基于DSP的自动平衡控制理论与方法研究
摘要
转子自动平衡系统一直是工程技术研究与开发的热点领域，具有很大的发展潜力。该项技术不仅可以消除运行中随机产生的动不平衡、实时减小设备振动，而且可以有效延长转动设备的运行周期、减少故障停机、降低维修费用，经济效应可观。同时其潜在的应用范围极为广泛，目前已知的应用报道，不仅有压缩机、汽轮机、离心分离机等大型机械设备，而且还有类似于硬盘磁头等高精密旋转机构。事实上，任何需要保持旋转体稳定运行的机械机构都是其潜在用对象，因而转子自动平衡技术的发展及应用前景非常广阔。
本课题是中国自然科学基金项目51135001号《透平机械复杂机电系统动力学行为与振动、噪声靶向抑制原理及方法研究》的一部分，同时也是国家重点基础研究计划（973）项目2012CB26000号《高端压缩机组高效可靠及智能化基础研究》的一部分。本课题在总结现有各种自动平衡头和平衡技术的基础上，以自愈调控理论为指导，研究和开发自有知识产权的基于DSP的转子振动自愈系统，为该项技术的国产化、工业化进行了初步探索。课题主要工作有：
1、旋转机械的振动一般是多个频率的简谐振动的叠加。旋转机械振动信号的基本要素与简谐振动既有一定的联系，又有其特殊性。鉴于，相位在研究旋转机械动平衡时具有重要的作用和意义，在简要介绍简谐振动初始相位定义的前提下，本论文重点梳理和研究了旋转机械振动信号的相位定义及其常用的测量方法及原理，并给出了利用快速傅里叶变换理论所得相位值与通常旋转机械振动信号相位值之间的相对转换公式。
在具体工程中，因测量的相对难易及精度要求不可避免的要用振动加速度传感器（或振动速度传感器），而技术指标却是振动的速度值（或振动的位移值）。故需要研究相关振动信号的积分工作。从理论上，本论文重点研究了三种振动信号的积分方法，即基于硬件的积分、基于数值运算的软件积分和利用Laplace变换的微分性质解决时域积分问题。
2、基于等相差映射的转子动平衡配重方法是一种改进的影响系数方法。该方法主要是利用振动系统可以简化为线性二阶系统。线性二阶系统的激励与其振动响应间的相位存在一定的理论关系。通过对激励与振动响应的相位的进一步研究，本论文得出：对于线性转子振动系统来说其激励间的相位差值等于相应振动响应间的相位差。利用该研究成果，我们在做动平衡时就可以通过系统原始振动信号与试重引起的净振动信号间的相位差反推平衡原始振动所需的平衡配重所在的相对位置。该方法对于指导手工动平衡和自动动平衡都有一定的指导意义。
本论文详细研究了转子系统在某一稳定转速下两个测点、两个平衡面的条件下双面动平衡的影响系数矩阵与力-偶动平衡方法的影响系数矩阵间的相互关系。通过对这一特例的分析，可以进一步分析相应测点的振动是由于力还是力偶引起的，为进一步分析配重的实施或受约束限制时如何有效施加配重提供理论依据。
3、为充分利用数字信号处理器DSP适于信号处理和控制的特点，本论文设计了基于DSP的控制系统的硬件平台。该硬件平台包括：DSP核心模块、键相传感器、锁相环程控倍频模块、电平转换模块、振动传感器，信号预处理模块、A/D转换模块、多路控制信号产生电路模块、外扩按键液晶人机接口电路、外扩E2PROM模块及通讯协议转换模块。其特征在于：DSP核心模块通过多路控制信号产生模块连接至用于控制平衡的平衡执行器；用于拾取旋转机械上测点原始振动信号的振动传感器的输出信号接口连接到信号预处理模块，再经过A/D转换模块进行模数转换后输入至DSP核心模块；用于拾取主轴的转速信号的键相传感器的输出信号接口连接到锁相环程控倍频模块，再经过用于将双向电压信号转变为A/D转换器所需的单电压信号的电平转换模块进行电平转换后输入至DSP核心模块；DSP核心模块还连接有用于人工输入参数的外扩按键液晶人机接口电路，用于参数动态存储、替换与恢复的外扩E2PROM模块，用于与上位机进行通信的通讯协议转换模块。
4、本论文研究了液压型主动平衡系统的平衡原理及系统设计。对液压型主动平衡系统中的执行机构（即平衡盘）的结构设计、注液后离心力计算、平衡盘腔体数量的优化及平衡盘平衡能力进行了详细研究。基于三腔注液式平衡头的工作机理及对转子振动系统的模型简化，设计了适合以注液式平衡头为执行机构的转子系统的仿真模型和PI控制算法。对转子系统进行了幅值为阶跃信号和斜坡信号两种形式的干扰进行了仿真，仿真结果表明，控制器在以比例环节为主的情况下适当增加积分环节能够在较短的时间内对系统做出响应，从响应时间和控制效果来说，PI效果要好于仅用比例控制。仿真数据为进一步实际应用提供了保障。
5、本论文进行了基于DSP和bently公司的RK-4转子实验台进行了振动信号处理和动平衡方法的实验研究。
On-line rotor auto-balancing has been a hot area of engineering researchand development over the years, which has a great potential of innovation.This technology can not only eliminate the dynamic random imbalances andreduce real-time equipment vibrations during rotor’s running period, but alsocan effectively extend the operation cycle of rotating machinery, decreasemalfunction downtimes, save maintenance costs, which has a very higheconomic value. Moreover, its potential application area is extremely broad.According to the reports so far, the applications cover not only largemechanical equipment, like compressors, turbines and centrifuges, but alsohighly precision rotary mechanism such as the hard disk drive heads. In fact,any machinery needs to maintain the stable operation of rotating facility is thelatent target, so the development and application prospects of rotor on-lineauto-balancing technology are very bright.
