大型皮带运输机软启动装置设计与性能研究
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摘要
随着科学技术的发展,皮带运输机越来越广泛的应用于各个行业。这些机械中有许多是大转动惯量或者必须带负载启动,启动冲击则是造成设备损坏或缩短其使用寿命的主要原因,最佳的解决方法是使用软启动技术。在分析了国内外重载机械软启动的方法和研究现状后,确定了使用机电结合式软启动技术作为所设计的大型皮带运输机的启动方式。
在软启动装置中,起动力合成作用的机械结构至关重要。本文以行星差动轮系为核心设计了软启动装置的机械结构,确定了正弦形加速度控制曲线作为装置的启动曲线。在此基础上,认真分析了机械结构的工作原理、运动学和动力学性能。整个软启动装置设计过程复杂,因此借助Pro/E三维软件建立了装置的虚拟样机,为物理样机的精确设计提供了保证。通过运动分析模块进行了装置的运动学和动力学仿真分析。
以PLC为核心设计了装置的控制系统,并确定了主电机、调速电机、变频器等关键零部件的型号。根据工作过程的要求,本文还分别针对软启动和软停车过程设计了控制系统程序流程。
在建立了软启动系统各个环节的数学模型的基础上,利用MATLAB/SIMULINK模块对系统进行了仿真研究。仿真结果表明,本文所设计的软启动系统能够满足运动要求,在重载的情况下能够实现系统可控的输出。
With the development of technology, the belt conveyor is becoming more and more widely used in various industries. A lot of these mechanical equipments are big votary inertia or have to start-up with overloaded. The impact of starting is the main reason why damage the machine or shorten its life. And the best solution way is to use a soft start-up technology. On the basis of analyzing the way and research status quo of start-up technology on the overloaded machine, the mechanical-electronic soft start-up technology is decided to use as the start way on giant belt conveyor that designed.
In the soft start-up equipment, the mechanism is very important. It has been designed with the planet differential gear train as the core, and the Sine-shaped acceleration control curve has been determined as the start-up curve. The thesis analyzed the mechanism’s working principle, kinematics and dynamics performance. Because of the complexity of the whole system, a virtual prototype of the device is established using the software Pro / E. which will ensure the physical prototype’s exactly design. The kinematics and dynamics simulation analysis is carried through the movement analysis module.
The control system has been designed with PLC as the core. The thesis has determined the model of the motors, the frequency converter that the key spare parts. According to the requirements of the work process, the control system’s program have been designed for soft start-up and stop.
On the basis of all aspects of mathematical model, the simulation experiment is made using MATLAB/SIMULINK. The result showed that the soft start-up system meet the movement requirement, the controllable output can be achieved In the case of overloading.
在软启动装置中,起动力合成作用的机械结构至关重要。本文以行星差动轮系为核心设计了软启动装置的机械结构,确定了正弦形加速度控制曲线作为装置的启动曲线。在此基础上,认真分析了机械结构的工作原理、运动学和动力学性能。整个软启动装置设计过程复杂,因此借助Pro/E三维软件建立了装置的虚拟样机,为物理样机的精确设计提供了保证。通过运动分析模块进行了装置的运动学和动力学仿真分析。
以PLC为核心设计了装置的控制系统,并确定了主电机、调速电机、变频器等关键零部件的型号。根据工作过程的要求,本文还分别针对软启动和软停车过程设计了控制系统程序流程。
在建立了软启动系统各个环节的数学模型的基础上,利用MATLAB/SIMULINK模块对系统进行了仿真研究。仿真结果表明,本文所设计的软启动系统能够满足运动要求,在重载的情况下能够实现系统可控的输出。
With the development of technology, the belt conveyor is becoming more and more widely used in various industries. A lot of these mechanical equipments are big votary inertia or have to start-up with overloaded. The impact of starting is the main reason why damage the machine or shorten its life. And the best solution way is to use a soft start-up technology. On the basis of analyzing the way and research status quo of start-up technology on the overloaded machine, the mechanical-electronic soft start-up technology is decided to use as the start way on giant belt conveyor that designed.
