压电振子在直线式振动送料器上的应用研究
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摘要
振动送料器是自动加工和自动装配系统中的一种供料装置，由于其整列定向性能优良，供料效率高，通用性好，因而广泛应用于自动装配、自动加工、自动包装等各种工序上。传统的振动送料器采用电磁铁为振动源，且一般要求工作频率为50Hz或100Hz，造成了消耗电能多、工作噪声大、结构调整复杂等不足。随着先进制造业的飞速发展，产品愈来愈趋向于轻、薄、细、小、精，对新型振动送料器的需求变得越来越迫切。20世纪七十年代末期，日本首次提出了利用矩形压电双晶片作为激励源的压电式振动送料器，随后的几十年里，取得了一系列的成果，申请了近十项发明专利，在自动化生产线上也得到了广泛应用。我国在20世纪90年代初期开始对压电振动送料器进行研究，也取得了一定成果，但是所设计的送料器结构与日本的产品类似，并没有较大创新，无法大批量生产。本论文结合国家863项目“垂直驱动式压电振动送料器的开发研究（项目编号：2006AA04Z225）”的研究工作，提出了利用环形压电振子、矩形压电振子和郎之万振子驱动的新型振动送料装置，以这三类新型结构为研究对象，进行了理论分析、动力学分析、样机设计与制作及试验研究。主要研究内容如下：
1、在查阅大量资料的基础上，深入分析了振动送料装置的国内外发展现状，总结了现有振动送料装置的驱动方式，指出了研究压电振子在振动送料装置上应用的意义。
2、通过分析压电陶瓷的性能参数和相关特性，获得了送料器所用压电陶瓷的性能参数要求，确定了适于送料器工作的压电陶瓷振动模式、送料器所用压电振子的类型、支撑方式与振动放大形式，为送料器的结构设计、理论分析及试验研究提供了必要的理论基础。
3、分析了压电驱动送料器能够对物料形成输送的基本原理和物料输送过程中存在的运动形式及输送形态，建立了物料的力学模型，确定了物料腾空和滑移的条件及料槽参数对运动状态的影响，推导了正向滑移状态的平均速度公式。
4、设计了直线式环形压电振子驱动送料器结构，分析了其工作原理；建立了送料器动力学模型，推导了系统固有频率关系式；在对其进行了模态分析和输出力推导的基础上，对环形压电双晶片振子进行了设计；对送料器的支撑弹簧片、底座、隔振和顶板进行了详细设计。分别从频率特性、电压特性、振幅与速度关系、物料重量、摩擦系数、料槽升角、弹簧片安装角度、噪声与耗电等方面对所开发的直线式环形压电振子驱动送料器样机进行了测试，并分析了影响规律。
5、设计了直线式矩形压电振子驱动送料器结构，分析了其工作原理；建立了送料器动力学模型，推导了振幅放大关系式；分析了矩形压电双晶片尺寸参数影响，利用有限软件分析了矩形压电双晶片振子的振动模态；对矩形压电双晶片振子进行了动力学分析，获得了影响驱动力的影响因素。对所开发的直线式矩形压电振子驱动送料器样机性能进行了性能测试。
6、设计了直线式郎之万振子驱动送料器结构，分析了其工作原理；根据使用要求，对其核心元件—郎之万振子结构进行了设计，并完成其结构相关参数计算推导，由此确定了振子的主要结构尺寸；用精密阻抗分析仪测试了郎之万振子的阻抗和谐振频率，采用激光测距仪完成了振子前端面的纵向振幅测试。分别从物料重量、频率特性、电压特性及噪声等方面对研制的送料器样机进行了性能测试。
本文结合压电学、机械学、力学、控制学等多学科知识，深入分析了所设计的新型压电驱动送料器的工作机理和动力学特性，系统测试了送料器的各项性能。本文研究所取得的成果丰富了压电式振动送料器驱动机理，为送料器性能改进提供了理论和试验支撑，为具有自主知识产权的压电式振动送料器的产品化奠定了基础。
Vibratory feeder is one kind of feeding construction for automatic production andassembly system. Due to good patterning performance and generality, high feedingefficiency, the feeder is widely used in automatic machining, assembly and packaging.However, the vibration source of the traditional vibratory feeder is electromagnet, whichnormally requires50Hz or100Hz in working frequency, therefore, there are disadvantageslike high power consumption and working noise, complicated structure to do adjustment,etc. With the rapid development in advanced manufacturing, the products are tending to belighter, thinner, smaller and more precise, which makes the development of novel vibratoryfeeder more and more urgent. In the end of70s in20thCentury, rectangular piezoelectricbimorph was brought up in the first time as excitation source in piezoelectric vibratoryfeeder by Japanese. In the following decades, there were series achievements coming out,and nearly10invention patents were applied in piezoelectric feeding area. And there waswide application in automation production line. Chinese researches on piezoelectricvibratory feeder started from beginning of90s last century, and there are someachievements, but no innovation compared with Japanese products, and can’t be used formass production. The paper is one task from National Project863(Project number:2006AA04Z225)“Research&Development on Vertical Driven Piezoelectric VibratoryFeeder”. Novel vibratory feeding structures on rectangular piezoelectric vibrator, roundpiezoelectric vibrator and piezoelectric transducer were brought forward. Based on thethree novel structures as the research objects, theoretical analysis, dynamic analysis,prototype design and production, experiment study were carried out. The contents in thispaper includes:
