路面冷铣刨机电液控制技术研究
摘要
本课题结合徐工XM200沥青冷铣刨机项目,对铣刨机电液控制技术进行研究。主要内容包括:分析铣刨机电液控制系统构成,比较各种解决方案,给予解决办法;针对企业实际问题,对铣刨机电液控制的核心部件电比例泵和阀的PWM控制特性做了试验研究和理论分析,为这两类元件在铣刨机应用中的PLC控制参数选取提供了依据;针对铣刨机轻载和重载两种情况,提出以行走压力和柴油机转速作为反馈变量,通过对行走马达和行走泵排量的比例控制来实现行走速度对负载的自适应控制,指出参数选取的办法并予以验证;最后简要给出了冷铣刨机电液控制系统的软、硬件设计框架。
PREFACE
The cold milling machine is one of the main models of maintaining machinery, used for the highway, town road, airport and bituminous concrete .Because of starting to produce lately, the large milling machines mainly depend on import at present, and the domestic research of the machine is of lack too. The main research contents of the paper include: analyzing the function request of the milling machine’s electro-hydraulic control system, comparing and studying the ideal control project, studying the control characteristic of the electric- proportional pump and valve and studying the core part of the control system-load control of speed elaborately.
CONSTITUTES OF ELECTRO-HYDRAULIC CONTROL SYSTEM The electro-hydraulic control system can be divided into five parts: the control of drive system, of the conveyor, of the milling depth, of the steering system and of the subsidiary organization. Control of the driving speed mainly concentrated at regulation of the displacement of the drive pump and the drive motor. Displacement of the drive pump is regulated by proportional current. There are two kinds of motor: two-position motor and pressure-control-proportional motor. And the later is better because it can raise the construction efficiency at light load. Including the former, control of the brake, of the anti-skid and the efficiency of the hydraulic is important also。The core of the conveyor control also lies in the rotating speed control which should adapt the load. On one hand the conveyor’s speed must big enough to send the waste material to the truck, on the other hand we can make use of the system pressure Pc to be the feeding parameter to adjust the displacement of the conveyor pump. Thus we can make full use of the ability of the conveyor and also it contributes to reduce the damage of the conveyor belt. The request of the steering system is high. But we can manipulate the front and rear steering separately through close-loop position control. The depth control usually adopts the standard controller, so the key of the depth control lies in the selection of the proportional direction valve and the fit control parameter. Control of the subsidiary organization mainly include cooling fan and sprinkle water pump which droved by a hydraulic motor.
ANALYSIS ON THE CONTROL PARAMETER OF THE PROPORTION- AL PUMP
The double direction proportional pump is the key parts of the control of the drive speed and the conveyor. The displacement of the pump is regulated by PWM current which generated by the controller. It is vital to find out how the PWM signal parameters including the frequency and magnitude influent the displacement of the pump. By which, we can make sure the dead-band current and the saturated current. The PWM output of the controller posses the electric current feedback, which usually looked as the direct current, and take no account of the influence of the frequency of PWM within the scope of certain frequency. However, experiments indicate that it’s very different about the effect of the PWM input according to the double direction pump and the single direction pump. The PWM signal frequency shows evidently influence on the dead-band current I0 and saturated current Im of the double direction pump. The value of the I0 and Im of the low frequencies input is much bigger than that of the DC. In addition there is increasing trend of these values with the increasing PWM frequency. Which make clear that it maybe a fault if we give the same value of the I0 and Im to different pump and we may not achieve the anticipant result.
LOAD CONTROL OF THE DRIVE SPEED
The Efficiency of the planer is measured by the physical volume of the destroyed road layer. Which means that we must guarantee the drive speed is faster as it could at all possible work condition. However, because of the existence of the milling drum, the machine is subjected to the resistance during milling work. Study expresses that the resistance is proportional to drive speed. And also there are other uncertain reasons which can lead to the change of the speed.
There are two ways to modulate the speed- changing the displacement of the motor or the pump automatically according to the work load. The proportional motor could be regulated automatically according to the pressure and the proportional pump can be modulated automatically according to the engine speed.