In the soft start-up equipment, the mechanism is very important. It has been designed with the planet differential gear train as the core, and the Sine-shaped acceleration control curve has been determined as the start-up curve. The thesis analyzed the mechanism’s working principle, kinematics and dynamics performance. Because of the complexity of the whole system, a virtual prototype of the device is established using the software Pro / E. which will ensure the physical prototype’s exactly design. The kinematics and dynamics simulation analysis is carried through the movement analysis module.
The control system has been designed with PLC as the core. The thesis has determined the model of the motors, the frequency converter that the key spare parts. According to the requirements of the work process, the control system’s program have been designed for soft start-up and stop.
On the basis of all aspects of mathematical model, the simulation experiment is made using MATLAB/SIMULINK. The result showed that the soft start-up system meet the movement requirement, the controllable output can be achieved In the case of overloading.
引文
1侯友夫,黄民,张永忠.带式输送机动态特性及控制技术.北京:煤炭工业出版社, 2004(5):53~66
2袁萍岳.泵控制功能软启动器的研究.科技广场. 2008(10): 191~193
3韩晶.基于差动轮系可控软启动装置虚拟产品开发研究.太原理工大学. 2005
4张以都.国内外重载机械设备软启动技术的研究.煤炭科学技术. 2001(9): 23~27
5赵国社.调速型液力偶合器的应用研究.中州煤炭. 2008(3):17~29
6陈叶,杨达文.调速型液力耦合器的研究及应用.煤矿机械. 2002(7):14~15
7王建华,王军.调速型液力偶合器在大型固定带式输送机中的软启动特点.煤矿现代化. 2001,1(40):32~33
8 Huang Xiaoguang, Wei Chenguan. Stability of oil film and output speed of hydro-viscous drive affected by the pressure of control oil. Journal of Beijing Institute of Technology. 2005, 3(3):185~187
9 Chen Ning, Qiu Minxiu. Research on the soft start-up performance of hydro-viscous drive. China Mechanical Engineering. 2005, 2(3): 305~307
10肖磊,尹岳等.液体粘性传动装置研究.煤矿机械. 2008, 29(4):04~106
11庄严.液体黏性传动装置在带式输送机中的应用.煤矿机械. 2008 (4):166~167
12阮忠唐.联轴器、离合器设计与选用指南.化学工业出版社, 2006
13 Vojislav D. Kalanovic, Dejan Popovic. Feedback error learning neural network for trans-femoral prosthesis. IEEE Trans on Rehabilitation Engineering. 2000,8(1): 71~80
14李改梅.低压大功率变频器的几个技术关注点.电机技术. 2009(6):35~39
15 Tian Hua Liu, Chih Ying Lin. Modeling and harmonics elimination for static frequency conveter driving a 300MVA synchronous machine. IEEE Transaction on Power Eletronics. 1996: 602~607
16 Tore Peterson, Kjell Frank. Starting of large synchronous motor using static frequency concreter IEEE Transaction on Power Eletronics. 2006:172~179
17周丽娜,尹志强.无刷直流电动机及其调速系统研究进展.电子技术. 2007(11):184~186
18 Tokuz L C. Hybrid machine modeling and control. Department of Mech. Marine and Production Eng. Liverpool Polytechnic, UK. 1992
19 Tokuz L C, Jones J R. Power transmission and flow in the hybrid machines. The 6thInternational Machine Design and Production Conf. MENU, ANKARA, TURKEY. 1994:209~218
20 Tokuz L C. A design guide for hybrid machine applications. TrJ. of Engineering and Environment Sciences. 1997, 21:1~11
21 Tokuz L C, Jones J R. Programmable modulation of motion using hybrid machines. Eurotech Direct-ImechE, European Engineering and Technology Transfer Congress, 414/071. 1991:85~91