1. Referring to plenty of research materials, the development status of the piezoelectricvibratory feeder home and abroad was deeply investigated. The vibratory feedingconstruction was summarized, and the piezoelectric vibrator sense and method in vibratoryfeeding construction application was pointed out.
2. Through discoursing upon piezoelectric ceramics related characteristic andperformance parameter, the performance parameter demand was obtained. Thepiezoelectric ceramics vibraiton mode fit for the feeder were defined, and also for the thepiezoelectric vibrator type, support mode, vibratory amplify form. The work here providedthe theory foudation for the feeder structure design, theoretical analysis and experimentstudy.
3. The basic mechanism on material feeding from the piezoelectric vibratory feederwas explained, and the feeding affecting rules from elliptic parameter were analyzed; themovement and feeding forms during material feeding were explained, and the mechanicsmode was established, material empty out and slippage conditions and material tray affecton the movement conditons were defined, besides, the average speed formula on forwardslip condition was deduced.
4. Straight-line annular piezoelectric vibrator driven feeder structure was designed, andthe working concept was analyzed; the feeder dynamics mode model was established, andthe systematic natural frequency relationship formula was deduced; based on the modeanalysis and output force deduction, the annular piezoelectric bimorph vibrator wasdesigned; the feeder supporting spring, base plate and vibratory isolation, top plate weredesigned in detail. From characteristics of frequency, voltage, amplitude and speedrelationship, single material weight, friction factor, feeding chute rise angle, springinstallation angle, noise and power consumption, and so on separately, the prototypeperformances on feeding parameters were tested on the developed straight-line annularpiezoelectric vibratory feeder, and affected rules were analyzed.
5. Straight-line rectangular piezoelectric vibrator driven feeder structure was designed,and the working concept was analyzed; the feeder dynamics mode was established, andthe amplitude amplified relationship formula was deduced; dimension parameter affect ofthe rectangular piezoelectric bimorph were analyzed, rectangular piezoelectric bimorphvibration mode was analyzd with FEM software; the dynamic analysis was carried out onrectangular piezoelectric bimorph vibrator, and the affecting factors on the driving forcewas achieved. The performance was bested on the developed straight-line rectangularpiezoelectric vibratory feeder prototype.
6. Straight-line langevin vibrator driven feeder structure was designed, and the workingconcept was analyzed; based on the operation requirement, the core part—langevin vibratorstructure was designed, and the structure related parameter calculation decution was done,from which the main structual dimensions of the transducer were defiend. With precisionimpedance analyzer, the impedance and resonance frequency of the piezoelectric sandwich transducer was tested; meanwhile, with laser rangefinder, the portrait amplitude in the frontside of the piezoelectric sandwich transducer was tested. From different sides like materialtype selectivity, frequency characteristic, voltage characteristic and noise and so on, thedesigned feeder prototype was tested.