This kind of control method can achieve ideal drive speed on one hand; the engine can work at ideal speed area on the other hand. Which means the work efficiency is the highest. This kind of control way changed the traditional theory which equates the speed control and the power distributed control, pointing out that the final purpose of the speed control is increasing the product efficiency. DESIGN FRAME OF PLC CONTROL SYSTEM
Control system of the milling machine is very complicated. The drive system and conveyor system are close-loop control with load adaptation; steering system is close control of steering angle and the control of auxiliary mechanism is complex too. The whole machine control needs to handle a great deal of data and carries out the complicated logic operation, the PID control, and fault diagnosis function, which must adopt the high performance PLC to carry out these tasks. The synopsis in text gives a PLC control system frame design of soft and hardware.
PREFACE
The cold milling machine is one of the main models of maintaining machinery, used for the highway, town road, airport and bituminous concrete .Because of starting to produce lately, the large milling machines mainly depend on import at present, and the domestic research of the machine is of lack too. The main research contents of the paper include: analyzing the function request of the milling machine’s electro-hydraulic control system, comparing and studying the ideal control project, studying the control characteristic of the electric- proportional pump and valve and studying the core part of the control system-load control of speed elaborately.
CONSTITUTES OF ELECTRO-HYDRAULIC CONTROL SYSTEM The electro-hydraulic control system can be divided into five parts: the control of drive system, of the conveyor, of the milling depth, of the steering system and of the subsidiary organization. Control of the driving speed mainly concentrated at regulation of the displacement of the drive pump and the drive motor. Displacement of the drive pump is regulated by proportional current. There are two kinds of motor: two-position motor and pressure-control-proportional motor. And the later is better because it can raise the construction efficiency at light load. Including the former, control of the brake, of the anti-skid and the efficiency of the hydraulic is important also。The core of the conveyor control also lies in the rotating speed control which should adapt the load. On one hand the conveyor’s speed must big enough to send the waste material to the truck, on the other hand we can make use of the system pressure Pc to be the feeding parameter to adjust the displacement of the conveyor pump. Thus we can make full use of the ability of the conveyor and also it contributes to reduce the damage of the conveyor belt. The request of the steering system is high. But we can manipulate the front and rear steering separately through close-loop position control. The depth control usually adopts the standard controller, so the key of the depth control lies in the selection of the proportional direction valve and the fit control parameter. Control of the subsidiary organization mainly include cooling fan and sprinkle water pump which droved by a hydraulic motor.
ANALYSIS ON THE CONTROL PARAMETER OF THE PROPORTION- AL PUMP
The double direction proportional pump is the key parts of the control of the drive speed and the conveyor. The displacement of the pump is regulated by PWM current which generated by the controller. It is vital to find out how the PWM signal parameters including the frequency and magnitude influent the displacement of the pump. By which, we can make sure the dead-band current and the saturated current. The PWM output of the controller posses the electric current feedback, which usually looked as the direct current, and take no account of the influence of the frequency of PWM within the scope of certain frequency. However, experiments indicate that it’s very different about the effect of the PWM input according to the double direction pump and the single direction pump. The PWM signal frequency shows evidently influence on the dead-band current I0 and saturated current Im of the double direction pump. The value of the I0 and Im of the low frequencies input is much bigger than that of the DC. In addition there is increasing trend of these values with the increasing PWM frequency. Which make clear that it maybe a fault if we give the same value of the I0 and Im to different pump and we may not achieve the anticipant result.
LOAD CONTROL OF THE DRIVE SPEED
The Efficiency of the planer is measured by the physical volume of the destroyed road layer. Which means that we must guarantee the drive speed is faster as it could at all possible work condition. However, because of the existence of the milling drum, the machine is subjected to the resistance during milling work. Study expresses that the resistance is proportional to drive speed. And also there are other uncertain reasons which can lead to the change of the speed.
There are two ways to modulate the speed- changing the displacement of the motor or the pump automatically according to the work load. The proportional motor could be regulated automatically according to the pressure and the proportional pump can be modulated automatically according to the engine speed.
