模糊PID自整定控制在基于PLC的辙叉焊机上的应用
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摘要
目前,我国拥有自主知识产权的国产辙叉闪光对接焊机尚属空白,现场生产的辙叉焊接主要依靠引进国外的焊接设备或技术。本课题在研究了国外现行的主流闪光焊接装备的基础上,综合利用和结合了我国现有的技术与成果,研制了第一台具有自主知识产权的辙叉闪光对接焊机。这一成果摆脱了辙叉闪光焊接依赖进口设备的局面,实现了辙叉焊接装备国产化,对于节约外汇,提高我国焊接设备自动化水平有重要意义。
在研制中,依照闪光焊工艺参数的特点,参考大量实际生产经验,确定了合理的闪光焊工艺参数。按照闪光焊各个闪光阶段的工艺要求,建立了闪光速度控制的模型。闪光焊机是一个多变量、非线性、时变、随机干扰较强的系统,且无法确定准确的数学模型。采用经典的PID控制,动态调节时间长,超调量大,而且PID参数难以在线整定,影响闪光控制效果。针对经典PID控制器存在的问题,引入了模糊控制的控制策略,模糊控制器是一种近年来发展起来的新型控制器,其优点是不要求掌握受控对象的精确数学模型,将模糊控制和PID控制两者结合起来,扬长避短,既具有模糊控制灵活而适应性强的优点,又具有PID控制精度高的特点。采用模糊PID控制策略来调整闪光速度,达到控制闪光电流的目的。该控制器结构简单,易于实现,系统跟踪性能好,超调量小,在实际应用中效果较理想。
以闪光焊接工艺控制模型为基础,开发了一套以模糊PID控制器为基础的计算机控制系统。控制系统由工控机、PLC、数据采集系统等部分组成。PLC负责控制焊接的过程控制,工控机负责实时数据的采集、显示和储存。以Rockwell公司的PLC为控制核心,以Fuzzy-PID参数自整定控制策略的控制系统,实现了闪光焊全过程自动控制,在连续闪光焊阶段,将电流控制在限制之内,超调部分也不超过10%。采用该控制系统后,提高了闪光焊设备的效率,自动化程度更高,更加有利于焊接出高质量的焊头,实现了较好的经济技术指标。
Now,the flash butt welder of frog which hold self-owned intellectual property has not been even put into operation in China,frog welding mainly depends on the technology and equipment from abroad. In this dissertation,we use existing technology and production and develop the first flash butt welder which hold self-owned intellectual property in China,based on researching on flash welding equipment abroad. This technical achievement breaks away from the situation that we depends on import equipment to weld frog, realizes localization of frog welding equipment. It is importance to improve our automation level of welding equipment and save foreign exchange.
In the dissertation,we definite the rational technological parameter of flash welding according to the feature of parameter and many of production experience. We build the model of flash speed control according to the each flash stage of flash welding. Flash welding is a kind of system with multivariable, nonlinear, time-variation and strong random disturbance,and it can not fix on its accurate mathematical model. Traditional PID control have the features of long dynamic regulation time and high overshoot,moreover its PID parameters can hardly set online,and all this will effect the quality of welding products. So, Fuzzy control is drown into use to resolve the fault of traditional PID. Fuzzy controller is a sort of late model controller developed in last several years, its is a kind of precision mathematical model which don't require control controlled plant, contrarily, it organize and control decision table according to manual control regulation,and then determine controlled variable by control decision table. The method that band fuzzy control and PID control together not only have the merit of flexible and strong adaptable fuzzy control, but also have the feature of high precision PID control.
We adjust flash speed by using Fuzzy-PID control strategy to control flash current. This controller is of simple structure, easy to achieve, better trace performance, less overshoot and good effects in practical application. On the basis of the mathematic model of controlling process, we design a set of computer control system for Fuzzy-PID controller by superior computer, PLC, data acquisition system and other units. The PLC take charge of process control of welding, computer take charge of data to collect, display and store. By taking PLC made by Rockwell Corp. as main unit and Fuzzy-PID controller as control strategy, the automatic control function of flash welding is realized. In the sequence-flashing stage, this controller is managing to control the current into setting range, and overshoot decline
10%. After using this control system, the welder is of efficiency to weld, good to get high-quality welding head, and better economic and technical indicators is achieved.