Combined know-how on piezoelectricity, mechanics, control science and other area inthis paper, the working mechanism and dynamics characteristics of the novel designedpiezoelectric vibratory feeder were investigated deeply, and the performance of the feederwere tested systematically. Driven mechanism of the piezoelectric vibratory feeder wasenriched by the research from this paper, which provided the theory and experimentfoundation for the feeder performance improvement and the productivity of theindependent intellectual property on piezoelectric vibratory feeder.
1、在查阅大量资料的基础上，深入分析了振动送料装置的国内外发展现状，总结了现有振动送料装置的驱动方式，指出了研究压电振子在振动送料装置上应用的意义。
2、通过分析压电陶瓷的性能参数和相关特性，获得了送料器所用压电陶瓷的性能参数要求，确定了适于送料器工作的压电陶瓷振动模式、送料器所用压电振子的类型、支撑方式与振动放大形式，为送料器的结构设计、理论分析及试验研究提供了必要的理论基础。
3、分析了压电驱动送料器能够对物料形成输送的基本原理和物料输送过程中存在的运动形式及输送形态，建立了物料的力学模型，确定了物料腾空和滑移的条件及料槽参数对运动状态的影响，推导了正向滑移状态的平均速度公式。
4、设计了直线式环形压电振子驱动送料器结构，分析了其工作原理；建立了送料器动力学模型，推导了系统固有频率关系式；在对其进行了模态分析和输出力推导的基础上，对环形压电双晶片振子进行了设计；对送料器的支撑弹簧片、底座、隔振和顶板进行了详细设计。分别从频率特性、电压特性、振幅与速度关系、物料重量、摩擦系数、料槽升角、弹簧片安装角度、噪声与耗电等方面对所开发的直线式环形压电振子驱动送料器样机进行了测试，并分析了影响规律。
5、设计了直线式矩形压电振子驱动送料器结构，分析了其工作原理；建立了送料器动力学模型，推导了振幅放大关系式；分析了矩形压电双晶片尺寸参数影响，利用有限软件分析了矩形压电双晶片振子的振动模态；对矩形压电双晶片振子进行了动力学分析，获得了影响驱动力的影响因素。对所开发的直线式矩形压电振子驱动送料器样机性能进行了性能测试。
6、设计了直线式郎之万振子驱动送料器结构，分析了其工作原理；根据使用要求，对其核心元件—郎之万振子结构进行了设计，并完成其结构相关参数计算推导，由此确定了振子的主要结构尺寸；用精密阻抗分析仪测试了郎之万振子的阻抗和谐振频率，采用激光测距仪完成了振子前端面的纵向振幅测试。分别从物料重量、频率特性、电压特性及噪声等方面对研制的送料器样机进行了性能测试。
本文结合压电学、机械学、力学、控制学等多学科知识，深入分析了所设计的新型压电驱动送料器的工作机理和动力学特性，系统测试了送料器的各项性能。本文研究所取得的成果丰富了压电式振动送料器驱动机理，为送料器性能改进提供了理论和试验支撑，为具有自主知识产权的压电式振动送料器的产品化奠定了基础。
Vibratory feeder is one kind of feeding construction for automatic production andassembly system. Due to good patterning performance and generality, high feedingefficiency, the feeder is widely used in automatic machining, assembly and packaging.However, the vibration source of the traditional vibratory feeder is electromagnet, whichnormally requires50Hz or100Hz in working frequency, therefore, there are disadvantageslike high power consumption and working noise, complicated structure to do adjustment,etc. With the rapid development in advanced manufacturing, the products are tending to belighter, thinner, smaller and more precise, which makes the development of novel vibratoryfeeder more and more urgent. In the end of70s in20thCentury, rectangular piezoelectricbimorph was brought up in the first time as excitation source in piezoelectric vibratoryfeeder by Japanese. In the following decades, there were series achievements coming out,and nearly10invention patents were applied in piezoelectric feeding area. And there waswide application in automation production line. Chinese researches on piezoelectricvibratory feeder started from beginning of90s last century, and there are someachievements, but no innovation compared with Japanese products, and can’t be used formass production. The paper is one task from National Project863(Project number:2006AA04Z225)“Research&Development on Vertical Driven Piezoelectric VibratoryFeeder”. Novel vibratory feeding structures on rectangular piezoelectric vibrator, roundpiezoelectric vibrator and piezoelectric transducer were brought forward. Based on thethree novel structures as the research objects, theoretical analysis, dynamic analysis,prototype design and production, experiment study were carried out. The contents in thispaper includes:
1. Referring to plenty of research materials, the development status of the piezoelectricvibratory feeder home and abroad was deeply investigated. The vibratory feedingconstruction was summarized, and the piezoelectric vibrator sense and method in vibratoryfeeding construction application was pointed out.
