HDD驱动臂结构拓扑与压电主动控制融合设计理论研究
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摘要
在微电子制造装备中,各种结构紧凑、高速和高精度运动的微小器件被广泛使用。这些在极端工作环境下运行的微小器件对动态精度和稳定性要求越来越高,从而使机械结构和控制系统间的耦合效应愈加明显,采用传统的先结构设计后控制设计的顺序方法,忽略了各子系统的相互耦合作用,制约了对系统动态特性的进一步提升。如何考虑机械结构和控制之间的相互作用,将结构动态性能设计和控制进行融合,特别是将大自由度、大计算量的结构拓扑设计和主动控制进行融合建模和求解是目前设计方法上的一大难题。磁头驱动臂是一种典型的柔性、高速和高精度运动的微小器件。由于空间限制,磁头驱动臂重量轻,厚度薄,柔性很大,在频繁的高加速起停和高动态精度等复杂工作环境中,寻道过程以及外部干扰产生的微小机械振动都会对数据的读写造成致命的错误。本论文受国家自然科学基金重大项目“面向芯片封装的高加速度运动系统的精确定位和操纵”(50390063)的资助,以磁头驱动臂为研究对象,对微小结构的动态拓扑设计理论、压电主动振动控制和结构拓扑/压电主动控制的融合建模技术和优化方法等进行了系统而深入的研究,并应用于磁头驱动臂拓扑结构形态、压电片的最优位置和控制参数等的融合优化设计。具体研究内容如下:
1.首先介绍并分析了硬盘驱动器的工作原理和磁头驱动系统目前面临的主要问题,对结构的拓扑设计理论、压电主动控制技术和机电融合设计等相关的理论和方法、发展现状和趋势以及在磁头驱动臂设计中的应用进行了分析和总结。
2.为提高二维柔性板结构的动态特性,研究了基于结构动态柔度、冲击动态响应和动态稳定性的拓扑设计建模理论,提出了二维柔性板基于冲击动态响应和动态稳定性的拓扑设计的建模和灵敏度分析方法等,推导了冲击动态响应和动态稳定性作为目标时优化模型的梯度分析表达式,解决了通常采用的数值方法或进化算法带来的大计算量问题,进一步拓展了结构拓扑设计的理论。在此研究的基础上,以硬盘驱动臂为对象,进行了基于动态响应特性、冲击特性和动态稳定性的硬盘驱动臂拓扑设计和优化结果的分析。通过研究,发现它们和静态拓扑、基于频率的拓扑设计结果具有一定的局部相似性,表明基于动态响应的拓扑设计具有更好的综合性能,为改善HDD(hard disk drive)驱动臂的动态性能提供了一个强有力的设计手段,同时为后面的结构拓扑/主动控制融合设计的研究打下了良好的基础。
3.为抑制磁头驱动臂的振动,以柔性悬臂梁为研究对象,系统分析了PZT压电材料和悬臂梁的耦合关系,研究了PZT压电材料在梁上分布的优化建模理论,提出了多对压电片的尺寸、位置和主动控制优化的机电融合模型和灵敏度分析方法,导出了优化模型的梯度分析表达式,并对磁头驱动臂压电主动控制的压电片位置、长度和控制增益进行了优化。和通常采用的数值方法和进化算法相比,改善了优化收敛过程的稳定性,提高了计算效率。通过计算、分析和数值仿真,揭示了在梁的主动振动控制中压电片的位置、长度和控制参数之间存在的复杂耦合特性,说明了这些参数以及它们之间的耦合、甚至它们和结构本身的参数之间的相互作用对系统动态响应具有决定性的影响。因此,针对磁头驱动臂工作过程中宽频振动的特点采用多压电片对多阶模态进行结构/控制融合设计是非常必要和合理的选择。本章的研究为结构拓扑与PZT主动控制之间的耦合问题分析提供了一定的理论基础。
4.为从方法论上进一步改善磁头驱动臂的动态性能,以智能柔性板梁为对象,将结构拓扑设计理论与振动主动控制相融合,研究了结构和压电材料的耦合关系,提出了智能柔性板梁结构拓扑形态和主动控制的融合设计模型、偏导数分析方法、压电片的重叠约束条件等完整的分析理论,建立了柔性板梁的结构拓扑、PZT压电驱动器/传感器单元在结构中的布置以及主动控制参数融合的优化设计模型。由于直接采用基于梯度的分析优化计算,保证了较高的计算效率,既克服了迭代算法静态耦合和设计域分解退化等问题,又解决了进化算法和数值计算在拓扑设计中的大计算量和数值不稳定问题。在此理论研究基础上,对HDD驱动臂的结构拓扑、PZT压电陶瓷片的位置以及主动控制参数进行了并行优化设计,并采用仿真和实验对计算结果进行了分析。计算结果和仿真分析表明,采用并行的融合建模优化比迭代优化设计方法效果更好。
研究成果对于一般机电融合设计的研究和应用也有重要的参考价值。
There are many tiny structural parts with small size, high acceleration and high dynamical accuracy in microelectronical manufacturing equipments. These parts used in the extreme condition have been imposed more and more stringent performances in advanced application. It results in a situation where interactions between structure and controller are more and more significant, and because the conventional design practice along the sequential lines of structure then controller design ignores the crucial influence of their interaction on global dynamical performance, it provides limit ability to improve the dynamical performance of these parts further. How to effectively integrate mechanical structure with controller in terms of their interaction, especially how to build and solve the mathematical model of integrated structural topological design with large degrees and great computation with controller design, is coming to a challenge in researches on design methodology. HDD suspension is a very flexible tiny structure with high speed and high dynamical accuracy. As limited by space size, the flexible suspension is usually made very thin in thickness, and very sensitive to any disturbance or shock impact. At this stringent situation, even small mechanical vibration induced by seeking motion and outer disturbance may result in catastrophic error in data reading.
Supported by the National Natural Science Foundation(50390063) of“Study on accurate positioning and manipulating of motion system with high acceleration for die packaging”, this dissertation is focused on the researches of structural topological optimal based on dynamical performance and stability, PZT Piezoelectric control, the integrated modeling theory and its simultaneous optimal design about structural topology and active vibration controller about tiny structural part in order to improve the dynamical performance of a HDD suspension. These researches are applied to the optimal design of structural topological design, the PZT positions and controller parameters about a HDD suspension. The detail researches are followed as below.