在研制中,依照闪光焊工艺参数的特点,参考大量实际生产经验,确定了合理的闪光焊工艺参数。按照闪光焊各个闪光阶段的工艺要求,建立了闪光速度控制的模型。闪光焊机是一个多变量、非线性、时变、随机干扰较强的系统,且无法确定准确的数学模型。采用经典的PID控制,动态调节时间长,超调量大,而且PID参数难以在线整定,影响闪光控制效果。针对经典PID控制器存在的问题,引入了模糊控制的控制策略,模糊控制器是一种近年来发展起来的新型控制器,其优点是不要求掌握受控对象的精确数学模型,将模糊控制和PID控制两者结合起来,扬长避短,既具有模糊控制灵活而适应性强的优点,又具有PID控制精度高的特点。采用模糊PID控制策略来调整闪光速度,达到控制闪光电流的目的。该控制器结构简单,易于实现,系统跟踪性能好,超调量小,在实际应用中效果较理想。
以闪光焊接工艺控制模型为基础,开发了一套以模糊PID控制器为基础的计算机控制系统。控制系统由工控机、PLC、数据采集系统等部分组成。PLC负责控制焊接的过程控制,工控机负责实时数据的采集、显示和储存。以Rockwell公司的PLC为控制核心,以Fuzzy-PID参数自整定控制策略的控制系统,实现了闪光焊全过程自动控制,在连续闪光焊阶段,将电流控制在限制之内,超调部分也不超过10%。采用该控制系统后,提高了闪光焊设备的效率,自动化程度更高,更加有利于焊接出高质量的焊头,实现了较好的经济技术指标。
Now,the flash butt welder of frog which hold self-owned intellectual property has not been even put into operation in China,frog welding mainly depends on the technology and equipment from abroad. In this dissertation,we use existing technology and production and develop the first flash butt welder which hold self-owned intellectual property in China,based on researching on flash welding equipment abroad. This technical achievement breaks away from the situation that we depends on import equipment to weld frog, realizes localization of frog welding equipment. It is importance to improve our automation level of welding equipment and save foreign exchange.
In the dissertation,we definite the rational technological parameter of flash welding according to the feature of parameter and many of production experience. We build the model of flash speed control according to the each flash stage of flash welding. Flash welding is a kind of system with multivariable, nonlinear, time-variation and strong random disturbance,and it can not fix on its accurate mathematical model. Traditional PID control have the features of long dynamic regulation time and high overshoot,moreover its PID parameters can hardly set online,and all this will effect the quality of welding products. So, Fuzzy control is drown into use to resolve the fault of traditional PID. Fuzzy controller is a sort of late model controller developed in last several years, its is a kind of precision mathematical model which don't require control controlled plant, contrarily, it organize and control decision table according to manual control regulation,and then determine controlled variable by control decision table. The method that band fuzzy control and PID control together not only have the merit of flexible and strong adaptable fuzzy control, but also have the feature of high precision PID control.
We adjust flash speed by using Fuzzy-PID control strategy to control flash current. This controller is of simple structure, easy to achieve, better trace performance, less overshoot and good effects in practical application. On the basis of the mathematic model of controlling process, we design a set of computer control system for Fuzzy-PID controller by superior computer, PLC, data acquisition system and other units. The PLC take charge of process control of welding, computer take charge of data to collect, display and store. By taking PLC made by Rockwell Corp. as main unit and Fuzzy-PID controller as control strategy, the automatic control function of flash welding is realized. In the sequence-flashing stage, this controller is managing to control the current into setting range, and overshoot decline
10%. After using this control system, the welder is of efficiency to weld, good to get high-quality welding head, and better economic and technical indicators is achieved.
引文
[01]董卫国,刘奇梅.钢轨无缝线路焊接技术现状.焊接. 2000(3):37~39.
[02]戴虹,吕其兵,骆德阳,谭克利.高速轨道焊接技术与装备的发展(一).电焊机. 2003(6):4~6.