22 Greenough J D. Design of hybrid machine . Proceeding of the 9th IF To MM world Congress. 1995:2501~2505
23 Connor. The synthesis of hybrid five-bar path generating mechanisms using genetic algorithms. Genetic Algorithms in Engineering System: Innovations and Application. 1995, 10(2):313~318
24 Connor. The kinematics synthesis of pat h generating mechanisms using genetic algorithms. Artificial Intelligence in Engineering. 1995, 11(3):238~ 244
25 Connor. The synthesis of hybrid mechanism using genetic algorithms. Ph. D. Thesis, Liverpool Polytechnic, U K. 1996
26 Sesha S V, Bhartendu S. Programmable cam mechanisms. The 26th International Symposium on Industrial Robots. 1998:267~272
27 Herman J, Van de Straete, Joris de Schutter. Hybrid cam mechanisms. IEEE/ASME Transactions on Mechatronics. 1996, 1(4):284~289
28马燕平.一种新型行星式软启动方法的研究.苏州大学. 2007
29 Figueredo, Mauro Femando. A efficient parallel collision detection algorithm for virtual prototype environments. Proceedings of the International Conference on Parallel and Distributed System, 2004, 11(4):256~259
30谭理刚.虚拟样机技术及其在新型内燃机开发中的应用.湖南大学. 2003
31沈卫娜.带式输送机软启动技术分析与展望.煤矿机械. 2008, 12(12):6~8
32 A Harrison and A W Roberts. Technical requirements for operating conveyor belts at high speed. Bulk Solids Handling. No.1, 1994
33 A Harrison. Criteria for minimizing transient stress in conveyer belts. International Materials Handing Conference. South Africa Johannesburg, 1983
34 L K Nordell. The channel 20Km overland—A flagship of modern belt conveyor belts at high speed. Bulk solids handling. No.4, November 1997:781~792
35 L K Nordell. The theory and the practices of belt conveyer dynamic analysis. International Materials Handing Conference. South Africa Johannesburg, 1987
36李玉瑾.带式输送机的动态分析与软启动设计.煤炭学报. 2002, 6(27): 294~299
37贾志斌.机械电子式软启动装置控制系统的研究.太原理工大学. 2003
38杨实如,段钦华. NGW型差动变速机构的特点与设计.机械设计与研究. 2003(19):29~30
39纪传建.差动轮系在扩大无级变速范围中的应用.机械设计. 2006, 1:53~55
40 He Yupeng, Zhao Shengdun. Study of utilizing differential gear train to achieve hybrid mechanism of mechanical press. Science in China Series E-technological Sciences. 2007(1): 69~80
41贾宝贤,边文凤. 2K-H差动轮系的功率流向与啮合效率.机械设计. 1999(5): 33~36
42侯红伟,王豪.差动轮系可控启动装置的数学建模.煤矿机械. 2005(7):34~35
43二代龙震工作室. Pro/Mechanism Wildfire 3.0/4.0机构/运动分析.北京:电子工业出版社, 2008
44李勇. PLC在液面自动控制数据远传方面的应用.科普资讯. 2006(3): 26~33
45张永飞.基于PLC系统可靠性的研究.天津理工大学学报. 2006, 04(3):24~25
46刘金龙.基于机电液一体化的可控软启动系统的研究.河北工业大学. 2006
47周万珍,高洪斌. PLC分析与设计应用.北京:电子工业出版社, 2004
48 Sabolic, Dubravko. Influence of PLC media quality on the capacity of automatic meter reading system. Processdings of the Second Joint EMBS/BMES Conference, 2002: 12~113
49 Namie, Masaki. Application of PLC for PA and future evolution of PLC based process controller. Seventh Australian and New Zealand Intelligent Information System Conference, 2001: 271~275
50 Mateos.F, Gonzalez,V.M. Design and development of an automatic small-scale house for teaching domestics. Ingenieria de Sistemas y Automatica, Oviedo Univ, Spain. 2007: T3C ~ 1-5 vol.1