2. Through discoursing upon piezoelectric ceramics related characteristic andperformance parameter, the performance parameter demand was obtained. Thepiezoelectric ceramics vibraiton mode fit for the feeder were defined, and also for the thepiezoelectric vibrator type, support mode, vibratory amplify form. The work here providedthe theory foudation for the feeder structure design, theoretical analysis and experimentstudy.
3. The basic mechanism on material feeding from the piezoelectric vibratory feederwas explained, and the feeding affecting rules from elliptic parameter were analyzed; themovement and feeding forms during material feeding were explained, and the mechanicsmode was established, material empty out and slippage conditions and material tray affecton the movement conditons were defined, besides, the average speed formula on forwardslip condition was deduced.
4. Straight-line annular piezoelectric vibrator driven feeder structure was designed, andthe working concept was analyzed; the feeder dynamics mode model was established, andthe systematic natural frequency relationship formula was deduced; based on the modeanalysis and output force deduction, the annular piezoelectric bimorph vibrator wasdesigned; the feeder supporting spring, base plate and vibratory isolation, top plate weredesigned in detail. From characteristics of frequency, voltage, amplitude and speedrelationship, single material weight, friction factor, feeding chute rise angle, springinstallation angle, noise and power consumption, and so on separately, the prototypeperformances on feeding parameters were tested on the developed straight-line annularpiezoelectric vibratory feeder, and affected rules were analyzed.
5. Straight-line rectangular piezoelectric vibrator driven feeder structure was designed,and the working concept was analyzed; the feeder dynamics mode was established, andthe amplitude amplified relationship formula was deduced; dimension parameter affect ofthe rectangular piezoelectric bimorph were analyzed, rectangular piezoelectric bimorphvibration mode was analyzd with FEM software; the dynamic analysis was carried out onrectangular piezoelectric bimorph vibrator, and the affecting factors on the driving forcewas achieved. The performance was bested on the developed straight-line rectangularpiezoelectric vibratory feeder prototype.
6. Straight-line langevin vibrator driven feeder structure was designed, and the workingconcept was analyzed; based on the operation requirement, the core part—langevin vibratorstructure was designed, and the structure related parameter calculation decution was done,from which the main structual dimensions of the transducer were defiend. With precisionimpedance analyzer, the impedance and resonance frequency of the piezoelectric sandwich transducer was tested; meanwhile, with laser rangefinder, the portrait amplitude in the frontside of the piezoelectric sandwich transducer was tested. From different sides like materialtype selectivity, frequency characteristic, voltage characteristic and noise and so on, thedesigned feeder prototype was tested.
Combined know-how on piezoelectricity, mechanics, control science and other area inthis paper, the working mechanism and dynamics characteristics of the novel designedpiezoelectric vibratory feeder were investigated deeply, and the performance of the feederwere tested systematically. Driven mechanism of the piezoelectric vibratory feeder wasenriched by the research from this paper, which provided the theory and experimentfoundation for the feeder performance improvement and the productivity of theindependent intellectual property on piezoelectric vibratory feeder.
引文
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