液压盘式制动器钳体强度测控系统试验设备的研制
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摘要
伴随对产品质量要求的提高,原本应用于生产线检测制动钳钳体静扭强度的试验台已不能满足产品精度的要求。生产线实验设备的产品检测常以效率为主,质量要求次之,故极易出现争议产品,而对待此类产品,企业现有设备无法作出客观的检测结果。本文应企业之需,结合浙江玉环摩托车生产企业关于制动钳总成试验台的开发项目,设计研制出制动钳钳体静扭强度测控系统试验台。
本论文研究的测控系统试验设备依照QC/T592—1999——轿车制动钳总成性能要求及台架试验方法标准进行设计,并根据其相关标准判断产品是否合格。该系统主要包括剪切机构、压力调节装置、制动液供给装置和西门子PLC控制系统四部分结构。该试验台产品检测质量,主要取决于制动扭矩与钳口夹紧力精度。剪切机构用于实现钳体总成的装夹定位和传送制动扭矩,故该部分主要从制动钳钳体夹具和动力传动结构入手设计。钳口夹紧力精度取决于压力供给装置,压力调节装置的重点为钳口夹紧力标准值的实现,故压力调节分两步完成,第一步进行压力粗调过程,第二步进行压力微调过程,从而准确控制压力变化。制动液供给系统的设计则以制动液的回收与储存为重点。
本试验设备控制系统基于以西门子PLC控制技术,按照试验步骤实现试验台检测动作的自动化。控制系统以模块组态和程序编制为重点,同时吸收以往试验台信息采集电路的经验,选择合适的传感器以及设计驱动放大电路和继电器电路。该控制系统与人机界面相结合,通过操作面板能够控制试验进程,并能实时观测检测数据与信号变化,使得操作人员可完全掌控产品检测的试验过程。
本论文设计了测控系统试验设备机械结构的二维图形与实体装配三维图形,完成了气动传递管路、西门子PLC控制系统的程序编制、PLC模块之间以及PLC与被控电磁阀的电路连接。该试验台操作简便,精度高,已成功地应用于企业中,为企业产品的性能检测质量提供了更有效的技术保障,为测控系统试验设备提供了更广阔的应用平台。
With the increase of the product quality, the past testing equipment which was used to inspect the stationary strength of braking caliper on line can't meet the requirement of product precision. The efficiency is the most important to the experimental equipment on line and the quality is little considered, so the disputed production maybe constant. Aim at this phenomenon, the present equipment can't make right result. So the enterprise must design advanced testing equipment. Combining with the certain product firm, I development a set of testing equipment for testing the stationary strength of braking caliper to accommodate with situation now. The equipment operates easily、precisely and meet the requirement of enterprise.
The equipment is designed according to the QCT/592-1999 standard. The control system includes shearing mechanical、pressure-regulating device、braking fluid-supplied mechanics and SIEMENS PLC control system. The testing quality lies on the precision of torque and the caliper force. The braking torque is realized by the internal mechanics of shearing device, so this part design start with caliper fixture and power driving parts. The pressure-regulating system is realized by caliper force, so this part is accomplished by two steps including brief and careful regulating course. The braking fluid-supplied system design emphasize on the recall and store of braking fluid.
The control system of testing system emphasizes on the SIEMENS PLC and inspects the automation of equipment. The part includes module configuration and program-written, meanwhile choose suitable sensor and driving circuit when absorbing past experience. The part can observe the data real time and signal variation, and make the operator master the testing course combined with interface.
At last, the thesis will finish the two-dimensions drawing and three-dimension assembly of the testing equipment, and accomplish the pneumatic driving pipeline、program-written of SIMENS PLC control system and the connection between PLC and electromagnetic valves. After designing it, the equipment can strengthen the conviction of enterprise、improve product quality and enterprise fame. It also can provide the applying platform for the testing equipment.