51蒋卫良.大功率带式输送机差动轮系软启动关键技术研究.上海交通大学.2002
52王小曼.通用变频器选型、应用与维修.北京:人民邮电出版社, 2005
53 Selleri, Stefano. A Matlab application programmer interface for educational electromagnetic. IEEE Antennas and Propagation Society, 2005, 4(1): 606~615
54 Forth, A Shaun. An efficient overloaded implementation of forward mode automatic differentiation in MATLAB. ACM Transactions on Mathematical Software, 2004, 51(4): 582~589
55 Chen S-J, Yao B-B. MATLAB-based e-design for aerostatic journal bearings. Advances in e-Engineering and Digital Enterprise Technology, 2004, 12(3): 36~40
2袁萍岳.泵控制功能软启动器的研究.科技广场. 2008(10): 191~193
3韩晶.基于差动轮系可控软启动装置虚拟产品开发研究.太原理工大学. 2005
4张以都.国内外重载机械设备软启动技术的研究.煤炭科学技术. 2001(9): 23~27
5赵国社.调速型液力偶合器的应用研究.中州煤炭. 2008(3):17~29
6陈叶,杨达文.调速型液力耦合器的研究及应用.煤矿机械. 2002(7):14~15
7王建华,王军.调速型液力偶合器在大型固定带式输送机中的软启动特点.煤矿现代化. 2001,1(40):32~33
8 Huang Xiaoguang, Wei Chenguan. Stability of oil film and output speed of hydro-viscous drive affected by the pressure of control oil. Journal of Beijing Institute of Technology. 2005, 3(3):185~187
9 Chen Ning, Qiu Minxiu. Research on the soft start-up performance of hydro-viscous drive. China Mechanical Engineering. 2005, 2(3): 305~307
10肖磊,尹岳等.液体粘性传动装置研究.煤矿机械. 2008, 29(4):04~106
11庄严.液体黏性传动装置在带式输送机中的应用.煤矿机械. 2008 (4):166~167
12阮忠唐.联轴器、离合器设计与选用指南.化学工业出版社, 2006
13 Vojislav D. Kalanovic, Dejan Popovic. Feedback error learning neural network for trans-femoral prosthesis. IEEE Trans on Rehabilitation Engineering. 2000,8(1): 71~80
14李改梅.低压大功率变频器的几个技术关注点.电机技术. 2009(6):35~39
15 Tian Hua Liu, Chih Ying Lin. Modeling and harmonics elimination for static frequency conveter driving a 300MVA synchronous machine. IEEE Transaction on Power Eletronics. 1996: 602~607
16 Tore Peterson, Kjell Frank. Starting of large synchronous motor using static frequency concreter IEEE Transaction on Power Eletronics. 2006:172~179
17周丽娜,尹志强.无刷直流电动机及其调速系统研究进展.电子技术. 2007(11):184~186
18 Tokuz L C. Hybrid machine modeling and control. Department of Mech. Marine and Production Eng. Liverpool Polytechnic, UK. 1992
19 Tokuz L C, Jones J R. Power transmission and flow in the hybrid machines. The 6thInternational Machine Design and Production Conf. MENU, ANKARA, TURKEY. 1994:209~218
20 Tokuz L C. A design guide for hybrid machine applications. TrJ. of Engineering and Environment Sciences. 1997, 21:1~11
21 Tokuz L C, Jones J R. Programmable modulation of motion using hybrid machines. Eurotech Direct-ImechE, European Engineering and Technology Transfer Congress, 414/071. 1991:85~91
22 Greenough J D. Design of hybrid machine . Proceeding of the 9th IF To MM world Congress. 1995:2501~2505
23 Connor. The synthesis of hybrid five-bar path generating mechanisms using genetic algorithms. Genetic Algorithms in Engineering System: Innovations and Application. 1995, 10(2):313~318
24 Connor. The kinematics synthesis of pat h generating mechanisms using genetic algorithms. Artificial Intelligence in Engineering. 1995, 11(3):238~ 244
25 Connor. The synthesis of hybrid mechanism using genetic algorithms. Ph. D. Thesis, Liverpool Polytechnic, U K. 1996
