巨型模锻液压机主动同步控制系统研究
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摘要
巨型模锻压机用于轻金属及其合金的大型模锻件的生产,也用于各种低塑性高强度钢、耐热钢以及碳素钢和低合金钢等黑色金属模锻件的生产,在国防和航空工业的大型模锻件生产中有着举足轻重的作用。由于液压系统的非线性,时变性,多缸运动交叉耦合影响;加工零件的非对称性产生的锻造偏心距等影响,导致活动横梁在运行过程中发生倾斜,影响工件的加工精度。在以往的大型锻压机中都是采用在活动横梁的下四角布置一套被动同步纠偏系统,这样不但增加设备开发维护的费用,而且在一些特殊的液压机由于结构和空间尺寸问题,不能布置被动同步系统。
本文紧密结合巨型模锻液压机同步控制的实际应用问题,提出一种基于多点驱动的主动同步控制方案,并开展了理论与实验研究,其主要内容为：
(1)设计了巨型模锻液压机多点驱动的主动同步控制系统；建立了以活动横梁为中心的多输入多输出数学模型；提出了保证压机良好控制性能的现代智能控制策略。
(2)研究了巨型模锻液压机主动同步控制系统的多通道解耦控制策略。仿真研究表明解耦后的系统对参数波动抑制性不强,当系统工况条件复杂多变、负载变化范围大时,不宜采用依赖精确数学模型的解耦算法。
(3)为了解决非线性参数波动对系统的影响,设计了主动同步控制系统的鲁棒控制器。仿真研究表明,该控制策略可以有效地调节系统的同步误差,并对系统参数波动的抑制性强。
(4)搭建了中南大学315T液压机实验平台,基于主动同步控制方案进行了具体的实验测试；实验结果表明本文提出的控制策略可以使系统有效地达到各项性能指标与要求。
Giant forging presses can be used to produce large-scale productions of light metal alloys, and also can be used to produce other ferrous metal forgings such as a variety of steel with low plasticity and high strength, heat-resistant steel and carbon steel and low-alloy steel and so on. It has a vital role in the production of forging of large-scale in defense and aviation industries. According to the effects of the hydraulic system's non-linearity, time variant, multi-cylinder sports cross-couple, the eccentricity produced by the non-symmetry of the processing of parts, as well as the active beams and framework can not have absolute rigidity, which easily occur elastic deformation and the power flow transmission distortion and so on, these lead to beam tilt during operation, affect the machining accuracy of parts. In the past, a large forging machines are used a passive sync correction system under the four corners of the active beams, which not only increase the cost of maintenance of equipment development, and some special hydraulic can not arrange passive synchronization system due to the problems of structural and spatial dimensions.
This close connection with the large hydraulic press forging the practical application of synchronization control issue, which is based on active multi-point-driven synchronous control program, and launched a theoretical and experimental research, and Its main contents include the following:
1、The Designed a giant hydraulic press forging multi-point-driven active sync control system; establishment of activity-beams centered multiple-input multiple-output mathematical model; made to ensure good control performance of the modern press intelligent control strategies.
2、Studied the giant die forging hydraulic press control system for active multi-channel synchronous decoupling control strategy. Simulation studies have shown that after decoupling the system parameters and volatility of inhibition is not strong, when the system is complex and changing working conditions, the load range is large, should not rely on accurate mathematical model using the decoupling algorithm.
3、In order to solve nonlinear parametric effects of fluctuations on the system design of active synchronous control system robust controller. Simulation studies show that the control strategy can effectively regulate the system synchronization error, and fluctuations in system parameters and strong inhibition.
4, Central South University,315T hydraulic machine to build experimental platform, based on active sync control program, using robust regulator control of a specific laboratory tests; Experimental results show that the robust regulator proposed in this paper allows the system to achieve various performance targets and requirements.