本论文研究的测控系统试验设备依照QC/T592—1999——轿车制动钳总成性能要求及台架试验方法标准进行设计,并根据其相关标准判断产品是否合格。该系统主要包括剪切机构、压力调节装置、制动液供给装置和西门子PLC控制系统四部分结构。该试验台产品检测质量,主要取决于制动扭矩与钳口夹紧力精度。剪切机构用于实现钳体总成的装夹定位和传送制动扭矩,故该部分主要从制动钳钳体夹具和动力传动结构入手设计。钳口夹紧力精度取决于压力供给装置,压力调节装置的重点为钳口夹紧力标准值的实现,故压力调节分两步完成,第一步进行压力粗调过程,第二步进行压力微调过程,从而准确控制压力变化。制动液供给系统的设计则以制动液的回收与储存为重点。
本试验设备控制系统基于以西门子PLC控制技术,按照试验步骤实现试验台检测动作的自动化。控制系统以模块组态和程序编制为重点,同时吸收以往试验台信息采集电路的经验,选择合适的传感器以及设计驱动放大电路和继电器电路。该控制系统与人机界面相结合,通过操作面板能够控制试验进程,并能实时观测检测数据与信号变化,使得操作人员可完全掌控产品检测的试验过程。
本论文设计了测控系统试验设备机械结构的二维图形与实体装配三维图形,完成了气动传递管路、西门子PLC控制系统的程序编制、PLC模块之间以及PLC与被控电磁阀的电路连接。该试验台操作简便,精度高,已成功地应用于企业中,为企业产品的性能检测质量提供了更有效的技术保障,为测控系统试验设备提供了更广阔的应用平台。
With the increase of the product quality, the past testing equipment which was used to inspect the stationary strength of braking caliper on line can't meet the requirement of product precision. The efficiency is the most important to the experimental equipment on line and the quality is little considered, so the disputed production maybe constant. Aim at this phenomenon, the present equipment can't make right result. So the enterprise must design advanced testing equipment. Combining with the certain product firm, I development a set of testing equipment for testing the stationary strength of braking caliper to accommodate with situation now. The equipment operates easily、precisely and meet the requirement of enterprise.
The equipment is designed according to the QCT/592-1999 standard. The control system includes shearing mechanical、pressure-regulating device、braking fluid-supplied mechanics and SIEMENS PLC control system. The testing quality lies on the precision of torque and the caliper force. The braking torque is realized by the internal mechanics of shearing device, so this part design start with caliper fixture and power driving parts. The pressure-regulating system is realized by caliper force, so this part is accomplished by two steps including brief and careful regulating course. The braking fluid-supplied system design emphasize on the recall and store of braking fluid.
The control system of testing system emphasizes on the SIEMENS PLC and inspects the automation of equipment. The part includes module configuration and program-written, meanwhile choose suitable sensor and driving circuit when absorbing past experience. The part can observe the data real time and signal variation, and make the operator master the testing course combined with interface.
At last, the thesis will finish the two-dimensions drawing and three-dimension assembly of the testing equipment, and accomplish the pneumatic driving pipeline、program-written of SIMENS PLC control system and the connection between PLC and electromagnetic valves. After designing it, the equipment can strengthen the conviction of enterprise、improve product quality and enterprise fame. It also can provide the applying platform for the testing equipment.