[03]戴虹,吕其兵,骆德阳,谭克利.高速轨道焊接技术与装备的发展(二).电焊机. 2003(7):7~11.
[04]董卫国,郭面焕,赵敏海,邓丙伟.铁道线路无缝连接技术发展.焊接. 2003(3):5~9.
[05]中国机械工程学会焊接学会.焊接手册(第二版)第一卷:焊接方法与设备.北京:机械工业出版社. 2001:196-201.
[06]王志中,杨来顺.钢轨焊接工.北京:中国铁道出版社. 1995:25-28.
[07]王治平,王克争,何方殿.闪光焊工艺与设备的发展.焊接学报. 2000,21(3)93~96.
[08]俞行峰. UN5-200型钢轨交流闪光焊机的研制[硕士论文].成都:西南交通大学. 2007
[09]钟肇新,彭侃.可编程控制器原理及应用(第二版).南昌:华南理工大学出版社. 1991:14-23.
[10]常斗南.可编程序控制器原理应用实验.北京:机械工业出版杜. 2003:43-46.
[11]吴建强,姜三勇.可编程控制器原理及其应用.哈尔滨:哈尔滨工业大学出版社. 1998:56-59.
[12]王永华.现代电气控制及PLC应用技术.北京:北京航空航天大学出版社. 2003:132-138.
[13] Allen-Bradley. SLC500TM系列可编程器系统概述. www.rockwellautomation.com. 2002.
[14] Allen-Bradley. RSLogix500编程软件. www.rockwellautomation.com. 2002.
[15]罗克韦尔自动化中国. DeviceNet分布式I/O快速配置.今日自动化期刊. 2003(5):34~35.
[16] Allen-Bradley. SLC 500TM系列可编程器选型指南. www.rockwellautomation.com. 2002.
[17] Allen-Bradley. SLC 500TM BASIC and BASIC-T Modules. www.rockwellautomation.com. 2002.
[18]郭敬枢,庄继东,孔峰.微机控制技术.重庆:重庆大学出版社. 1994:79-82.
[19]何克忠,郝忠恕.计算机控制系统分析与设计.北京:清华大学出版社. 1988:156-162.
[20]张宇河,金钰.计算机控制系统.北京:北京理工大学出版社. 1996:34-39.
[21]陶永华. PID控制原理和自整定策略.工业仪表与自动化装置. 1997(4):60~64.
[22]俞忠原,陈一民.工业过程控制计算机系统.北京:北京理工大学出版社. 1995:231-235.
[23]孙亮,杨鹏.自动控制原理.北京:北京工业大学出版社. 2001:79-84.
[24]吴林,陈善本.智能化焊接技术(第1版).北京:国防工业出版社. 2000:62-65.
[25]王守唐.模糊辨识模糊控制和稳定性的若干问题的研究.北京:中国科学院自动化研究所. 2001(14):10-14.
[26]王立新.模糊系统与模糊控制教程.北京:清华大学出版社. 2003:67-73.
[27]李人厚.智能控制理论和方法.西安:西安电子科技大学出版社. 1999:143-146.
[28] Sigeru O,Michifuml Y. Self-tuning neuron PID applied to an inverted pendulum system. Journal A. 2000,37(7):17~21.
[29] Astrom KJ.,Hang C C.Persson Pand Ho W K. Towards Intelligent PID Control. Automation. 2002,28(1):1~9.
[30] Wu ZhiQiao,Masaharu Mizumoto. PID Type Fuzzy and Parameters AdaptiveMethod. Fuzzy Sets and Systems. 1999(78):23~35.
[31] Minyou Chen,D.A.Linkens. A hybrid neuro- fuzzy PID controller. Fuzzy Sets and System. 2001,99(1):27~36.
[32] Sigeru O.,Michifuml Y. Self-tuning neuron PID applied to an inverted pendulum system.Journal A,2000,37(7):17~21.
[33] M Zhuang,D.P.Atherton. Automatic tuning of optimum PID controllers. IEEE Proceedings Control and Applications. 1998(140):216~224.
[34] Kraus T.W.,T.J.Myron. SeIf-Tuning PID Controller Use Pattern Recognition Approch. Control Engineering. 1999(6):106~111.
