高精度二板式注塑机电液系统控制机理及性能研究
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摘要
高精度二板式注塑机作为精密注塑机的一个发展方向,越来越为注塑机制造企业所关注。液压控制系统是注塑机的核心技术之一,直接决定注塑机的性能。开发具有高响应速度、高精度、低超调等性能的液压系统是目前急需解决的问题,具有较大的经济效益。
本文在总结国内外注塑机液压系统相关研究的基础上,以宁波海天集团HT1600二板机型为研究对象,结合国家科技支撑计划项目“注塑机高效、节能的高精度液压控制系统研制”,分析了二板式注塑机液压控制系统的设计过程,对开关模、注射保压及顶出等典型工作过程进行数学建模及动态特性仿真分析。针对系统动态性能存在的不足,结合遗传算法,进行了控制策略的优化研究,达到改善系统响应特性的目的。本文具体研究内容如下:
1.基于二板注塑机的工作原理,分析了压力流量总液压控制系统及开关模、锁模、注射、顶出等过程模块液压控制系统的设计过程,并给出相应液压元件的选用原则。
2.对控制开关模和注射过程的大流量电液比例阀及控制顶出过程的三通比例阀等关键元件进行等效数学模型的建立工作,并分析了液流经过的各管道对系统性能的影响因素。
3.利用MATLAB/SIMULINK的仿真平台,对各典型工作过程进行仿真研究,分析了开关模、注射过程保压及顶出过程中系统的动态特性。
4.对于开关模及注塑等过程系统响应特性存在的不足,考虑到注射工艺对于注塑机工作过程中速度、压力、位置等参数的控制要求,控制过程中采取了双反馈闭环控制的策略,注塑保压过程采用流量压力切换控制,结合遗传算法,得到了高速、高精度、低超调量的系统响应特性曲线,改善了液压控制系统的性能。
As one development trend of high-precision injection molding machine, two-plate plastic injection molding machine has been paid more and more attention to by manufacturers. The design of its hydraulic control system, which has excellent dynamic characteristics of fast response speed, high precision and low overshoot, is one of the most sophisticated problems needed to be solved and a successfully developed hydraulic system with high performance will make big economic profits. Research presented in the paper plays an important role in the accomplishment of the national supporting project named 'Research on Precision Injection Molding Machine with High Efficiency and Low Energy Consumption'.
On summarizing researches related to hydraulic system at home and abroad, the design principles of electro-hydraulic system is presented by taking the two-plate injection molding machine 'HT1600' of Ningbo Haitian Co., Ltd as a research object. After analyzing the systems, mathematical models are built for the machine's typical working processes of which dynamic characteristics are simulated on the platform of MATLAB/SIMLINK6.0. Then an optimal control method adopting the idea of GA(Genetic Algorithms) is introduced to overcome shortages of the system's dynamic properties shown in the above simulation results. The main research contents go as follows:
1. According to the operating principles of two-plate injection molding machine, the design process of the hydraulic control system is presented which includes the plate open-close module, plate locking module, injecting module and pushing-out module.
2. An equivalent mathematical model of the electro-hydraulic valve which controls the process of open-close plate and injection as well as the tee proportional valve which controls the pushing-out action is established respectively, meanwhile, the influencing factors of each pipeline flowed through by fluid stream are analyzed.
3. On the basis of the modeling, operation processes of open-close plate, push-out action and injection are simulated on the platform of MATLAB/SIMLINK6.0 and their dynamic property curves are shown and analyzed.
4. To cope with the deficiencies of the system response, a double feedback closed-loop control is adopted, which meets the requirements of speed, pressure and position during machine's operating process. In the process of pressure maintaining, pressure and flow control switchover method combined with GA was adopted and thus, a satisfying response curve with fast speed, high degree of accuracy and low overshoot is got.
