控制算法在自动浇注系统中的研究与仿真
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摘要
浇注是现代化铸造生产中十分重要的方法和工艺过程。我国是一个铸造生产大国,各铸造企业为了使自己能在激烈竞争的市场中赢得一席之地,对铸件质量的要求越来越苛刻。然而许多因素影响或制约了铸件质量、产量的提高,甚至很多铸造企业依然停留在人工浇注阶段,虽然人工浇注的铸件质量比较好,生产效率却很低。作者通过对铸造过程中浇注系统的分析和研究,发现影响铸件质量的主要因素是浇注过程中浇口杯的液位。它的高低不仅影响着铸件的质量和产量,而且如果控制不好,液位过高,会导致金属液从浇口杯中漏出,破坏整个浇注系统的正常工作;液位过低,又会造成铸件中缩松、缩孔、气泡等现象,甚至导致残次品的产生。
浇注系统是一个非常复杂的被控对象,它具有非线性、时变性、灰色性等特点,简单的PID控制方式虽然能实现浇注的自动化,但存在一定的缺点,控制参数很难调整,而且需要有经验的操作工人在线不断地对这些参数进行调整,才有可能达到浇注这个复杂多变被控系统的工艺要求。这种控制方法控制效果和有经验操作工人的控制效果相比,铸件的质量和产量存在较大的差别,而且随着操作工人的不断变更,这些宝贵的操作经验知识也有可能会随着丢失。因此有必要给浇注系统引进一些新的控制方法,以满足铸造中浇注系统自动控制的要求,从而推动我国铸造业的发展。
本文是围绕铸造浇注系统中液位的控制问题而展开的。浇口杯液位控制是浇注系统中重要的环节,是铸造生产的核心。如上所述,它的控制直接影响到铸件的质量和产量。采用传统的控制方法又很难达到控制要求。在对浇注系统进行分析和研究的基础上,作者通过现场不断地手动浇注以及与有丰富操作经验的工人进行交流,收集了大量的浇注知识。针对现有自动浇注系统的特点,将这些操作知识进行归纳总结,提出采用模糊控制的方法,并在简单模糊控制和PID控制的基础上提出一种新的控制算法,较好地解决了这一问题,达到了工艺要求。
在设计模糊控制器的过程中,通过不断仿真试验,作者发现隶属度函数,控制规则,调整因子等因素,对自动浇注系统中模糊控制器性能
Casting is a very important technique in modern casting. China is a big country for casting, all this kind of companies want to be successful in the hotly compete market, so the request to the cast is higher and higher, but there are many factors influence and restrict the improvement of the products. There are many factories still stay in the period of using workers to pouring, the result is that the quality is good, but the efficiency is low. The writer analyzed and studied the pouring system, found the key factor which influence the casts' quality is the fluid-station in the pouring cup. It is too higher, will make the molten metal overflow and destroy the whole common manufacturing process; or it is too lower, will make inferior products.The pouring system is a complex object to be controlled, which has the character of non-linear, occasional and ashen. Although simple control method can realize the auto-pouring, it has some shortcomings, that is, with the declining of molten iron level in pouring bag, it can' t response automatically to the change of the parameters of the controlled object, and need seasoned workers to adjust these parameters online, which is possible to reach the technical request. Compare the result with the seasoned workers' , the quality is very different, and if the workers are different and changing, the operational knowledge will be lost. So it' s necessary to in-troduce some new control method in the pouring system, in order to reach the technical request and impulse the development of the casting manufacturing in our country.This thesis is developed on an existing problem for the control of molten iron level in the casting system. The level of the pouring cup is the core in the casting procession; like what we said, the control will influence the quality and output of the production directly. It is very difficult to realize the control request if we just use traditional control methods. Base on the analyze and study, the writer constantly operate in the factory and communicate with the seasoned workers, collect a lot of operational knowledge, provide a fuzzy control based on the present existing problems in
the casting system, and combine the two control method to a new way to resolve the problem better, which realize the technical request.During designing the fuzzy control, the writer found the subject function, control rule, and adjusting-gene play very important roles to the capability of the controller, constantly correct these factors, emendate the controller which has been designed; chose the best factors which suit to the pouring system. Summarize the advantage and disadvantage in the traditional control and the fuzzy control, the writer design a new one which is a kind of controller can self-adjust parameters. At last, emulation proved that this control method has reached the respected control effect.