1. The principle of head assembly and the main problems about design suspension design are introduced firstly. Structural topological design theories based on static compliance or resonance frequency, piezoelectric active control, integrated structure/controller design techniques , their application and development in HDD suspension design are also analyzed in detail.
2. In order to improve the dynamical performance of plane flexible beam, the topological design approach based on structural dynamical compliance, or dynamic response and stability under shock impact are studied, and the techniques about modeling of the topological design based on structural dynamical compliance, or dynamic response and stability under shock impact and their sensitive analysis are presented. Using these methods, the formulas of gradations of optimal model which objective function is dynamic response and stability under shock impact are derived . It saves large computational time by indirectly optimization based on gradations instead of numerical method or evolutional method, and extends the theory of structural topology design. Based above, HDD suspension topological design by structural dynamical compliance, or dynamic response and stability under shock impact is performed, and the optimal results are analyzed. As a result, several new topological structures of HDD suspension are obtained. It is discovered that the topological structures based on dynamical compliance are similar to that based on static compliance, first order torsion and sway frequencies at some local areas. This shows the former results have better synthetic performance than the latter. The presented methodology of HDD suspension will give another new approach to improve dynamical performance of HDD suspension. In the meantime, it also lay a good foundation for the research on design methodology of integrated structural topology and active controller.
3. The piezoelectric materials have been widely used in the field of structural active vibration control because of their excellent mechanical-electrical coupling characteristics. In this part, the interactive relationship between PZT and beam structure has been analyzed. To suppress head suspension vibration, by a cantilever as a researching object, the modeling theory about optimal locations of several PZT pieces along a cantilever surface is studied carefully, the integrated structure/control model, sensitive analysis techniques and its the formulas of gradations are presented. By above method, the computational time is reduced and the convergent instability is avoided compared to numerical method or evolutional method. It is discovered that there is a complicated interactive relationship between PZT location, length and controller in active vibration control, and shows that these parameters and their interactions, especially the interactions between structural parameters and these parameters, have decisive effect on dynamical performance. In term of the vibration feature in HDD running, it is necessary and proper that integrated optimization of structural topology and controller with multiple PZT pieces is performed in order to control several modes simultaneously. The researches also give a good theory foundation for further analysis to the interaction of integrated structural topology and PZT active controller.