本文在总结国内外注塑机液压系统相关研究的基础上,以宁波海天集团HT1600二板机型为研究对象,结合国家科技支撑计划项目“注塑机高效、节能的高精度液压控制系统研制”,分析了二板式注塑机液压控制系统的设计过程,对开关模、注射保压及顶出等典型工作过程进行数学建模及动态特性仿真分析。针对系统动态性能存在的不足,结合遗传算法,进行了控制策略的优化研究,达到改善系统响应特性的目的。本文具体研究内容如下:
1.基于二板注塑机的工作原理,分析了压力流量总液压控制系统及开关模、锁模、注射、顶出等过程模块液压控制系统的设计过程,并给出相应液压元件的选用原则。
2.对控制开关模和注射过程的大流量电液比例阀及控制顶出过程的三通比例阀等关键元件进行等效数学模型的建立工作,并分析了液流经过的各管道对系统性能的影响因素。
3.利用MATLAB/SIMULINK的仿真平台,对各典型工作过程进行仿真研究,分析了开关模、注射过程保压及顶出过程中系统的动态特性。
4.对于开关模及注塑等过程系统响应特性存在的不足,考虑到注射工艺对于注塑机工作过程中速度、压力、位置等参数的控制要求,控制过程中采取了双反馈闭环控制的策略,注塑保压过程采用流量压力切换控制,结合遗传算法,得到了高速、高精度、低超调量的系统响应特性曲线,改善了液压控制系统的性能。
As one development trend of high-precision injection molding machine, two-plate plastic injection molding machine has been paid more and more attention to by manufacturers. The design of its hydraulic control system, which has excellent dynamic characteristics of fast response speed, high precision and low overshoot, is one of the most sophisticated problems needed to be solved and a successfully developed hydraulic system with high performance will make big economic profits. Research presented in the paper plays an important role in the accomplishment of the national supporting project named 'Research on Precision Injection Molding Machine with High Efficiency and Low Energy Consumption'.
On summarizing researches related to hydraulic system at home and abroad, the design principles of electro-hydraulic system is presented by taking the two-plate injection molding machine 'HT1600' of Ningbo Haitian Co., Ltd as a research object. After analyzing the systems, mathematical models are built for the machine's typical working processes of which dynamic characteristics are simulated on the platform of MATLAB/SIMLINK6.0. Then an optimal control method adopting the idea of GA(Genetic Algorithms) is introduced to overcome shortages of the system's dynamic properties shown in the above simulation results. The main research contents go as follows:
1. According to the operating principles of two-plate injection molding machine, the design process of the hydraulic control system is presented which includes the plate open-close module, plate locking module, injecting module and pushing-out module.
2. An equivalent mathematical model of the electro-hydraulic valve which controls the process of open-close plate and injection as well as the tee proportional valve which controls the pushing-out action is established respectively, meanwhile, the influencing factors of each pipeline flowed through by fluid stream are analyzed.
3. On the basis of the modeling, operation processes of open-close plate, push-out action and injection are simulated on the platform of MATLAB/SIMLINK6.0 and their dynamic property curves are shown and analyzed.
4. To cope with the deficiencies of the system response, a double feedback closed-loop control is adopted, which meets the requirements of speed, pressure and position during machine's operating process. In the process of pressure maintaining, pressure and flow control switchover method combined with GA was adopted and thus, a satisfying response curve with fast speed, high degree of accuracy and low overshoot is got.
引文
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[20]M.R.Sirouspour,S.E.Salcudean.Nonlinear Control of a Hydraulic Parallel Manipulator.Proceedings of the 2001 IEEE,International Conference on Robotics and Automation.2001(5):21-26