[35]高东杰,谭杰,林红权.应用先进控制技术.北京:国防工业出版社. 2003:171-175.
[36]李士勇.模糊控制神经控制与智能控制论.哈尔滨:哈尔滨工业大学出版社. 1996:79-84.
[37] Wu ZhiQiao,Masaharu Mizumoto,PID Type Fuzzy and Parameters AdaptiveMethod. Fuzzy sets and Systems. 1999.78:23-35.
[38]张淑琴.参数自调整Fuzzy-PI控制算法在低压真空烧结炉中的应用.工业加热. 1997(5):21~25.
[39] Goberhansingh E,Cluett W R. Evaluation of an Industrail PID Auto-turner. Lecture Notes Control and Information Science. 1998(137):295~305.
[40]吴晓莉,林哲辉. MATLAB辅助模糊系统设计.西安:西安电子科技大学出版社. 2002:4-5.
[41]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:西安电子科技大学出版社. 2001:15-22.
[42]马常举,马伯渊.基于MATLAB的参数模糊自整定PID控制器的设计与仿真研究.虚拟仪器与EDA专题. 2007(10):20~22.
[43]张晶,汪滨琦,崔大海.基于MATLAB的转台模糊自适应控制器设计.应用科技. 2007,34(10):43~46.
[44]肖奇军,李胜勇.模糊自整定PID控制器设计以及MATLAB仿真分析.计算机仿真. 2005(9):242~244.
[45]刘建,秦春节,黄中原.基于MATLAB的电液伺服系统预测研究及优化设计.现代制造工程. 2006(8):89~91.
[46] Rockwell Automation. Logix 500 Controllers General Instructions. www.rockwellautomation.com. 2005.
[47] Rockwell Automation.ControlLogix Controllers User Manual. www.rockwellautomation.com. 2005.
[48] Rockwell Automation.RsLogix500 Getting Results Guid. www.rockwellautomation.com. 2000.
[49]李凤阁,佟为明.电气控制与可编程控制器应用技术.北京:机械工业出版社. 2007:251-259.
[50] David. Geller.可编程序控制器原理与设计.北京:清华大学出版社. 2006:49-55.
[51]钱晓龙,李晓理.循序渐进SLC500控制系统与PanelView训练课.北京:机械工业出版社. 2008:266-272.
[02]戴虹,吕其兵,骆德阳,谭克利.高速轨道焊接技术与装备的发展(一).电焊机. 2003(6):4~6.
[03]戴虹,吕其兵,骆德阳,谭克利.高速轨道焊接技术与装备的发展(二).电焊机. 2003(7):7~11.
[04]董卫国,郭面焕,赵敏海,邓丙伟.铁道线路无缝连接技术发展.焊接. 2003(3):5~9.
[05]中国机械工程学会焊接学会.焊接手册(第二版)第一卷:焊接方法与设备.北京:机械工业出版社. 2001:196-201.
[06]王志中,杨来顺.钢轨焊接工.北京:中国铁道出版社. 1995:25-28.
[07]王治平,王克争,何方殿.闪光焊工艺与设备的发展.焊接学报. 2000,21(3)93~96.
[08]俞行峰. UN5-200型钢轨交流闪光焊机的研制[硕士论文].成都:西南交通大学. 2007
[09]钟肇新,彭侃.可编程控制器原理及应用(第二版).南昌:华南理工大学出版社. 1991:14-23.
[10]常斗南.可编程序控制器原理应用实验.北京:机械工业出版杜. 2003:43-46.
[11]吴建强,姜三勇.可编程控制器原理及其应用.哈尔滨:哈尔滨工业大学出版社. 1998:56-59.
[12]王永华.现代电气控制及PLC应用技术.北京:北京航空航天大学出版社. 2003:132-138.
[13] Allen-Bradley. SLC500TM系列可编程器系统概述. www.rockwellautomation.com. 2002.
[14] Allen-Bradley. RSLogix500编程软件. www.rockwellautomation.com. 2002.
[15]罗克韦尔自动化中国. DeviceNet分布式I/O快速配置.今日自动化期刊. 2003(5):34~35.