4. In order to further improve the characteristics of HDD suspension, the design method of integrated topology theory and active vibration control is studied. By a smart flexible beam as a researching object, the coupling relationship between structure and PZT is analyzed. The analytic techniques including simultaneous optimal modeling, partial derivative analysis and PZT overlapping constraint condition etc. are presented. Integrated optimal design of structural topology, locations of several PZT actuators/sensors and active control parameters for plate structure are performed. The decomposition of design space in iterative method is avoided because of simultaneous optimal method. In the meantime, computational efficiency is increased and the convergent instability is improved by indirectly optimization based on gradations instead of numerical method or evolutional method. It is essential to farther researches and application of general integrated mechanical/controller design. Based above, the structural topology, PZT actuators/sensors and active controller parameters for HDD suspension are simultaneously optimized by MMA(method of moving asymptotes) method. Finally, the theoretical results have been simulated and analyzed by simulation and experiment. By computation and simulation, it is found the optimal result using simultaneous method is better than that using iterative method.
Above results will have important reference values to the futher researches and application on more general integrated design of mechatronical system.
1.首先介绍并分析了硬盘驱动器的工作原理和磁头驱动系统目前面临的主要问题,对结构的拓扑设计理论、压电主动控制技术和机电融合设计等相关的理论和方法、发展现状和趋势以及在磁头驱动臂设计中的应用进行了分析和总结。
2.为提高二维柔性板结构的动态特性,研究了基于结构动态柔度、冲击动态响应和动态稳定性的拓扑设计建模理论,提出了二维柔性板基于冲击动态响应和动态稳定性的拓扑设计的建模和灵敏度分析方法等,推导了冲击动态响应和动态稳定性作为目标时优化模型的梯度分析表达式,解决了通常采用的数值方法或进化算法带来的大计算量问题,进一步拓展了结构拓扑设计的理论。在此研究的基础上,以硬盘驱动臂为对象,进行了基于动态响应特性、冲击特性和动态稳定性的硬盘驱动臂拓扑设计和优化结果的分析。通过研究,发现它们和静态拓扑、基于频率的拓扑设计结果具有一定的局部相似性,表明基于动态响应的拓扑设计具有更好的综合性能,为改善HDD(hard disk drive)驱动臂的动态性能提供了一个强有力的设计手段,同时为后面的结构拓扑/主动控制融合设计的研究打下了良好的基础。
3.为抑制磁头驱动臂的振动,以柔性悬臂梁为研究对象,系统分析了PZT压电材料和悬臂梁的耦合关系,研究了PZT压电材料在梁上分布的优化建模理论,提出了多对压电片的尺寸、位置和主动控制优化的机电融合模型和灵敏度分析方法,导出了优化模型的梯度分析表达式,并对磁头驱动臂压电主动控制的压电片位置、长度和控制增益进行了优化。和通常采用的数值方法和进化算法相比,改善了优化收敛过程的稳定性,提高了计算效率。通过计算、分析和数值仿真,揭示了在梁的主动振动控制中压电片的位置、长度和控制参数之间存在的复杂耦合特性,说明了这些参数以及它们之间的耦合、甚至它们和结构本身的参数之间的相互作用对系统动态响应具有决定性的影响。因此,针对磁头驱动臂工作过程中宽频振动的特点采用多压电片对多阶模态进行结构/控制融合设计是非常必要和合理的选择。本章的研究为结构拓扑与PZT主动控制之间的耦合问题分析提供了一定的理论基础。
4.为从方法论上进一步改善磁头驱动臂的动态性能,以智能柔性板梁为对象,将结构拓扑设计理论与振动主动控制相融合,研究了结构和压电材料的耦合关系,提出了智能柔性板梁结构拓扑形态和主动控制的融合设计模型、偏导数分析方法、压电片的重叠约束条件等完整的分析理论,建立了柔性板梁的结构拓扑、PZT压电驱动器/传感器单元在结构中的布置以及主动控制参数融合的优化设计模型。由于直接采用基于梯度的分析优化计算,保证了较高的计算效率,既克服了迭代算法静态耦合和设计域分解退化等问题,又解决了进化算法和数值计算在拓扑设计中的大计算量和数值不稳定问题。在此理论研究基础上,对HDD驱动臂的结构拓扑、PZT压电陶瓷片的位置以及主动控制参数进行了并行优化设计,并采用仿真和实验对计算结果进行了分析。计算结果和仿真分析表明,采用并行的融合建模优化比迭代优化设计方法效果更好。
研究成果对于一般机电融合设计的研究和应用也有重要的参考价值。
There are many tiny structural parts with small size, high acceleration and high dynamical accuracy in microelectronical manufacturing equipments. These parts used in the extreme condition have been imposed more and more stringent performances in advanced application. It results in a situation where interactions between structure and controller are more and more significant, and because the conventional design practice along the sequential lines of structure then controller design ignores the crucial influence of their interaction on global dynamical performance, it provides limit ability to improve the dynamical performance of these parts further. How to effectively integrate mechanical structure with controller in terms of their interaction, especially how to build and solve the mathematical model of integrated structural topological design with large degrees and great computation with controller design, is coming to a challenge in researches on design methodology. HDD suspension is a very flexible tiny structure with high speed and high dynamical accuracy. As limited by space size, the flexible suspension is usually made very thin in thickness, and very sensitive to any disturbance or shock impact. At this stringent situation, even small mechanical vibration induced by seeking motion and outer disturbance may result in catastrophic error in data reading.