浇注系统是一个非常复杂的被控对象,它具有非线性、时变性、灰色性等特点,简单的PID控制方式虽然能实现浇注的自动化,但存在一定的缺点,控制参数很难调整,而且需要有经验的操作工人在线不断地对这些参数进行调整,才有可能达到浇注这个复杂多变被控系统的工艺要求。这种控制方法控制效果和有经验操作工人的控制效果相比,铸件的质量和产量存在较大的差别,而且随着操作工人的不断变更,这些宝贵的操作经验知识也有可能会随着丢失。因此有必要给浇注系统引进一些新的控制方法,以满足铸造中浇注系统自动控制的要求,从而推动我国铸造业的发展。
本文是围绕铸造浇注系统中液位的控制问题而展开的。浇口杯液位控制是浇注系统中重要的环节,是铸造生产的核心。如上所述,它的控制直接影响到铸件的质量和产量。采用传统的控制方法又很难达到控制要求。在对浇注系统进行分析和研究的基础上,作者通过现场不断地手动浇注以及与有丰富操作经验的工人进行交流,收集了大量的浇注知识。针对现有自动浇注系统的特点,将这些操作知识进行归纳总结,提出采用模糊控制的方法,并在简单模糊控制和PID控制的基础上提出一种新的控制算法,较好地解决了这一问题,达到了工艺要求。
在设计模糊控制器的过程中,通过不断仿真试验,作者发现隶属度函数,控制规则,调整因子等因素,对自动浇注系统中模糊控制器性能
Casting is a very important technique in modern casting. China is a big country for casting, all this kind of companies want to be successful in the hotly compete market, so the request to the cast is higher and higher, but there are many factors influence and restrict the improvement of the products. There are many factories still stay in the period of using workers to pouring, the result is that the quality is good, but the efficiency is low. The writer analyzed and studied the pouring system, found the key factor which influence the casts' quality is the fluid-station in the pouring cup. It is too higher, will make the molten metal overflow and destroy the whole common manufacturing process; or it is too lower, will make inferior products.The pouring system is a complex object to be controlled, which has the character of non-linear, occasional and ashen. Although simple control method can realize the auto-pouring, it has some shortcomings, that is, with the declining of molten iron level in pouring bag, it can' t response automatically to the change of the parameters of the controlled object, and need seasoned workers to adjust these parameters online, which is possible to reach the technical request. Compare the result with the seasoned workers' , the quality is very different, and if the workers are different and changing, the operational knowledge will be lost. So it' s necessary to in-troduce some new control method in the pouring system, in order to reach the technical request and impulse the development of the casting manufacturing in our country.This thesis is developed on an existing problem for the control of molten iron level in the casting system. The level of the pouring cup is the core in the casting procession; like what we said, the control will influence the quality and output of the production directly. It is very difficult to realize the control request if we just use traditional control methods. Base on the analyze and study, the writer constantly operate in the factory and communicate with the seasoned workers, collect a lot of operational knowledge, provide a fuzzy control based on the present existing problems in
the casting system, and combine the two control method to a new way to resolve the problem better, which realize the technical request.During designing the fuzzy control, the writer found the subject function, control rule, and adjusting-gene play very important roles to the capability of the controller, constantly correct these factors, emendate the controller which has been designed; chose the best factors which suit to the pouring system. Summarize the advantage and disadvantage in the traditional control and the fuzzy control, the writer design a new one which is a kind of controller can self-adjust parameters. At last, emulation proved that this control method has reached the respected control effect.
引文
[1] 王文清,铸造工艺学,机械工业出版社,1999
[2] 曲卫涛,铸造工艺学,西北工业大学出版社,2000:226-252
[3] 赵浩峰,现代压力铸造技术,中国标准出版社,2003.4
[4] 陈士梁,铸造机械化,机械工业出版社,1999
[5] 隋雪平译,自动浇注机国外铸造技术,1982:48-54
[6] 任天庆,铸造生产自动化装置与系统,机械工业出版社,1986
[7] 石纯一,黄昌宁,人工智能原理,清华大学出版社,1996
[8] 何新贵,模糊知识处理的理论与技术,国防工业出版社,1998
[9] Michio Sugeno, An Introductory Survey of Fuzzy Control, Information Science, 1985: (36)
[10] Wedsker L R, Hybrid neural network and expert systems, Norwell.Kluwer Academic Publishers,1994
[11] 韩俊峰,李玉惠,模糊控制技术,重庆大学出版社,2003
[12] 王士同,陈惠萍,赵跃华,钱旭,人工智能教程,电子工业出版社,181-215
[13] D.Driankov, H.Hellendoom, M.Reinfrunk, An introduction to fuzzy control, Springer-Verlag Berlin Heidelberg ,1996(Second Edition), 20-240
[14] R.Tong.etal, Theoretical Aspects of Fuzzy Control, Joho Wiley & Sons, Inc, 1995
[15] 黄坚,自动控制原理及其应用,高等教育出版社,2004.1
[16] 方康玲,过程控制系统,武汉理工大学出版社,2001
[17] 孙增析,系统分析与控制.清华大学出版社,1994
[18] Shinskey F G, Process Control Systems(Second Edition 1979),McCraw-Hill, New York
[19] 刘有才,刘增良,模糊专家系统原理与设计,北京航空航天大学出版社,1995,15-51
[20] 吴波,马玉祥,专家系统,北京理工大学出版社,2001.1
[21] 章卫国,杨向忠,模糊控制理论与应用,西北工业大学出版社,2001.2
[22] 张曾科,模糊数学在自动化技术中的应用,清华大学出版社,1996
[23] 楼顺天,胡昌华,张伟,基于MATLAB的系统分析与设计——模糊系统,西安电子科技大学出版社,2001
[24] 张乃绕,阎平凡,神经网络与模糊控制,清华大学出版社,166-216
[25] 诸静,模糊控制原理及应用.机械工业出版社,1999
[26] 窦振中,模糊逻辑控制技术及其应用,北京航空航天大学出版社,2001
[27] King P J, Mamdani E H, The Application of Fuzzy Control System to Industrial Process, 6th IFAC World Congr, Boston, 1975.
