高速薄膜流涎机组的控制技术研究
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摘要
流涎机是一类复杂的机械产品,高速化、智能化、精密化是高速流涎机组发展的方向。近年来,国产流涎设备的制造能力取得了长足发展,但与国际先进技术相比较,在智能化操作控制、薄膜收卷速度、薄膜厚度误差、薄膜幅宽等关键指标方面,还存在一定的差距。
要提高薄膜流涎机的生产效率,在宽面幅、多层数及高稳定性的前提下,尽量提高机组运行速度,关键是要解决制约运行速度提高的那些难题,主要有系统中多电机的速度同步控制问题,薄膜在高速宽幅收卷时的张力控制问题,及薄膜厚度的误差控制问题等,这些问题是国内外流涎机研制中存在的共同问题,也是目前国内所欠缺的。
论文以高速流涎机组为研究对象,以研发高速流涎机组自动化控制系统为目标,对相关控制技术进行了研究,并设计和开发了相应的控制系统。
论文主要的研究内容如下：
(1)多电机的速度同步控制问题
针对流涎机中的多电机速度同步问题,提出了一种改进型相邻交叉耦合结构模糊PID控制算法。通过对相邻交叉耦合控制结构进行改进,在原有基础上增加比例环节,对控制参数进行重新定义,并建立重新定义的控制参数关系方程组；同时,为解决电机模型的时变、非线性等问题,在改进型相邻交叉耦合结构中加入了智能控制算法,利用模糊推理的思想,将模糊控制器与PID控制器相结合,设计了模糊PID控制器。
(2)薄膜高速收卷时的张力控制问题
针对流涎机收卷系统,根据其在收卷过程中的动态过程,分析了张力与线速度、卷径及转速之间的动力学关系,并计算出薄膜在收换卷时卷径及电机转速的变化规律；由此,设计了薄膜张力控制系统,通过控制速度差形成速度闭环,同时采用BP神经网络PID控制器调节收卷转速形成张力闭环,并针对系统特有的机械结构对电机转速进行了补偿,从而维持系统在整个收换卷过程中的张力稳定。
(3)薄膜厚度的精度控制问题
运用虚拟仪器技术,将采集板卡和控制板卡集成于工控机中,使用Labview软件编写可视化的程序,并在其中运用了神经网络控制算法,开发出一套流涎机薄膜厚度控制系统。
(4)流涎机控制系统的实现技术研究
对高速流涎机组控制系统的软硬件实现进行了研究,设计开发了控制系统的软硬件模块,并对其中的多电机速度同步控制、薄膜收卷张力控制等子系统进行了设计。所设计的控制系统,具有实时性、标准化、模块化等特点,为下一代流涎机控制系统的研究提供了充裕的软硬件资源,并对一般实时多任务控制系统的研发具有重要的参考价值。在此基础上,对控制系统的整体性能和所提出的改进型相邻交叉耦合结构模糊PID多电机比例同步控制算法和收卷张力控制算法进行了实验验证,结果表明本文所提出的控制算法具有较高的精度和稳定性,这对改善流涎机的品质和整体动态性能有着重要意义。
The film casting machine is a kind of complex mechanical equipment, and its development direction is high speed, intelligent and high accuracy. In recent years, the capacity of manufacture of the domestic film casting machine has improved a lot, but when it compared with the international advanced technology, there is still a gap in the key indexes such as the intelligent operation, the winding speed, the error of film thickness and the width of film, etc.
To improve the production efficiency of the film casting machine and ensure the width of film, the layer of film and the high stability, it is important to solve those problems that constrain the speed of the casting machine. The problems mainly contain the multi-motor synchronization control, the tension control when film is winded in a high speed, and the error control of film thickness. They are the common problems that exist in the designing of film casting machine at home and abroad, and mastered not enough in the domestic production currently.
The research object of this dissertation is the high speed film casting machine, and the aim is to establish its automatic control system, to research the interrelated control technologies, and to design the control system.