引文
[1]崔德祥,苏广平.ATE—Krauss摩擦试验机的结构特点及其发展[J].大众科技,2005.11:249-251
[2]赵奇平,王翔.盘式制动器性能试验台模拟机的设计[J].汽车科技,2007.(1):47-49
[3]赵奇平,刘东晓,陈汉汛.摩托车湿式摩擦离合器性能试验台的研制[J].中国工程机械学报.2006.4(2):223-227
[4]吴向春,陈汉汛,贾建生.液压盘式制动器钳体强度自动检测技术[J].中国水运(理论版),2007.5(3):202-203
[5]徐达伟,吉孔武,陈汉汛等.摩托车制动器试验台测量精度分析[J].武汉汽车工业大学学报,1997.19(2):19-22
[6]罗宇航.流行PLC实用程序设计[M].西安:西安电子科技大学出版社,2006.12.34-54
[7]龚仲华.S7-200/300/400PLC应用技术—通用篇[M].北京:人民邮电出版社,2007.6.82-118
[8]陈其志,陈三昧.摩托车液压盘式制动器总成综合试验台的研制[J].摩托车技术,2004.10:22-24
[9]康冰.制动器试验系统开发:[硕士学位论文].吉林:吉林大学软件学院,2006.6
[10]赵奇平,陈汉汛,徐火燃.制动器性能试验台智能CAD系统实现[J].武汉理工大学学报(信息与管理工程版).2003.25(4):54-56
[11]宋家杰.PLC控制系统中的工程问题研究:[硕士学位论文].南京:南京理工大学自动化学院,2004
[12]韩占华,张志勇,孙晓明等.汽车用刹车泵试验台控制系统[J].流体技术,2006.34(5):34-37
[13]黄漫国,陶元芳,樊尚春.传感器在制动器试验台信号采集系统的应用[J].微纳电子技术,2007.7/8:183-187
[14]李平,卢博友,杨兵力等.PLC在水泵综合试验台控制系统中的应用[J].微机电信息,2006.2(12):53-54
[15]连志勇.电梯模型PLC控制系统设计:[硕士学位论文].西安:西安建筑科技大学机械学院,2005
[16]陈家瑞.汽车构造(下册)[M].北京:机械工业出版社,2005:82-370
[17]黄崇莉.基于CAN总线数控技术试验台控制系统的设计:[硕士学位论文].西安:西安科技大学电器工程学院,2006
[18]王先锋.惯性制动器试验台的控制系统设计及数据处理与分析:[硕士学文论文].长沙:湖南大学机械与汽车工程学院,2006
[19]齐玉峰,廖力清,欧阳昌华.飞机机轮联合载荷试验台的PLC控制系统[J].自动化与仪表,2006(1):55-57
[20]詹友刚.Pro/E中文野火版教程[M].北京:清华大学出版社,2004.1-46
[21]张继春,杨建国.装配设计与运动仿真及Pro/E实现[M].北京:国防工业出版社,2006.11-200
[22]徐兰君,邵卫宏.西门子PLC在工业热处理电炉中的应用[J].工业炉,2007.29(4):41-43
[23]华小洋,吴景刚,陈剑群.制动器参数可靠性研究及制动力矩的选择[J].起重运输机械.1995.(6)8-12
[24]陈小元,方凯,杨银贤.汽车制动器惯性试验台的系统设计与实现[J]..电子技术,2004.(5):55-57
[25]徐灏.机械设计手册(第一卷、第二卷、第三卷、第四卷)[M].北京:机械工业出版社,1992.22-146
[26]阎石主编.数字电子技术基础[M].北京:高等教育出版社,1998.114-186
[28]谭雪松,朱金波,朱新涛.Pro/ENGINEER Wildfire典型实例[M].北京:人民邮电出版社,2005.50-76
[29]童诗白,华成英.模拟电子技术基础[M].北京:高等教育出版社,2000.71-384
[30]苏铁力.传感器及其接口技术[M].北京:中国石化出版社,1998.2-211
[31]朱龙根.机械设计[M].北京:机械工业出版社,2006.321-328
[32]孙德辉.微型计算机控制系统[M].北京:冶金工业出版社,2001.183-204
[33]胡钢.微机原理及应用[M].北京:机械工业出版社,2001.348-355
[34]李澄,吴天生等.机械制图[M].北京:高等教育出版社,1997.183-371
[35]Corres Jesus M,Bravo Javier,Arregui,Francisco J,Matias Ignacio R.Vibration monitoring in electrical engines using an in-line fiber etalon sensors and Actuators[M],2006.8(4):506-515
[36]Gol O,Ojeah G.E,Blandford S.Computer aided testing of electrical machines[J].National Conference Publication-Institution of Engineers,1994.12(5):269-274