[16] Allen-Bradley. SLC 500TM系列可编程器选型指南. www.rockwellautomation.com. 2002.
[17] Allen-Bradley. SLC 500TM BASIC and BASIC-T Modules. www.rockwellautomation.com. 2002.
[18]郭敬枢,庄继东,孔峰.微机控制技术.重庆:重庆大学出版社. 1994:79-82.
[19]何克忠,郝忠恕.计算机控制系统分析与设计.北京:清华大学出版社. 1988:156-162.
[20]张宇河,金钰.计算机控制系统.北京:北京理工大学出版社. 1996:34-39.
[21]陶永华. PID控制原理和自整定策略.工业仪表与自动化装置. 1997(4):60~64.
[22]俞忠原,陈一民.工业过程控制计算机系统.北京:北京理工大学出版社. 1995:231-235.
[23]孙亮,杨鹏.自动控制原理.北京:北京工业大学出版社. 2001:79-84.
[24]吴林,陈善本.智能化焊接技术(第1版).北京:国防工业出版社. 2000:62-65.
[25]王守唐.模糊辨识模糊控制和稳定性的若干问题的研究.北京:中国科学院自动化研究所. 2001(14):10-14.
[26]王立新.模糊系统与模糊控制教程.北京:清华大学出版社. 2003:67-73.
[27]李人厚.智能控制理论和方法.西安:西安电子科技大学出版社. 1999:143-146.
[28] Sigeru O,Michifuml Y. Self-tuning neuron PID applied to an inverted pendulum system. Journal A. 2000,37(7):17~21.
[29] Astrom KJ.,Hang C C.Persson Pand Ho W K. Towards Intelligent PID Control. Automation. 2002,28(1):1~9.
[30] Wu ZhiQiao,Masaharu Mizumoto. PID Type Fuzzy and Parameters AdaptiveMethod. Fuzzy Sets and Systems. 1999(78):23~35.
[31] Minyou Chen,D.A.Linkens. A hybrid neuro- fuzzy PID controller. Fuzzy Sets and System. 2001,99(1):27~36.
[32] Sigeru O.,Michifuml Y. Self-tuning neuron PID applied to an inverted pendulum system.Journal A,2000,37(7):17~21.
[33] M Zhuang,D.P.Atherton. Automatic tuning of optimum PID controllers. IEEE Proceedings Control and Applications. 1998(140):216~224.
[34] Kraus T.W.,T.J.Myron. SeIf-Tuning PID Controller Use Pattern Recognition Approch. Control Engineering. 1999(6):106~111.
[35]高东杰,谭杰,林红权.应用先进控制技术.北京:国防工业出版社. 2003:171-175.
[36]李士勇.模糊控制神经控制与智能控制论.哈尔滨:哈尔滨工业大学出版社. 1996:79-84.
[37] Wu ZhiQiao,Masaharu Mizumoto,PID Type Fuzzy and Parameters AdaptiveMethod. Fuzzy sets and Systems. 1999.78:23-35.
[38]张淑琴.参数自调整Fuzzy-PI控制算法在低压真空烧结炉中的应用.工业加热. 1997(5):21~25.
[39] Goberhansingh E,Cluett W R. Evaluation of an Industrail PID Auto-turner. Lecture Notes Control and Information Science. 1998(137):295~305.
[40]吴晓莉,林哲辉. MATLAB辅助模糊系统设计.西安:西安电子科技大学出版社. 2002:4-5.
[41]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:西安电子科技大学出版社. 2001:15-22.
[42]马常举,马伯渊.基于MATLAB的参数模糊自整定PID控制器的设计与仿真研究.虚拟仪器与EDA专题. 2007(10):20~22.
[43]张晶,汪滨琦,崔大海.基于MATLAB的转台模糊自适应控制器设计.应用科技. 2007,34(10):43~46.
[44]肖奇军,李胜勇.模糊自整定PID控制器设计以及MATLAB仿真分析.计算机仿真. 2005(9):242~244.
[45]刘建,秦春节,黄中原.基于MATLAB的电液伺服系统预测研究及优化设计.现代制造工程. 2006(8):89~91.
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