The main reseach contents of the dissertation are as follows:
(1) Multi-motor speed synchronization control
To solve the problem of multi-motor speed synchronization in film casting machine, an improved adjacent cross-coupling structure fuzzy PID control algorithm is proposed. The adjacent cross-coupling structure is improved, the control parameters are redefined, and equations of the redefined parameters are established. Also, to solve the time-varying and nonlinear problem of the motor model, fuzzy PID controllers are designed and added to the improved adjacent cross-coupling structure. Based on the theory of fuzzy inference, fuzzy PID controller is designed, which is combined with fuzzy controller and PID controller.
(2) Tension control when film is winded in a high speed
According to the dynamic process of the winding system of the film casting, the dynamic relationships of tension and speed, radius, rotate speed are analyzed, and the compensating law of the radius and the rotaty speed are calculated. Based on the models, a tension control system is established. The speed closed loop is formed by controlling the difference of speed, the tension closed loop is formed by controlling the winding speed using BP Neural Network PID controller, and a compensation is added to the winding speed according to the mechanical structure of the system, so the tension can maintain stability in the whole winding process.
(3) Accuracy control of the film thickness
The dissertation establishes a set of control system for the film thickness, using the technology of virtual instrument. It integrates the data-collection cards and the control cards to the computer, uses the Labview software to compile the visual monitoring procedures, and uses the neural network intelligent control algorithm to ensure the accuracy.
(4) Establishment of the casting machine's control system
The control system of the high-speed film casting machine is established, the software and hardware are designed, and the subsystems of the multi-motor speed synchronization control and the winding tension control are designed. The control system has the characteristics of real-time, standardization, modularity, etc., provides sufficient resources of hardware and software for the study of next-generation casting machine, and has an important reference value for the common real-time multi-task control system. Based on it, the whole performance of the control system, the improved adjacent cross-coupling structure fuzzy PID multi-motor proportional synchronizition control algorithm and the winding tension control algorithm are verified by experiments. The results show that the proposed control algorithm has high accuracy and stability, which has great significance to improve the quality and the whole dynamic performance of the casting machine.
要提高薄膜流涎机的生产效率,在宽面幅、多层数及高稳定性的前提下,尽量提高机组运行速度,关键是要解决制约运行速度提高的那些难题,主要有系统中多电机的速度同步控制问题,薄膜在高速宽幅收卷时的张力控制问题,及薄膜厚度的误差控制问题等,这些问题是国内外流涎机研制中存在的共同问题,也是目前国内所欠缺的。
论文以高速流涎机组为研究对象,以研发高速流涎机组自动化控制系统为目标,对相关控制技术进行了研究,并设计和开发了相应的控制系统。
论文主要的研究内容如下：
(1)多电机的速度同步控制问题
针对流涎机中的多电机速度同步问题,提出了一种改进型相邻交叉耦合结构模糊PID控制算法。通过对相邻交叉耦合控制结构进行改进,在原有基础上增加比例环节,对控制参数进行重新定义,并建立重新定义的控制参数关系方程组；同时,为解决电机模型的时变、非线性等问题,在改进型相邻交叉耦合结构中加入了智能控制算法,利用模糊推理的思想,将模糊控制器与PID控制器相结合,设计了模糊PID控制器。
(2)薄膜高速收卷时的张力控制问题
针对流涎机收卷系统,根据其在收卷过程中的动态过程,分析了张力与线速度、卷径及转速之间的动力学关系,并计算出薄膜在收换卷时卷径及电机转速的变化规律；由此,设计了薄膜张力控制系统,通过控制速度差形成速度闭环,同时采用BP神经网络PID控制器调节收卷转速形成张力闭环,并针对系统特有的机械结构对电机转速进行了补偿,从而维持系统在整个收换卷过程中的张力稳定。
(3)薄膜厚度的精度控制问题
运用虚拟仪器技术,将采集板卡和控制板卡集成于工控机中,使用Labview软件编写可视化的程序,并在其中运用了神经网络控制算法,开发出一套流涎机薄膜厚度控制系统。
(4)流涎机控制系统的实现技术研究
对高速流涎机组控制系统的软硬件实现进行了研究,设计开发了控制系统的软硬件模块,并对其中的多电机速度同步控制、薄膜收卷张力控制等子系统进行了设计。所设计的控制系统,具有实时性、标准化、模块化等特点,为下一代流涎机控制系统的研究提供了充裕的软硬件资源,并对一般实时多任务控制系统的研发具有重要的参考价值。在此基础上,对控制系统的整体性能和所提出的改进型相邻交叉耦合结构模糊PID多电机比例同步控制算法和收卷张力控制算法进行了实验验证,结果表明本文所提出的控制算法具有较高的精度和稳定性,这对改善流涎机的品质和整体动态性能有着重要意义。