This kind of control method can achieve ideal drive speed on one hand; the engine can work at ideal speed area on the other hand. Which means the work efficiency is the highest. This kind of control way changed the traditional theory which equates the speed control and the power distributed control, pointing out that the final purpose of the speed control is increasing the product efficiency. DESIGN FRAME OF PLC CONTROL SYSTEM
Control system of the milling machine is very complicated. The drive system and conveyor system are close-loop control with load adaptation; steering system is close control of steering angle and the control of auxiliary mechanism is complex too. The whole machine control needs to handle a great deal of data and carries out the complicated logic operation, the PID control, and fault diagnosis function, which must adopt the high performance PLC to carry out these tasks. The synopsis in text gives a PLC control system frame design of soft and hardware.
引文
[1] 孙祖望.沥青路面养护技术的发展与展望. 筑路机械与施工机械化. 2004(1):4-7
[2] 刘伟.路面铣刨机械的发展前景与市场展望. 科技情报开发与经济. 2004(14):114-120
[3] 王黎宏.我国路面铣刨机的发展现状与机遇.筑路机械与施工机械化[j]2004(1):8-10
[4] 陆青平.铣刨机整机功率自适应匹配的研究.长安大学硕士论文.2002
[5] 王阿庆,李璋,姚怀新.铣刨机功率自分配探讨.养护机械与施工技术. 2006(12):34-36
[6] 赵敏.沥青路面铣刨机作业阻力及牵引性能的研究.长安大学硕士论问.2003
[7] 田晋跃,刘益民,肖种宇,于英.基于深度基准的道路铣刨机控制技术.苏州大学学报(自然科学版).2004(3):289-293
[8] 田晋跃, 向华荣.路面铣刨机铣削阻力及其参数影响规律分析. 江苏大学学报(自然科学版) .2004(9):381-385
[9] 向华荣,田晋跃,于英.路面铣刨机深度控制系统应用技术.养护机械与施工技术.2003(6):32-33
[10] 徐文山,刘益民,肖种宇.国内外沥青路面铣刨机的发展概况.筑路机械与施工机械化[j].2001(6): 17-19
[11] 甘建兵.维特根铣刨机及其发展.筑路机械与施工机械化. 2001(1):11-12
[12] http://www.roadtec.com/www/docs/101/cold-planer-milling-machine
[13] 王黎宏.小荷初露尖尖角一谈国内外路面铣刨机的发展[j].工程机械与维修 2003.2. 52-53
[14] W2000 操作手册.德国 Wirgen 公司
[15] 刘 俊 . 卡 特 PM-200 路 面 冷 铣 刨 机 . 筑 路 机 械 与 施 工 自 动 化[j].2006(1):13-14
[16] 关怀.PL2000S 型路面冷铣刨机.工程机械.2000.(4):42
[17] 徐军强.西安宏大 HD2000super 铣刨机.筑路机械与施工机械化. 2006(1):14-15
[18] 林惠瑜,王文丽,丁晓红.W2000 型路面铣刨机.建筑机械 2001(6):49-50
[19] 任军峰.崭露头角的 CM1900 冷铣刨机.筑路机械与施工机械化. 2004(1):14-15
[20] 李永强.基于 CAN 总线下的电控柴油机多 ECU 通信平台的设计.大连理工大学硕士学位论文.2003
[21] Detuz 1015 电控柴油机样本资料
[22] 徐鹤.车用 CAN 总线拓扑结构设计与性能分析方法研究.中国农业大学硕士学位论文.2005
[23] 苏国辉.基于CAN-bus的数字电液控制系统应用研究—硬件设计.长安大学硕士学位论文.2004
[24] 陈宇峰,黎涛.智能化路面冷铣刨机开发研究.建设机械技术与管理.2003(6):20-21
[25] 喻钢,尹苟保,谢长宇.智能型路面铣刨机发展方向及设计分析.建设机械技术与管理(11):31-32
[26] 张平,丁晓东.可调速液压驱动冷却系统在铣刨机上的应用.养护机械与施工技术.2006(7):28-29
[27] 尚涛.液压挖掘机作业及行走系统节能控制研究.吉林大学博士论文.2004
[28] 吴根茂,丘敏秀,王庆丰等.新编实用电液比例控制技术.杭州.浙江大学出版社 2006.9
[29] 黄宏甲,黄谊,王积伟.液压与气压传动.北京.机械工业出版社. 2000.05
[30] SAUER-SUNDSTRAND Applications Manual
[31] 高纪念,蔚长春.电液控制技术及其应用.石油工业出版社.1993.6
[32] 杨俭.电液比例位置系统复合控制及相关研究.浙江大学博士学位论文.2005
[33] EATON Vickers V-PV-EEPS-0001A:C2-C12
[34] 姜继海,宋锦春,高常识.液压与气压传动.北京.高等教育出版社.2002.1
[35] Cummins Inc. QSX15 Engine Performance Data
[36] 上海派芬自动控制有限公司.2005 年样本
[37] 曹承志.微型计算机控制技术.北京.机械工业出版社.2001.3
[38] 胡寿松.自动控制原理(第四版).北京.科学出版社.