[27]Ma Huai-Jian,Wu Li-Hua,ZhangJian.Integration of automatic test systems for middle/small motor[J].Proceedings of the Second International Symposium on Instrumentation Science and Technology.2002.15(5):669-673
[37]Thermally induced roughness of tread-braked railway wheels.Part 1:Brake rig experiments Vernersson T.(Chalmers Univ of Technology)Source:Wear,v 236,n 1-2,Dec,1999.13(4):96-105
[38] D. Roy Choudhury and Shall Jain. Linear Interated Circuits. John Wiley and Son Inc, 1991
[39] Tamasho, Tadashi Doi, Kazuhiro. Technique for reducing brake drag torque in the non -braking mode JSAE REVIEW[J], 2000.12(2): 23-25
[40] Vernersson, T. Thermally induced roughness of tread-braked railway wheels[J]. Wear, 1999.236(2): 54-85
[41]SMS Eumuco. Clutch/Brake System For Eccentric Processes[M]. Metallurgia, 1999.13— 14
[42] Cui Shu-Mei, Wang Yue, Chai Feng. Virtual test system for permanent-magnet DC motor[J]. Journal of Harbin Institute of Technology (New Series), 2003.13(6): 200-203
[43] Voller, G. P. Tirovic,M, Morris,R. Analysis of automotive disc brake cooling characteristics Proceedings of the Institution of Mechanical Engineers[J], Part D: Journal of Automobile Egineering. 2003.8(5): 13-15
[2]赵奇平,王翔.盘式制动器性能试验台模拟机的设计[J].汽车科技,2007.(1):47-49
[3]赵奇平,刘东晓,陈汉汛.摩托车湿式摩擦离合器性能试验台的研制[J].中国工程机械学报.2006.4(2):223-227
[4]吴向春,陈汉汛,贾建生.液压盘式制动器钳体强度自动检测技术[J].中国水运(理论版),2007.5(3):202-203
[5]徐达伟,吉孔武,陈汉汛等.摩托车制动器试验台测量精度分析[J].武汉汽车工业大学学报,1997.19(2):19-22
[6]罗宇航.流行PLC实用程序设计[M].西安:西安电子科技大学出版社,2006.12.34-54
[7]龚仲华.S7-200/300/400PLC应用技术—通用篇[M].北京:人民邮电出版社,2007.6.82-118
[8]陈其志,陈三昧.摩托车液压盘式制动器总成综合试验台的研制[J].摩托车技术,2004.10:22-24
[9]康冰.制动器试验系统开发:[硕士学位论文].吉林:吉林大学软件学院,2006.6
[10]赵奇平,陈汉汛,徐火燃.制动器性能试验台智能CAD系统实现[J].武汉理工大学学报(信息与管理工程版).2003.25(4):54-56
[11]宋家杰.PLC控制系统中的工程问题研究:[硕士学位论文].南京:南京理工大学自动化学院,2004
[12]韩占华,张志勇,孙晓明等.汽车用刹车泵试验台控制系统[J].流体技术,2006.34(5):34-37
[13]黄漫国,陶元芳,樊尚春.传感器在制动器试验台信号采集系统的应用[J].微纳电子技术,2007.7/8:183-187
[14]李平,卢博友,杨兵力等.PLC在水泵综合试验台控制系统中的应用[J].微机电信息,2006.2(12):53-54
[15]连志勇.电梯模型PLC控制系统设计:[硕士学位论文].西安:西安建筑科技大学机械学院,2005
[16]陈家瑞.汽车构造(下册)[M].北京:机械工业出版社,2005:82-370
[17]黄崇莉.基于CAN总线数控技术试验台控制系统的设计:[硕士学位论文].西安:西安科技大学电器工程学院,2006
[18]王先锋.惯性制动器试验台的控制系统设计及数据处理与分析:[硕士学文论文].长沙:湖南大学机械与汽车工程学院,2006
[19]齐玉峰,廖力清,欧阳昌华.飞机机轮联合载荷试验台的PLC控制系统[J].自动化与仪表,2006(1):55-57
[20]詹友刚.Pro/E中文野火版教程[M].北京:清华大学出版社,2004.1-46