The film casting machine is a kind of complex mechanical equipment, and its development direction is high speed, intelligent and high accuracy. In recent years, the capacity of manufacture of the domestic film casting machine has improved a lot, but when it compared with the international advanced technology, there is still a gap in the key indexes such as the intelligent operation, the winding speed, the error of film thickness and the width of film, etc.
To improve the production efficiency of the film casting machine and ensure the width of film, the layer of film and the high stability, it is important to solve those problems that constrain the speed of the casting machine. The problems mainly contain the multi-motor synchronization control, the tension control when film is winded in a high speed, and the error control of film thickness. They are the common problems that exist in the designing of film casting machine at home and abroad, and mastered not enough in the domestic production currently.
The research object of this dissertation is the high speed film casting machine, and the aim is to establish its automatic control system, to research the interrelated control technologies, and to design the control system.
The main reseach contents of the dissertation are as follows:
(1) Multi-motor speed synchronization control
To solve the problem of multi-motor speed synchronization in film casting machine, an improved adjacent cross-coupling structure fuzzy PID control algorithm is proposed. The adjacent cross-coupling structure is improved, the control parameters are redefined, and equations of the redefined parameters are established. Also, to solve the time-varying and nonlinear problem of the motor model, fuzzy PID controllers are designed and added to the improved adjacent cross-coupling structure. Based on the theory of fuzzy inference, fuzzy PID controller is designed, which is combined with fuzzy controller and PID controller.
(2) Tension control when film is winded in a high speed
According to the dynamic process of the winding system of the film casting, the dynamic relationships of tension and speed, radius, rotate speed are analyzed, and the compensating law of the radius and the rotaty speed are calculated. Based on the models, a tension control system is established. The speed closed loop is formed by controlling the difference of speed, the tension closed loop is formed by controlling the winding speed using BP Neural Network PID controller, and a compensation is added to the winding speed according to the mechanical structure of the system, so the tension can maintain stability in the whole winding process.
(3) Accuracy control of the film thickness
The dissertation establishes a set of control system for the film thickness, using the technology of virtual instrument. It integrates the data-collection cards and the control cards to the computer, uses the Labview software to compile the visual monitoring procedures, and uses the neural network intelligent control algorithm to ensure the accuracy.
(4) Establishment of the casting machine's control system
The control system of the high-speed film casting machine is established, the software and hardware are designed, and the subsystems of the multi-motor speed synchronization control and the winding tension control are designed. The control system has the characteristics of real-time, standardization, modularity, etc., provides sufficient resources of hardware and software for the study of next-generation casting machine, and has an important reference value for the common real-time multi-task control system. Based on it, the whole performance of the control system, the improved adjacent cross-coupling structure fuzzy PID multi-motor proportional synchronizition control algorithm and the winding tension control algorithm are verified by experiments. The results show that the proposed control algorithm has high accuracy and stability, which has great significance to improve the quality and the whole dynamic performance of the casting machine.
引文
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