[39] Bahney.J.H. Hydraulic pumps: the key to power generation. Aerospace Engineering.1991(12)
[40] Alan .J. Hugo. Performance assessment of single-loop industrial controllers Journal of Process Control.2006(4)
[41] 柯明纯,丁凡,李 宾.电液比例方向节流阀的特性测试方法探讨.工程机械.2006(3):48-50
[42] 宫文斌,刘昕晖,孙延伟.电液比例 PWM 控制方法.吉林大学学报( 工学版).2003(7):104-106
[43] 牛占海,王宏武,刘 榛.对电液比例控制系统的综述.机械研究与应用.2004(12):16-17
[44] 舒进,陈思忠,杨林.电液比例位置控制系统的死区模糊补偿控制研究.液压与气动.2005(1):20-22
[45] Zeng Libin .The application of microcomputer control of electro-hydraulic proportional level adjustment system of the telescopic fork-lift truck. Proceedings Of The Fourth International Symposium On Fluid Power Transmission And Control
[46] Tapio Virvalo .Computer pressure control methods .Proceedings Of The Fourth International Symposium On Fluid Power Transmission And Control
[47] Yu.W.S .Continuous-time indirect adaptive control of the electro- hydraulic servo systems .IEEE Transactions On Control Systems Technology
[48] Wei Jianhua .Transient response of a valve control system with long pipe.机械工程学报(英文版)2004(3)
[2] 刘伟.路面铣刨机械的发展前景与市场展望. 科技情报开发与经济. 2004(14):114-120
[3] 王黎宏.我国路面铣刨机的发展现状与机遇.筑路机械与施工机械化[j]2004(1):8-10
[4] 陆青平.铣刨机整机功率自适应匹配的研究.长安大学硕士论文.2002
[5] 王阿庆,李璋,姚怀新.铣刨机功率自分配探讨.养护机械与施工技术. 2006(12):34-36
[6] 赵敏.沥青路面铣刨机作业阻力及牵引性能的研究.长安大学硕士论问.2003
[7] 田晋跃,刘益民,肖种宇,于英.基于深度基准的道路铣刨机控制技术.苏州大学学报(自然科学版).2004(3):289-293
[8] 田晋跃, 向华荣.路面铣刨机铣削阻力及其参数影响规律分析. 江苏大学学报(自然科学版) .2004(9):381-385
[9] 向华荣,田晋跃,于英.路面铣刨机深度控制系统应用技术.养护机械与施工技术.2003(6):32-33
[10] 徐文山,刘益民,肖种宇.国内外沥青路面铣刨机的发展概况.筑路机械与施工机械化[j].2001(6): 17-19
[11] 甘建兵.维特根铣刨机及其发展.筑路机械与施工机械化. 2001(1):11-12
[12] http://www.roadtec.com/www/docs/101/cold-planer-milling-machine
[13] 王黎宏.小荷初露尖尖角一谈国内外路面铣刨机的发展[j].工程机械与维修 2003.2. 52-53
[14] W2000 操作手册.德国 Wirgen 公司
[15] 刘 俊 . 卡 特 PM-200 路 面 冷 铣 刨 机 . 筑 路 机 械 与 施 工 自 动 化[j].2006(1):13-14
[16] 关怀.PL2000S 型路面冷铣刨机.工程机械.2000.(4):42
[17] 徐军强.西安宏大 HD2000super 铣刨机.筑路机械与施工机械化. 2006(1):14-15
[18] 林惠瑜,王文丽,丁晓红.W2000 型路面铣刨机.建筑机械 2001(6):49-50