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[37]李福义.液压技术与液压伺服系统.哈尔滨船舶工程学院出版社,1992.12
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[2]张玉梅.从全液压式二板注塑机看机电一体化.科技情报开发与经济,2003年第13卷第7期
[3]章胜亮.二板式注塑机的技术探讨及发展前景.轻工机械,2002年第1期
[4]王兴天.注塑技术与注塑机.化工工业出版社,2005:162
[5]刘成峰.注塑机电液控制系统的建模及仿真研究(学位论文).太原理工大学,2003.5
[6]宋孝臣.入口特性对蓄能器性能影响的研究(学位论文).燕山大学,2006.2
[7]霍族亮.悬臂式掘进机电液控制系统研究与仿真(学位论文).山东科技大学,2006.5
[8]H.Higo,K.Yamamoto,K.Tanaka.Bondgraph Analysis on Pressure Fluctuation in Hydraulic Pipes.Dept.of Mechanical Systems Engineering Kyushu Institute of Technology,2000
[9]贺鹏.电液比例速度控制系统的设计及特性研究(学位论文).昆明理工大学,2002.3
[10]H.C.W.Lau,T.T.Wong,K.F.Pun.Neural-fuzzy model ing of plastic injection molding machine for intelligent control.Expert Systems with Applications,1999(17):33-43
[11]邵安岑.电液比例压力流量复合控制阀的特性研究(学位论文).浙江大学,2002.2
[12]Heather Havlicsek,Andrew Aileyne.Nonlinear Modeling of an Electrohydraulic Injection Molding Machine.Department of Mechanical and Industrial Engineering.University of Illinois,1999.6
[13]Alexander Fink,Tarunraj Singh.Discrete Sliding Mode Controller for Pressure Control with an Electrohydraulic Servovalve.Proceedings of the 1998 IEEE,International Conference on Control Applications.1998(9):1-4
[14]曾宗桢,肖飞,张小安.反馈线性化在注塑机位置控制中的应用.液压与气动,2005年第11期
[15]Jouni Mattila,Tapio Virvalo.Energy-efficient Motion Control of a Hydraulic Manipulator.Proceedings of the 2000 IEEE,International Conference on Robotics and Automation.2000(4):3001-3002
[16]刘延俊,于刚,赵敬伟.基于模糊神经元网络的阀控马达系统仿真.山东大学学报(工学版),2006年8月第36卷第4期
[17]T.Knohl,H.Unbehauen.Adaptive Position Control of Electrohydraulic Servo Systems Using ANN.Mechatronics,2000(10):127-143
[18]J.L.Chang.Design of a robust controller using only output feedback to solve the servomechanism problem.IEE Proceedings online,No.20030081,2002.10
[19]蔡立.基于MATLAB的液压仿真系统的研究(学位论文).东南大学,2005.3
[20]M.R.Sirouspour,S.E.Salcudean.Nonlinear Control of a Hydraulic Parallel Manipulator.Proceedings of the 2001 IEEE,International Conference on Robotics and Automation.2001(5):21-26
[21]Rajesh Rajamani,Karl Hedrick.Adaptive Observers for Active Automotive Suspensions:Theory and Experiment.IEEE TRANSACTION ON CONTROL SYSTEMS TECHNOLOGY,1995(3)
[22]Andrew Alleyne,Rui Liu.A simplified approach to force control for electro-hydraulic system-s.Control Engineering Practice.2000(8):1347-1356
[23]王幼民、周革、王曙光.基于MATLAB的电液力伺服系统设计与优化.机械传动,2005年第29卷第4期
[24]Sang Yeal Lee,Hyung Suck Cho.A fuzzy controller for an electro-hydraulic fin actuator using phase plane method.Control Engineering Practice 2003(11):697-708
[25]成大先.机械设计手册(单行本:液压传动).化学工业出版社,2004
[26]杨培元,朱福元.液压系统设计简明手册.机械工业出版社,1994
[27]王守城,段俊勇.液压元件及选用.化学工业出版社,2007.4
[28]马永辉,徐宝富等.工程机械液压系统设计计算.机械工业出版社,1985
[29]陈愈,沈关耿,徐国俊等.液压阀.中国铁道出版社,1982.12
[30]张利平.液压传动系统及设计.化学工业出版社,2005
[31]张利平.液压控制系统及设计.化学工业出版社,2006
[32]陈启松.液压传动与控制手册.上海科学技术出版社,2006
[33]王红卫.建模与仿真.科学出版社,2002.3(2003.1第二次印刷)
[34]方水良.现代控制理论及其MATLAB实践.浙江大学出版社,第二版,2006.7
[35]王显正,陈正航.控制理论基础.科学出版社,2000.11(2004.8重印)
[36]吴根茂,邱敏秀,王庆丰,魏建华,孔晓武,傅新等.新编实用电液比例技术.浙江大学出版社,2006.9
[37]李福义.液压技术与液压伺服系统.哈尔滨船舶工程学院出版社,1992.12
[38]Bora Eryilmaz,Bruce H.Wilson.Unified modeling and analysis of a proportional valve.Journal of the Franklin Institute,2006(343):48-68
[39]路甬祥,胡大紘.电液比例控制技术.机械工业出版社,1988.11
[40]陆元章.液压系统的建模与分析.上海交通大学出版社,1989.12
[41]李永堂,雷步芳,高雨茁.液压系统建模与仿真.冶金工业出版社,2003.2
[42]王永安,马路,刘慧敏.MATLAB7.0/SIMULINK6.0建模仿真开发与高级工程应用.清华大学出版社,2005.12(2006.5重印)
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