[28] R.I.Moor,et.al," A Real-Time Expert System for Process Control", Proc 1th Conf on AI Application, 1985
[29] Cai Zixing, Wang Yaonan, Tong Tiaosheng, A Real-Time Expert Control System: AI in Engineering, 1996, 10(4): 317-322
[30] K.Tamaka, T.Ikeda, H.Wang, Design of fuzzy control systems based on relaxed LMI stability conditions, Proceedings, 35th CDC, Japan, 1996: 598-602
[31] 王耀南,李树涛,王建旭,计算机图像处理与识别技术,高等教育出版社,2001.6
[32] 李士勇,模糊控制和智能控制理论与应用,哈尔滨工业大学出版社,2000
[33] 王建勋,模糊控制·神经控制和智能控制,北京航空航天大学出版社,1998
[34] M.Y.Chen, D.A.Linkens, A rule self-generating approach for fuzzy control, Proceedings, 35th CDC, Japan, 1996
[35] S.F.Graebe, G.C.Goodwin, M.R.west etal, An application of advanced control to steel casting, IEEE Control System, 1994, 64-71
[36] C.Ling, T.F. Edgar, The tuning of MIMO fuzzy heuristic controllers,Proceedings 12th IFAC World Congress, 1993, 67-70
[37] K.A.Ei-Metwally, O.P.Malik. Parameter tuning for a fuzzy logic controller, Proceedings 12th IFAC World Congress, 1993, 123-126
[38] 王顺晃,舒迪前,智能控制系统及应用,机械工业出版社,1995
[39] S.Xommuri, F.L.Lewis, Design and stability analysis of adaptive-fuzzy controllers for a class of nonlinear systems, Proceedings, 35th CDC, Japan, 1996:2729-2730
[40] 王耀南,模糊逻辑·专家系统·神经网络控制,湖南大学出版社,1996
[41] 杨西侠,林家恒,基于专家系统的自校正模糊控制器,模糊与决策,1999.2
[42] Chao C.T, Teng C.C, Implementation of a fuzzy inference system using a normalized fuzzy neural networks, Fuzzy Sets and Systems, 1995: 17-31
[43] 寒业,刘吉臻,董泽,过程建模方法的研究及其应用,华北电力学院学报,1994 NO.2
[44] 胡寿松,自动控制原理,国防工业出版社,1994
[45] 刘金坤,先进PID控制及其MATLAB仿真,电子工业出版社,2003.1
[46] 徐晰,李涛,伯晓晨,MATLAB工具箱应用指南-控制工程篇,电子工业出版社,2000.5
[47] 黄文梅,系统分析与仿真-MATLAB语言及应用,国防科技大学出版社,2001:52-55
[48] 楼顺天,施阳,基于MATLAB的系统分析与设计,西安电子科技大学出版社,1998.9
[2] 曲卫涛,铸造工艺学,西北工业大学出版社,2000:226-252
[3] 赵浩峰,现代压力铸造技术,中国标准出版社,2003.4
[4] 陈士梁,铸造机械化,机械工业出版社,1999
[5] 隋雪平译,自动浇注机国外铸造技术,1982:48-54
[6] 任天庆,铸造生产自动化装置与系统,机械工业出版社,1986
[7] 石纯一,黄昌宁,人工智能原理,清华大学出版社,1996
[8] 何新贵,模糊知识处理的理论与技术,国防工业出版社,1998
[9] Michio Sugeno, An Introductory Survey of Fuzzy Control, Information Science, 1985: (36)
[10] Wedsker L R, Hybrid neural network and expert systems, Norwell.Kluwer Academic Publishers,1994
[11] 韩俊峰,李玉惠,模糊控制技术,重庆大学出版社,2003
[12] 王士同,陈惠萍,赵跃华,钱旭,人工智能教程,电子工业出版社,181-215
[13] D.Driankov, H.Hellendoom, M.Reinfrunk, An introduction to fuzzy control, Springer-Verlag Berlin Heidelberg ,1996(Second Edition), 20-240