As a part of the National Natural Science Foundation Project:“The theoryand methods for dynamic behavior of turbo machinery complexelectromechanical systems and vibration noise targeted inhibition”(No.51135001). This research project summarized several typical auto-balancinghead and balancing technique, and then a rotor vibration self-recoveringsystem based on DSP with independent intellectual property was completedunder the guidance of self-recovering theory, which may build the initialfoundation for the localization and industrialization of this bright technology.The main tasks of this project contained:
1. The vibration of rotating machinery generally consists of a series ofharmonic vibration. The basic elements of rotating machinery vibration signalare related to harmonic vibration, but there are also specialties. Since phaseplay an important role in the study of the rotating machinery dynamicbalancing, the paper first briefly introduced the definition of initial phase ofharmonic vibration, then made a comprehensive analysis and study ondefinition, common measurement methods and principle of phase of vibrationsignal in rotating machinery, and gave the transfer formula between phaseobtained through FFT and phase of rotating machinery vibration signal in theusual sense.
In specific project, due to the difficulty of measuring and requirementaccuracy, using of acceleration sensors (vibration velocity sensors) isinevitable. So the integral of the vibration signal is needed to study. This paper focused on three integral methods of vibration signals in theory to solve thetime domain integral problem: the method based on hardware, the methodbased on numerical computation and the method Laplace transform.
2. Rotor dynamic balance weights method based on equal phase differencemapping is a modified influence coefficient method. The method is the use ofthe vibration system can be simplified to a linear second order system. Thereis a certain theoretical relation between excitation and vibration phaseresponse of linear second-order system. Through further research, the paperconcluded: the phase difference between the excitations is equal to thevibration phase response for linear rotor vibration system. Using this result,we can deduce relative position of balance mass for balancing systemvibration by the phase difference between the excitations. This method hasgreat significance for the guidance of hand-balancing and automaticbalancing.