[21]张继春,杨建国.装配设计与运动仿真及Pro/E实现[M].北京:国防工业出版社,2006.11-200
[22]徐兰君,邵卫宏.西门子PLC在工业热处理电炉中的应用[J].工业炉,2007.29(4):41-43
[23]华小洋,吴景刚,陈剑群.制动器参数可靠性研究及制动力矩的选择[J].起重运输机械.1995.(6)8-12
[24]陈小元,方凯,杨银贤.汽车制动器惯性试验台的系统设计与实现[J]..电子技术,2004.(5):55-57
[25]徐灏.机械设计手册(第一卷、第二卷、第三卷、第四卷)[M].北京:机械工业出版社,1992.22-146
[26]阎石主编.数字电子技术基础[M].北京:高等教育出版社,1998.114-186
[28]谭雪松,朱金波,朱新涛.Pro/ENGINEER Wildfire典型实例[M].北京:人民邮电出版社,2005.50-76
[29]童诗白,华成英.模拟电子技术基础[M].北京:高等教育出版社,2000.71-384
[30]苏铁力.传感器及其接口技术[M].北京:中国石化出版社,1998.2-211
[31]朱龙根.机械设计[M].北京:机械工业出版社,2006.321-328
[32]孙德辉.微型计算机控制系统[M].北京:冶金工业出版社,2001.183-204
[33]胡钢.微机原理及应用[M].北京:机械工业出版社,2001.348-355
[34]李澄,吴天生等.机械制图[M].北京:高等教育出版社,1997.183-371
[35]Corres Jesus M,Bravo Javier,Arregui,Francisco J,Matias Ignacio R.Vibration monitoring in electrical engines using an in-line fiber etalon sensors and Actuators[M],2006.8(4):506-515
[36]Gol O,Ojeah G.E,Blandford S.Computer aided testing of electrical machines[J].National Conference Publication-Institution of Engineers,1994.12(5):269-274
[27]Ma Huai-Jian,Wu Li-Hua,ZhangJian.Integration of automatic test systems for middle/small motor[J].Proceedings of the Second International Symposium on Instrumentation Science and Technology.2002.15(5):669-673
[37]Thermally induced roughness of tread-braked railway wheels.Part 1:Brake rig experiments Vernersson T.(Chalmers Univ of Technology)Source:Wear,v 236,n 1-2,Dec,1999.13(4):96-105
[38] D. Roy Choudhury and Shall Jain. Linear Interated Circuits. John Wiley and Son Inc, 1991
[39] Tamasho, Tadashi Doi, Kazuhiro. Technique for reducing brake drag torque in the non -braking mode JSAE REVIEW[J], 2000.12(2): 23-25
[40] Vernersson, T. Thermally induced roughness of tread-braked railway wheels[J]. Wear, 1999.236(2): 54-85
[41]SMS Eumuco. Clutch/Brake System For Eccentric Processes[M]. Metallurgia, 1999.13— 14
[42] Cui Shu-Mei, Wang Yue, Chai Feng. Virtual test system for permanent-magnet DC motor[J]. Journal of Harbin Institute of Technology (New Series), 2003.13(6): 200-203
[43] Voller, G. P. Tirovic,M, Morris,R. Analysis of automotive disc brake cooling characteristics Proceedings of the Institution of Mechanical Engineers[J], Part D: Journal of Automobile Egineering. 2003.8(5): 13-15