[14] R.Tong.etal, Theoretical Aspects of Fuzzy Control, Joho Wiley & Sons, Inc, 1995
[15] 黄坚,自动控制原理及其应用,高等教育出版社,2004.1
[16] 方康玲,过程控制系统,武汉理工大学出版社,2001
[17] 孙增析,系统分析与控制.清华大学出版社,1994
[18] Shinskey F G, Process Control Systems(Second Edition 1979),McCraw-Hill, New York
[19] 刘有才,刘增良,模糊专家系统原理与设计,北京航空航天大学出版社,1995,15-51
[20] 吴波,马玉祥,专家系统,北京理工大学出版社,2001.1
[21] 章卫国,杨向忠,模糊控制理论与应用,西北工业大学出版社,2001.2
[22] 张曾科,模糊数学在自动化技术中的应用,清华大学出版社,1996
[23] 楼顺天,胡昌华,张伟,基于MATLAB的系统分析与设计——模糊系统,西安电子科技大学出版社,2001
[24] 张乃绕,阎平凡,神经网络与模糊控制,清华大学出版社,166-216
[25] 诸静,模糊控制原理及应用.机械工业出版社,1999
[26] 窦振中,模糊逻辑控制技术及其应用,北京航空航天大学出版社,2001
[27] King P J, Mamdani E H, The Application of Fuzzy Control System to Industrial Process, 6th IFAC World Congr, Boston, 1975.
[28] R.I.Moor,et.al," A Real-Time Expert System for Process Control", Proc 1th Conf on AI Application, 1985
[29] Cai Zixing, Wang Yaonan, Tong Tiaosheng, A Real-Time Expert Control System: AI in Engineering, 1996, 10(4): 317-322
[30] K.Tamaka, T.Ikeda, H.Wang, Design of fuzzy control systems based on relaxed LMI stability conditions, Proceedings, 35th CDC, Japan, 1996: 598-602
[31] 王耀南,李树涛,王建旭,计算机图像处理与识别技术,高等教育出版社,2001.6
[32] 李士勇,模糊控制和智能控制理论与应用,哈尔滨工业大学出版社,2000
[33] 王建勋,模糊控制·神经控制和智能控制,北京航空航天大学出版社,1998
[34] M.Y.Chen, D.A.Linkens, A rule self-generating approach for fuzzy control, Proceedings, 35th CDC, Japan, 1996
[35] S.F.Graebe, G.C.Goodwin, M.R.west etal, An application of advanced control to steel casting, IEEE Control System, 1994, 64-71
[36] C.Ling, T.F. Edgar, The tuning of MIMO fuzzy heuristic controllers,Proceedings 12th IFAC World Congress, 1993, 67-70
[37] K.A.Ei-Metwally, O.P.Malik. Parameter tuning for a fuzzy logic controller, Proceedings 12th IFAC World Congress, 1993, 123-126
[38] 王顺晃,舒迪前,智能控制系统及应用,机械工业出版社,1995
[39] S.Xommuri, F.L.Lewis, Design and stability analysis of adaptive-fuzzy controllers for a class of nonlinear systems, Proceedings, 35th CDC, Japan, 1996:2729-2730
[40] 王耀南,模糊逻辑·专家系统·神经网络控制,湖南大学出版社,1996
[41] 杨西侠,林家恒,基于专家系统的自校正模糊控制器,模糊与决策,1999.2
[42] Chao C.T, Teng C.C, Implementation of a fuzzy inference system using a normalized fuzzy neural networks, Fuzzy Sets and Systems, 1995: 17-31
[43] 寒业,刘吉臻,董泽,过程建模方法的研究及其应用,华北电力学院学报,1994 NO.2
[44] 胡寿松,自动控制原理,国防工业出版社,1994
[45] 刘金坤,先进PID控制及其MATLAB仿真,电子工业出版社,2003.1
[46] 徐晰,李涛,伯晓晨,MATLAB工具箱应用指南-控制工程篇,电子工业出版社,2000.5
[47] 黄文梅,系统分析与仿真-MATLAB语言及应用,国防科技大学出版社,2001:52-55
[48] 楼顺天,施阳,基于MATLAB的系统分析与设计,西安电子科技大学出版社,1998.9