This paper studied in detail: the relationship between the influencecoefficients of double-sided dynamic balance method and force-coupledynamic balance method the rotor system in the condition of two measuringpoints, two balance planes and a stable rotating speed. Through the analysis ofthe special case, further analyze that the vibration of corresponding measuringpoint is whether caused due to the force or couple, to provide theoretical basicfor how to effectively add balance mass within constraint.
To take full advantage of the characteristics of the digital signal processor(DSP) suitable for signal processing and control, this paper designed aDSP-based control system hardware platform, which includes: DSP coremodules, key phase sensor, program-controlled phase-locked loop multipliermodule, level conversion module, vibration sensors, signal pre-processingmodule, A/D converter module, multi-channel control signal generating circuitmodule, external LCD human-machine interface circuit, external E2PROMmodules and communications protocol conversion module. DSP core modulecontrol signals generated by multiple modules connected to the balancedactuator. In order to pick up the original vibration signal of the measuringpoint on the rotating machinery, pre-processing module connected to signalinterface of vibration sensor, and then go through the A/D converter modulebefore giving to the DSP core modules. For the purpose of picking up thespindle speed signal, key phase sensor connected to the phase-locked loopprogrammable multiplier module, and then go through level conversionmodule which translated bi-directional voltage signal into single voltage signal,what the A/D converter required for, before giving to the DSP core module.Besides, DSP core module connected to LCD Human Interface circuit withmanual input parameters button, used for parameter dynamic storage,replacement and restoration. The E2PROM module mainly used for thecommunication protocol convers to the host computer.
This paper thoroughly studied the balance principle and system design of hydraulic type active balance system, including structure design ofimplementing agencies (i.e. balance dish), centrifugal force calculate afterliquid injected, number of cavity optimize in balance dish and the balanceability of the dish. Based on the mechanism of three cavities liquid injectiontype balancing head and the simplified model of rotor vibration system,designed the simulation model of rotor system and the PI control algorithm forthe system with liquid injection type balancing head as body implementingagencies. Simulation analysis about the system with interference signal as stepsignal and ramp signal was also done. The result demonstrate that based on thecondition proportion links as the leading, appropriate added the integrators canshorten the time controller responding to system. The PI control algorithm isbetter than only the proportion control algorithm according to responsetime and control effect. The simulation data provided a guarantee for furtherpractical application.