Supported by the National Natural Science Foundation(50390063) of“Study on accurate positioning and manipulating of motion system with high acceleration for die packaging”, this dissertation is focused on the researches of structural topological optimal based on dynamical performance and stability, PZT Piezoelectric control, the integrated modeling theory and its simultaneous optimal design about structural topology and active vibration controller about tiny structural part in order to improve the dynamical performance of a HDD suspension. These researches are applied to the optimal design of structural topological design, the PZT positions and controller parameters about a HDD suspension. The detail researches are followed as below.
1. The principle of head assembly and the main problems about design suspension design are introduced firstly. Structural topological design theories based on static compliance or resonance frequency, piezoelectric active control, integrated structure/controller design techniques , their application and development in HDD suspension design are also analyzed in detail.
2. In order to improve the dynamical performance of plane flexible beam, the topological design approach based on structural dynamical compliance, or dynamic response and stability under shock impact are studied, and the techniques about modeling of the topological design based on structural dynamical compliance, or dynamic response and stability under shock impact and their sensitive analysis are presented. Using these methods, the formulas of gradations of optimal model which objective function is dynamic response and stability under shock impact are derived . It saves large computational time by indirectly optimization based on gradations instead of numerical method or evolutional method, and extends the theory of structural topology design. Based above, HDD suspension topological design by structural dynamical compliance, or dynamic response and stability under shock impact is performed, and the optimal results are analyzed. As a result, several new topological structures of HDD suspension are obtained. It is discovered that the topological structures based on dynamical compliance are similar to that based on static compliance, first order torsion and sway frequencies at some local areas. This shows the former results have better synthetic performance than the latter. The presented methodology of HDD suspension will give another new approach to improve dynamical performance of HDD suspension. In the meantime, it also lay a good foundation for the research on design methodology of integrated structural topology and active controller.
3. The piezoelectric materials have been widely used in the field of structural active vibration control because of their excellent mechanical-electrical coupling characteristics. In this part, the interactive relationship between PZT and beam structure has been analyzed. To suppress head suspension vibration, by a cantilever as a researching object, the modeling theory about optimal locations of several PZT pieces along a cantilever surface is studied carefully, the integrated structure/control model, sensitive analysis techniques and its the formulas of gradations are presented. By above method, the computational time is reduced and the convergent instability is avoided compared to numerical method or evolutional method. It is discovered that there is a complicated interactive relationship between PZT location, length and controller in active vibration control, and shows that these parameters and their interactions, especially the interactions between structural parameters and these parameters, have decisive effect on dynamical performance. In term of the vibration feature in HDD running, it is necessary and proper that integrated optimization of structural topology and controller with multiple PZT pieces is performed in order to control several modes simultaneously. The researches also give a good theory foundation for further analysis to the interaction of integrated structural topology and PZT active controller.
4. In order to further improve the characteristics of HDD suspension, the design method of integrated topology theory and active vibration control is studied. By a smart flexible beam as a researching object, the coupling relationship between structure and PZT is analyzed. The analytic techniques including simultaneous optimal modeling, partial derivative analysis and PZT overlapping constraint condition etc. are presented. Integrated optimal design of structural topology, locations of several PZT actuators/sensors and active control parameters for plate structure are performed. The decomposition of design space in iterative method is avoided because of simultaneous optimal method. In the meantime, computational efficiency is increased and the convergent instability is improved by indirectly optimization based on gradations instead of numerical method or evolutional method. It is essential to farther researches and application of general integrated mechanical/controller design. Based above, the structural topology, PZT actuators/sensors and active controller parameters for HDD suspension are simultaneously optimized by MMA(method of moving asymptotes) method. Finally, the theoretical results have been simulated and analyzed by simulation and experiment. By computation and simulation, it is found the optimal result using simultaneous method is better than that using iterative method.
Above results will have important reference values to the futher researches and application on more general integrated design of mechatronical system.
引文
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