[19] 任军峰.崭露头角的 CM1900 冷铣刨机.筑路机械与施工机械化. 2004(1):14-15
[20] 李永强.基于 CAN 总线下的电控柴油机多 ECU 通信平台的设计.大连理工大学硕士学位论文.2003
[21] Detuz 1015 电控柴油机样本资料
[22] 徐鹤.车用 CAN 总线拓扑结构设计与性能分析方法研究.中国农业大学硕士学位论文.2005
[23] 苏国辉.基于CAN-bus的数字电液控制系统应用研究—硬件设计.长安大学硕士学位论文.2004
[24] 陈宇峰,黎涛.智能化路面冷铣刨机开发研究.建设机械技术与管理.2003(6):20-21
[25] 喻钢,尹苟保,谢长宇.智能型路面铣刨机发展方向及设计分析.建设机械技术与管理(11):31-32
[26] 张平,丁晓东.可调速液压驱动冷却系统在铣刨机上的应用.养护机械与施工技术.2006(7):28-29
[27] 尚涛.液压挖掘机作业及行走系统节能控制研究.吉林大学博士论文.2004
[28] 吴根茂,丘敏秀,王庆丰等.新编实用电液比例控制技术.杭州.浙江大学出版社 2006.9
[29] 黄宏甲,黄谊,王积伟.液压与气压传动.北京.机械工业出版社. 2000.05
[30] SAUER-SUNDSTRAND Applications Manual
[31] 高纪念,蔚长春.电液控制技术及其应用.石油工业出版社.1993.6
[32] 杨俭.电液比例位置系统复合控制及相关研究.浙江大学博士学位论文.2005
[33] EATON Vickers V-PV-EEPS-0001A:C2-C12
[34] 姜继海,宋锦春,高常识.液压与气压传动.北京.高等教育出版社.2002.1
[35] Cummins Inc. QSX15 Engine Performance Data
[36] 上海派芬自动控制有限公司.2005 年样本
[37] 曹承志.微型计算机控制技术.北京.机械工业出版社.2001.3
[38] 胡寿松.自动控制原理(第四版).北京.科学出版社.
[39] Bahney.J.H. Hydraulic pumps: the key to power generation. Aerospace Engineering.1991(12)
[40] Alan .J. Hugo. Performance assessment of single-loop industrial controllers Journal of Process Control.2006(4)
[41] 柯明纯,丁凡,李 宾.电液比例方向节流阀的特性测试方法探讨.工程机械.2006(3):48-50
[42] 宫文斌,刘昕晖,孙延伟.电液比例 PWM 控制方法.吉林大学学报( 工学版).2003(7):104-106
[43] 牛占海,王宏武,刘 榛.对电液比例控制系统的综述.机械研究与应用.2004(12):16-17
[44] 舒进,陈思忠,杨林.电液比例位置控制系统的死区模糊补偿控制研究.液压与气动.2005(1):20-22
[45] Zeng Libin .The application of microcomputer control of electro-hydraulic proportional level adjustment system of the telescopic fork-lift truck. Proceedings Of The Fourth International Symposium On Fluid Power Transmission And Control
[46] Tapio Virvalo .Computer pressure control methods .Proceedings Of The Fourth International Symposium On Fluid Power Transmission And Control
[47] Yu.W.S .Continuous-time indirect adaptive control of the electro- hydraulic servo systems .IEEE Transactions On Control Systems Technology
[48] Wei Jianhua .Transient response of a valve control system with long pipe.机械工程学报(英文版)2004(3)