The vibration signal processing and dynamic balance method have beenused to the experiment in this paper based on DSP, using the bently RK-4rotortesting rig.
本课题是中国自然科学基金项目51135001号《透平机械复杂机电系统动力学行为与振动、噪声靶向抑制原理及方法研究》的一部分，同时也是国家重点基础研究计划（973）项目2012CB26000号《高端压缩机组高效可靠及智能化基础研究》的一部分。本课题在总结现有各种自动平衡头和平衡技术的基础上，以自愈调控理论为指导，研究和开发自有知识产权的基于DSP的转子振动自愈系统，为该项技术的国产化、工业化进行了初步探索。课题主要工作有：
1、旋转机械的振动一般是多个频率的简谐振动的叠加。旋转机械振动信号的基本要素与简谐振动既有一定的联系，又有其特殊性。鉴于，相位在研究旋转机械动平衡时具有重要的作用和意义，在简要介绍简谐振动初始相位定义的前提下，本论文重点梳理和研究了旋转机械振动信号的相位定义及其常用的测量方法及原理，并给出了利用快速傅里叶变换理论所得相位值与通常旋转机械振动信号相位值之间的相对转换公式。
在具体工程中，因测量的相对难易及精度要求不可避免的要用振动加速度传感器（或振动速度传感器），而技术指标却是振动的速度值（或振动的位移值）。故需要研究相关振动信号的积分工作。从理论上，本论文重点研究了三种振动信号的积分方法，即基于硬件的积分、基于数值运算的软件积分和利用Laplace变换的微分性质解决时域积分问题。
2、基于等相差映射的转子动平衡配重方法是一种改进的影响系数方法。该方法主要是利用振动系统可以简化为线性二阶系统。线性二阶系统的激励与其振动响应间的相位存在一定的理论关系。通过对激励与振动响应的相位的进一步研究，本论文得出：对于线性转子振动系统来说其激励间的相位差值等于相应振动响应间的相位差。利用该研究成果，我们在做动平衡时就可以通过系统原始振动信号与试重引起的净振动信号间的相位差反推平衡原始振动所需的平衡配重所在的相对位置。该方法对于指导手工动平衡和自动动平衡都有一定的指导意义。
本论文详细研究了转子系统在某一稳定转速下两个测点、两个平衡面的条件下双面动平衡的影响系数矩阵与力-偶动平衡方法的影响系数矩阵间的相互关系。通过对这一特例的分析，可以进一步分析相应测点的振动是由于力还是力偶引起的，为进一步分析配重的实施或受约束限制时如何有效施加配重提供理论依据。
3、为充分利用数字信号处理器DSP适于信号处理和控制的特点，本论文设计了基于DSP的控制系统的硬件平台。该硬件平台包括：DSP核心模块、键相传感器、锁相环程控倍频模块、电平转换模块、振动传感器，信号预处理模块、A/D转换模块、多路控制信号产生电路模块、外扩按键液晶人机接口电路、外扩E2PROM模块及通讯协议转换模块。其特征在于：DSP核心模块通过多路控制信号产生模块连接至用于控制平衡的平衡执行器；用于拾取旋转机械上测点原始振动信号的振动传感器的输出信号接口连接到信号预处理模块，再经过A/D转换模块进行模数转换后输入至DSP核心模块；用于拾取主轴的转速信号的键相传感器的输出信号接口连接到锁相环程控倍频模块，再经过用于将双向电压信号转变为A/D转换器所需的单电压信号的电平转换模块进行电平转换后输入至DSP核心模块；DSP核心模块还连接有用于人工输入参数的外扩按键液晶人机接口电路，用于参数动态存储、替换与恢复的外扩E2PROM模块，用于与上位机进行通信的通讯协议转换模块。
4、本论文研究了液压型主动平衡系统的平衡原理及系统设计。对液压型主动平衡系统中的执行机构（即平衡盘）的结构设计、注液后离心力计算、平衡盘腔体数量的优化及平衡盘平衡能力进行了详细研究。基于三腔注液式平衡头的工作机理及对转子振动系统的模型简化，设计了适合以注液式平衡头为执行机构的转子系统的仿真模型和PI控制算法。对转子系统进行了幅值为阶跃信号和斜坡信号两种形式的干扰进行了仿真，仿真结果表明，控制器在以比例环节为主的情况下适当增加积分环节能够在较短的时间内对系统做出响应，从响应时间和控制效果来说，PI效果要好于仅用比例控制。仿真数据为进一步实际应用提供了保障。
5、本论文进行了基于DSP和bently公司的RK-4转子实验台进行了振动信号处理和动平衡方法的实验研究。
On-line rotor auto-balancing has been a hot area of engineering researchand development over the years, which has a great potential of innovation.This technology can not only eliminate the dynamic random imbalances andreduce real-time equipment vibrations during rotor’s running period, but alsocan effectively extend the operation cycle of rotating machinery, decreasemalfunction downtimes, save maintenance costs, which has a very higheconomic value. Moreover, its potential application area is extremely broad.According to the reports so far, the applications cover not only largemechanical equipment, like compressors, turbines and centrifuges, but alsohighly precision rotary mechanism such as the hard disk drive heads. In fact,any machinery needs to maintain the stable operation of rotating facility is thelatent target, so the development and application prospects of rotor on-lineauto-balancing technology are very bright.