本文紧密结合巨型模锻液压机同步控制的实际应用问题,提出一种基于多点驱动的主动同步控制方案,并开展了理论与实验研究,其主要内容为：
(1)设计了巨型模锻液压机多点驱动的主动同步控制系统；建立了以活动横梁为中心的多输入多输出数学模型；提出了保证压机良好控制性能的现代智能控制策略。
(2)研究了巨型模锻液压机主动同步控制系统的多通道解耦控制策略。仿真研究表明解耦后的系统对参数波动抑制性不强,当系统工况条件复杂多变、负载变化范围大时,不宜采用依赖精确数学模型的解耦算法。
(3)为了解决非线性参数波动对系统的影响,设计了主动同步控制系统的鲁棒控制器。仿真研究表明,该控制策略可以有效地调节系统的同步误差,并对系统参数波动的抑制性强。
(4)搭建了中南大学315T液压机实验平台,基于主动同步控制方案进行了具体的实验测试；实验结果表明本文提出的控制策略可以使系统有效地达到各项性能指标与要求。
Giant forging presses can be used to produce large-scale productions of light metal alloys, and also can be used to produce other ferrous metal forgings such as a variety of steel with low plasticity and high strength, heat-resistant steel and carbon steel and low-alloy steel and so on. It has a vital role in the production of forging of large-scale in defense and aviation industries. According to the effects of the hydraulic system's non-linearity, time variant, multi-cylinder sports cross-couple, the eccentricity produced by the non-symmetry of the processing of parts, as well as the active beams and framework can not have absolute rigidity, which easily occur elastic deformation and the power flow transmission distortion and so on, these lead to beam tilt during operation, affect the machining accuracy of parts. In the past, a large forging machines are used a passive sync correction system under the four corners of the active beams, which not only increase the cost of maintenance of equipment development, and some special hydraulic can not arrange passive synchronization system due to the problems of structural and spatial dimensions.
This close connection with the large hydraulic press forging the practical application of synchronization control issue, which is based on active multi-point-driven synchronous control program, and launched a theoretical and experimental research, and Its main contents include the following:
1、The Designed a giant hydraulic press forging multi-point-driven active sync control system; establishment of activity-beams centered multiple-input multiple-output mathematical model; made to ensure good control performance of the modern press intelligent control strategies.
2、Studied the giant die forging hydraulic press control system for active multi-channel synchronous decoupling control strategy. Simulation studies have shown that after decoupling the system parameters and volatility of inhibition is not strong, when the system is complex and changing working conditions, the load range is large, should not rely on accurate mathematical model using the decoupling algorithm.
3、In order to solve nonlinear parametric effects of fluctuations on the system design of active synchronous control system robust controller. Simulation studies show that the control strategy can effectively regulate the system synchronization error, and fluctuations in system parameters and strong inhibition.
4, Central South University,315T hydraulic machine to build experimental platform, based on active sync control program, using robust regulator control of a specific laboratory tests; Experimental results show that the robust regulator proposed in this paper allows the system to achieve various performance targets and requirements.
引文
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[2]俞新陆.液压机[M].北京：机械工业出版社,1990：21-34
[3]黄明辉.巨型精密模锻水压机力流传递与监控研究：[博士学位论文].长沙：中南大学,2006
[4]北京重机厂.锻造液压机本体结构发展述评[J].重型机械,1982,39(1)：1-3
[5]林峰,颜永年.现代重型模锻液压机的关键技术.机械工程学报,2006,35(2)：9-14
[6]别洛夫著(靳辅安等译).水压机模锻.北京：国防工业出版社,1981：56-88
[7]颜永年.预应力钢丝缠绕机架立柱刚度的研究.清华大学科学学报,1980,45(3)：45-54
[8]俞新陆,杨津光.液压机的结构与控制.北京：机械工业出版社,2003：23-56
[9]王兆祥.液压机本体结构刚度行为分析的研究及其结构布局理论：[博士学位论文].北京：清华大学,1986：23-25
[10]钟掘,谭建平.大型模锻液压机同步系统特性仿真分析.中南工业大学学报,1995,增刊(1)：42-46
[11]国外巨型模锻水压机和航空大锻件概况.北京：三机部三O一所,1974：6-7
[12]李盛海.液压机构及其组合.北京：清华大学出版社,1992,34(2)：42-23
[13]段智勇.巨型模锻液压机整体功能评估与优化设计[硕士学位论文].长沙：中南大学,2007：12-23
[14]彭伟波.巨型模锻液压机典型组合结构的综合力学分析[硕士学位论文].长沙：中南大学,2007：6-7
[15]田会然.800MN多向模锻液压机本体结构设计及分析[硕士学位论文].秦皇岛：燕山大学,2005：34-35
[16]俞新陆.液压机的设计与应用.北京：机械工业出版社,2006：89-100
[17]赵长材,李文平,周维海.液压机柱塞球面支持的力学及机构学分析.重型机械,2006,44(1)：13-14
[18]李军.超大吨位球型支座的结构设计[博士学位论文].重庆：重庆大学,2006：9-10
[19]万福龙.电子机械设备中球面铰的设计.中国制造业信息化,2004,33(2)：75-80
[20]施光林,史维祥,李天石.液压同步闭环控制及其研究.机床与液压,1997,4(2)：3-7
[21]罗艳蕾.液压同步回路及同步控制系统实现的方法.液压与气动,2004,4(1)：65-67
[22]成大先主编.机械设计手册.北京：化学工业出版社,2002：36-37
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