26 Sesha S V, Bhartendu S. Programmable cam mechanisms. The 26th International Symposium on Industrial Robots. 1998:267~272
27 Herman J, Van de Straete, Joris de Schutter. Hybrid cam mechanisms. IEEE/ASME Transactions on Mechatronics. 1996, 1(4):284~289
28马燕平.一种新型行星式软启动方法的研究.苏州大学. 2007
29 Figueredo, Mauro Femando. A efficient parallel collision detection algorithm for virtual prototype environments. Proceedings of the International Conference on Parallel and Distributed System, 2004, 11(4):256~259
30谭理刚.虚拟样机技术及其在新型内燃机开发中的应用.湖南大学. 2003
31沈卫娜.带式输送机软启动技术分析与展望.煤矿机械. 2008, 12(12):6~8
32 A Harrison and A W Roberts. Technical requirements for operating conveyor belts at high speed. Bulk Solids Handling. No.1, 1994
33 A Harrison. Criteria for minimizing transient stress in conveyer belts. International Materials Handing Conference. South Africa Johannesburg, 1983
34 L K Nordell. The channel 20Km overland—A flagship of modern belt conveyor belts at high speed. Bulk solids handling. No.4, November 1997:781~792
35 L K Nordell. The theory and the practices of belt conveyer dynamic analysis. International Materials Handing Conference. South Africa Johannesburg, 1987
36李玉瑾.带式输送机的动态分析与软启动设计.煤炭学报. 2002, 6(27): 294~299
37贾志斌.机械电子式软启动装置控制系统的研究.太原理工大学. 2003
38杨实如,段钦华. NGW型差动变速机构的特点与设计.机械设计与研究. 2003(19):29~30
39纪传建.差动轮系在扩大无级变速范围中的应用.机械设计. 2006, 1:53~55
40 He Yupeng, Zhao Shengdun. Study of utilizing differential gear train to achieve hybrid mechanism of mechanical press. Science in China Series E-technological Sciences. 2007(1): 69~80
41贾宝贤,边文凤. 2K-H差动轮系的功率流向与啮合效率.机械设计. 1999(5): 33~36
42侯红伟,王豪.差动轮系可控启动装置的数学建模.煤矿机械. 2005(7):34~35
43二代龙震工作室. Pro/Mechanism Wildfire 3.0/4.0机构/运动分析.北京:电子工业出版社, 2008
44李勇. PLC在液面自动控制数据远传方面的应用.科普资讯. 2006(3): 26~33
45张永飞.基于PLC系统可靠性的研究.天津理工大学学报. 2006, 04(3):24~25
46刘金龙.基于机电液一体化的可控软启动系统的研究.河北工业大学. 2006
47周万珍,高洪斌. PLC分析与设计应用.北京:电子工业出版社, 2004
48 Sabolic, Dubravko. Influence of PLC media quality on the capacity of automatic meter reading system. Processdings of the Second Joint EMBS/BMES Conference, 2002: 12~113
49 Namie, Masaki. Application of PLC for PA and future evolution of PLC based process controller. Seventh Australian and New Zealand Intelligent Information System Conference, 2001: 271~275
50 Mateos.F, Gonzalez,V.M. Design and development of an automatic small-scale house for teaching domestics. Ingenieria de Sistemas y Automatica, Oviedo Univ, Spain. 2007: T3C ~ 1-5 vol.1
51蒋卫良.大功率带式输送机差动轮系软启动关键技术研究.上海交通大学.2002
52王小曼.通用变频器选型、应用与维修.北京:人民邮电出版社, 2005
53 Selleri, Stefano. A Matlab application programmer interface for educational electromagnetic. IEEE Antennas and Propagation Society, 2005, 4(1): 606~615
54 Forth, A Shaun. An efficient overloaded implementation of forward mode automatic differentiation in MATLAB. ACM Transactions on Mathematical Software, 2004, 51(4): 582~589
55 Chen S-J, Yao B-B. MATLAB-based e-design for aerostatic journal bearings. Advances in e-Engineering and Digital Enterprise Technology, 2004, 12(3): 36~40