As a part of the National Natural Science Foundation Project:“The theoryand methods for dynamic behavior of turbo machinery complexelectromechanical systems and vibration noise targeted inhibition”(No.51135001). This research project summarized several typical auto-balancinghead and balancing technique, and then a rotor vibration self-recoveringsystem based on DSP with independent intellectual property was completedunder the guidance of self-recovering theory, which may build the initialfoundation for the localization and industrialization of this bright technology.The main tasks of this project contained:
1. The vibration of rotating machinery generally consists of a series ofharmonic vibration. The basic elements of rotating machinery vibration signalare related to harmonic vibration, but there are also specialties. Since phaseplay an important role in the study of the rotating machinery dynamicbalancing, the paper first briefly introduced the definition of initial phase ofharmonic vibration, then made a comprehensive analysis and study ondefinition, common measurement methods and principle of phase of vibrationsignal in rotating machinery, and gave the transfer formula between phaseobtained through FFT and phase of rotating machinery vibration signal in theusual sense.
In specific project, due to the difficulty of measuring and requirementaccuracy, using of acceleration sensors (vibration velocity sensors) isinevitable. So the integral of the vibration signal is needed to study. This paper focused on three integral methods of vibration signals in theory to solve thetime domain integral problem: the method based on hardware, the methodbased on numerical computation and the method Laplace transform.
2. Rotor dynamic balance weights method based on equal phase differencemapping is a modified influence coefficient method. The method is the use ofthe vibration system can be simplified to a linear second order system. Thereis a certain theoretical relation between excitation and vibration phaseresponse of linear second-order system. Through further research, the paperconcluded: the phase difference between the excitations is equal to thevibration phase response for linear rotor vibration system. Using this result,we can deduce relative position of balance mass for balancing systemvibration by the phase difference between the excitations. This method hasgreat significance for the guidance of hand-balancing and automaticbalancing.
This paper studied in detail: the relationship between the influencecoefficients of double-sided dynamic balance method and force-coupledynamic balance method the rotor system in the condition of two measuringpoints, two balance planes and a stable rotating speed. Through the analysis ofthe special case, further analyze that the vibration of corresponding measuringpoint is whether caused due to the force or couple, to provide theoretical basicfor how to effectively add balance mass within constraint.
To take full advantage of the characteristics of the digital signal processor(DSP) suitable for signal processing and control, this paper designed aDSP-based control system hardware platform, which includes: DSP coremodules, key phase sensor, program-controlled phase-locked loop multipliermodule, level conversion module, vibration sensors, signal pre-processingmodule, A/D converter module, multi-channel control signal generating circuitmodule, external LCD human-machine interface circuit, external E2PROMmodules and communications protocol conversion module. DSP core modulecontrol signals generated by multiple modules connected to the balancedactuator. In order to pick up the original vibration signal of the measuringpoint on the rotating machinery, pre-processing module connected to signalinterface of vibration sensor, and then go through the A/D converter modulebefore giving to the DSP core modules. For the purpose of picking up thespindle speed signal, key phase sensor connected to the phase-locked loopprogrammable multiplier module, and then go through level conversionmodule which translated bi-directional voltage signal into single voltage signal,what the A/D converter required for, before giving to the DSP core module.Besides, DSP core module connected to LCD Human Interface circuit withmanual input parameters button, used for parameter dynamic storage,replacement and restoration. The E2PROM module mainly used for thecommunication protocol convers to the host computer.
This paper thoroughly studied the balance principle and system design of hydraulic type active balance system, including structure design ofimplementing agencies (i.e. balance dish), centrifugal force calculate afterliquid injected, number of cavity optimize in balance dish and the balanceability of the dish. Based on the mechanism of three cavities liquid injectiontype balancing head and the simplified model of rotor vibration system,designed the simulation model of rotor system and the PI control algorithm forthe system with liquid injection type balancing head as body implementingagencies. Simulation analysis about the system with interference signal as stepsignal and ramp signal was also done. The result demonstrate that based on thecondition proportion links as the leading, appropriate added the integrators canshorten the time controller responding to system. The PI control algorithm isbetter than only the proportion control algorithm according to responsetime and control effect. The simulation data provided a guarantee for furtherpractical application.
The vibration signal processing and dynamic balance method have beenused to the experiment in this paper based on DSP, using the bently RK-4rotortesting rig.
引文
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