摘要
巨型模锻液压机是一种广泛应用于航空、汽车、船舶、电力工业等关键部件制造的核心加工装备,它是一个国家国防工业及重型机械制造业水平和能力的重要体现。巨型模锻液压机具有大惯性、大流量、负载复杂多变等特点,加之液压系统的非线性、时变性及多缸运动交叉耦合,以及模锻件的非对称性产生的偏心矩等影响,导致活动横梁在运行过程中发生倾斜,从而影响到模锻件的加工成型精度,甚至影响到液压机本体和模具的安全,因此,活动横梁的同步控制具有极其重要的意义,这也是自主研制必须突破的瓶颈。
本文紧密结合巨型模锻液压机同步控制的实际应用问题,以满足我国国防、航空航天等工业对大型关键模锻构件制造高精度的要求为目标,以800MN模锻液压机同步控制系统为研究对象,综合运用液压流体力学、现代控制理论等知识,在理论建模、计算机仿真和实验研究的基础上,查找影响同步控制精度的因素并提出相应措施,寻找最佳控制策略,提高液压同步控制系统的同步跟踪精度、鲁棒性、稳定性等,解决传统的同步控制系统控制精度低、动态响应慢、实时性差的、抗干扰能力弱的缺点,有效地改善产品的加工精度,并实现复杂制造系统确定性平稳运动控制技术的自主创新,进一步达到国际先进水平。
本文主要内容具体如下：
1、以现有300MN模锻液压机同步控制系统为借鉴,针对800MN模锻液压机同步控制系统的特点,重新设计了新的液压同步控制方案。
2、以锻件精化制造为目标,基于液压基础理论和动力学理论,建立了活动横梁运行时同步控制系统的数学模型,为研究同步控制系统的控制策略提供依据。同时,针对二种同步控制方案进行了对比仿真,仿真结果表明：新设计的800MN同步控制系统响应特性较原方案有较大幅度的改善,响应速度和动、静精度均有较大的提高,能满足当前我国航空航天、国防军工、冶金化工、能源动力等领域对大型构件的制造精度与内在性能提出的要求。
3、研究了影响巨型模锻液压机同步控制性能的因素并提出了解决措施。应用MARC软件,分析了液压机本体刚度对同步控制性能的影响；分析了活动横梁与导向立柱之间的配合间隙以及同步控制系统提供的工作压力与回油背压的压差对同步控制性能的影响等。为巨型模锻液压机同步控制系统的设计及控制策略的应用提供了参考。
4、分别研究了鲁棒H∞控制、基于干扰观测器鲁棒控制及模糊自适应鲁棒控制在同步控制系统上的应用。仿真结果表明：以上控制策略,可以有效地解决多缸驱动下的巨型模锻液压机被动同步控制的问题,具有极强的鲁棒性,能很好地抑制参数的不确定性、模型的不确定性对系统带来的影响,能有效抑制外部扰动所引起的动态误差,达到了提高同步控制系统的稳定性和动态精度的目的。
5、参与了315T液压机实验平台研发,并进行了实验测试。实验结果表明,试验与仿真结果相互吻合,证明了所建系统数学模型的正确性,同时也论证了本文提出的控制策略的有效性与智能性。
The giant forging hydraulic press is the core processing equipment which widely used in aviation, automobile, shipbuilding, electric power industry and other key components manufacturing, it is the important embodiment of a national defense industry's and heavy machinery manufacturing's level and ability. The giant forging hydraulic press has large inertia, big flow, load characteristics such as complex and changeable, in addition to the hydraulic system of nonlinear time-varying, and cylinder cross coupling movement, and the influence of the asymmetry of the die forgings produce torque to the eccentricity, resulting in the moving beam happened tilt in the running, thus affecting die forging a processing precision molding, even affect the safety of hydraulic press's body and mould, therefore, moving beam of synchronous control has very important significance, this also is independent research must break the bottleneck.
This paper closely combining the giant forging hydraulic press the practical application of synchronous control problems, in order to meet our country national defense, aerospace and other industrial for large drop forged components manufacturing high accuracy of the key requirements as the goal, the800MN die forging hydraulic press synchronous control system as the research object, the integrated use of fluid mechanics, modern control theory knowledge, on the basis of theoretical modeling, computer simulation and experimental research, to find out the influencing factors of synchronous control precision and puts forward the corresponding measures, to solve the traditional synchronous control system's shortcomings such as the low control precision, slow dynamic response, real-time poor, weak anti-jamming ability, effectively improve the product processing precision, and realize the complicated manufacturing system smooth motion control technology of independent innovation, and further reached the international advanced level.
The main research achievements are as follows:
1. Taking the existing300MN die forging hydraulic machine synchronous control system for reference, according to the800MN die forging hydraulic machine synchronous control system characteristics, to design a new hydraulic synchronization control system.
2. To precision manufacture the forging as the goal, based on hydraulic theory and dynamics theory, establishing the model of the synchronization control system when moving beam running, to provide the basis for the research synchronous control system control strategy. On this basis, the two kinds of schemes are compared through simulation, the simulation results show that the new design of800MN synchronous control system response characteristics is substantial improvement, the response speed and dynamic&static precision are a large improvement, it can meet our country aerospace, defense industry, metallurgy industry, energy power fields of large components to manufacture precision and internal performance of the proposed more and more high demand.
3. To study the effect of the giant die forging hydraulic press synchronous control performance factor and puts forward the solving measures. Using of MARC software, analysis of the hydraulic press body stiffness on the performance of synchronous control effect; analysis of moving beam and the fit clearance between the guide column and synchronous control system provides the work pressure and back pressure in the pressure difference on the synchronization control performance influence. To provide reference for the giant die forging hydraulic press synchronous control system design and the application for control strategy.
4. H∞robust control, based on disturbance observer robust control and adaptive fuzzy robust control in synchronous control system application were studied. The simulation results show that:the above control strategys can effectively solve the passive synchronization control problems with the multi-cylinder driven by a giant die forging hydraulic press, it has strong robustness, can completely suppress the parameter uncertainty, uncertainty of model of the system, can effectively restrain the disturbance caused by the dynamic error, achieve to the purpose of improving the stability of the synchronization control system and the dynamic accuracy.
5.Participate in researching and developing the315T hydraulic experiment platform, and conducted experiments to test.The experimental results show that, the results of the test and simulation are coincident with each other, which validates the correctness of the mathematical model of the system, and it is proved that the proposed control strategy is effective and intelligent.
引文
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