Mallison. Investigation into a class of brushless DC motor with quasisquare voltages and currents[J]. IEEE Proceedings. 1986,133(2):669~674.
48双诺公司. AC1558使用手册.
49陆丽峰.三色电子柱量仪的研制.哈尔滨工业大学硕士论文. 2006:10~29
50殷建军,余忠华,吴昭同.面向SPC的高精度位移检测系统.仪器仪表学报. 2005, 26(5): 492~496
51 T.Kourti, J.F.McGregor. Multivariate SPC Methods For Process and Product Monitoring. Journal of Quality Technology. 1996,28(4):409~428
52 Flott, Leslie W. X-bar and R Charts. Metal Finishing. 1991,3: 29~31
54朱正德.测量能力指数C_g的本质及其实际应用.工具技术.2000,11(34):37~39
53尚有林,李保安.(x|-)-R控制图在工序质量控制中的应用.洛阳工学院学报.2001,22(2):33~35