锻造油压机液压控制系统的关键技术研究
摘要
锻造液压机的装备水平是衡量一个国家机械制造水平和能力的标志之一。锻造油压机以其速度快、精度高、自动化程度高等特点成为目前大型自由锻锤及中小型传统水压机的更新换代产品。液压控制系统是提高锻造油压机工作特性及锻件产品质量的关键设备,开展锻造油压机液压控制系统工作特性和控制特性的研究具有重要的理论意义和实际应用价值。它可以为现代化锻造油压机液压系统优化设计提供技术支撑;可以改进现有的锻造油压机液压控制系统设计,改善系统性能,优化控制技术,以提高锻造油压机的整体水平。
本文针对现代化锻造油压机快速、无冲击及高精度的要求,开展了锻造油压机工作特性影响因素和锻造油压机控制特性两方面的专题研究。
利用机理建模技术,进行了锻造油压机液压控制系统及元件的动态建模研究。建立了插装类方向阀、插装类压力阀、三级插装阀、电液比例插装阀、蓄能器、管道、执行机构以及油压机机架振动等关键元件的数学模型。在此基础上,进行了不同快锻回路液压控制系统数学模型的研究,为锻造油压机工作特性影响因素和控制特性研究奠定理论基础。
从工作速度、关键元件的动态特性、建压时间、卸压时间、各阀间的协调控制和电液比例控制的系统设计等方面,通过大量的仿真和试验研究,对锻造油压机快速性的影响因素进行了研究。从卸压卸荷冲击、管道压力冲击和失荷冲击振动三个方面进行了锻造油压机冲击振动的影响因素研究,并结合生产现场实测数据,利用仿真技术,研究了理想卸压曲线、不同位置管道对系统冲击振动的影响规律,减少失荷造成压机和基础振动的措施等。
研究了锻造油压机阀控缸控制特性,利用液压系统独立插装单元控制工作缸的特殊性,设计控制器参数,优化了锻造油压机液压控制系统的控制特性,并减小了回程缸的压力跃变,提高了系统的快速性,在实际锻造油压机生产过程中得到了应用,验证了所提出的控制策略的正确性和适用性。
在仿真和实验研究的基础上,研究了开关型快锻回路、差动溢流快锻回路、比例控制快锻回路的控制特性,分析和比较它们的特点及控制特性,并给出相应的计算机快锻工序。对新型的节能型蓄能器快锻回路进行了仿真和试验研究,提出了计算选择蓄能器的依据,证明了利用蓄能器实现快锻节能的可行性,验证了蓄能器及蓄能器快锻回路数学模型的正确性。
Forging hydraulic press is one symbol which weighs a country machinery manufacturing level and ability. Forging oil press is considered as substitute of large type forging hammer and middle-small traditonal forging water press because of its fast forging speed, high control accuracy and high automatization etc. Developing the hydraulic control system essential characteristics research on the forging oil press has important theoretical significance and practical application value. It can provide the technical support for hydraulic system design optimization of the modernized forging oil press; it can improve hydraulic control system essential characteristics, structure parameters and system design of the existing forging oil press, optimize control technology, and then enhance forging oil press overall level.
Aming at modernization forging oil press rapid, non-impact and high precision, the influencing factors of forging oil press operating characteristics and the forging oil press control characteristics had been studied. This work around these two special subjects had been carried on as follows:
Using the mechanism modeling technology, based on hydraulic system dynamic modeling research of the forging oil press, the essential components mathematical model consist of the kind of cartridge directional valves, the kind of cartridge pressure valves, the triple-stage cartridge valves, the electro-hydraulic proportional cartridge valves, the accumulator, the pipeline, the executive mechanism, the hydraulic press vibration etc. were found. According to these, different hydraulic control system mathematical model of fast forging circuit were found. All above models are laying a theoretical foundation for the essential characteristics research of the forging oil press.
Based on the theoretical modeling foundation, through the massive simulations and the experimental study, comprehensive and systematic analysis of forging oil press rapid influencing factors, which include working speed, the essential components static and dynamic performance, the set-pressure time, the unloading pressure time, various valves coordination control and electro-hydraulic proportional control system design and so on, were carried out. From pressure relief and unloading impact, the pipeline pressure impact and sudden unloading impact vibration three aspects, the influencing key factors of forging oil press impact vibration were conducted. In combination with measured data of production progress, using simulation technology, the ideal release of pressure curve, the influence rules of pipeline to the system impact vibration in the different position, the measures of reducing unloading to lead to the press and the foundation vibration had been obtained, it has the practical significance and the application value.
The valve controlled cylinder characteristics of the forging oil press was studied. Through designing the controller parameters, the forging hydraulic press hydraulic control system control characteristics was optimized, the return cylinder pressure jump was reduced, the hydraulic system rapidity was enhanced. What is more important it was applied and verified in the actual forging oil press.
On the basis of the simulation and experimental study, the control characteristics of the switching type fast forging circuit, the differential overflow fast forging circuit and the proportional control fast forging circuit had been analyzed and compared. The corresponding computer fast forging procedures were given. The simulation and the experimental with emphasis on forging circuit using accumulator were studied, the basis of selecting calculation of accumulator was proposed, the simulation and test results had proved energy conservation of fast forging by using the accumulator is feasible and realized, and the mathematical model of the accumulator and the fast forging circuit using accumulator is accuracy.
本文针对现代化锻造油压机快速、无冲击及高精度的要求,开展了锻造油压机工作特性影响因素和锻造油压机控制特性两方面的专题研究。
利用机理建模技术,进行了锻造油压机液压控制系统及元件的动态建模研究。建立了插装类方向阀、插装类压力阀、三级插装阀、电液比例插装阀、蓄能器、管道、执行机构以及油压机机架振动等关键元件的数学模型。在此基础上,进行了不同快锻回路液压控制系统数学模型的研究,为锻造油压机工作特性影响因素和控制特性研究奠定理论基础。
从工作速度、关键元件的动态特性、建压时间、卸压时间、各阀间的协调控制和电液比例控制的系统设计等方面,通过大量的仿真和试验研究,对锻造油压机快速性的影响因素进行了研究。从卸压卸荷冲击、管道压力冲击和失荷冲击振动三个方面进行了锻造油压机冲击振动的影响因素研究,并结合生产现场实测数据,利用仿真技术,研究了理想卸压曲线、不同位置管道对系统冲击振动的影响规律,减少失荷造成压机和基础振动的措施等。
研究了锻造油压机阀控缸控制特性,利用液压系统独立插装单元控制工作缸的特殊性,设计控制器参数,优化了锻造油压机液压控制系统的控制特性,并减小了回程缸的压力跃变,提高了系统的快速性,在实际锻造油压机生产过程中得到了应用,验证了所提出的控制策略的正确性和适用性。
在仿真和实验研究的基础上,研究了开关型快锻回路、差动溢流快锻回路、比例控制快锻回路的控制特性,分析和比较它们的特点及控制特性,并给出相应的计算机快锻工序。对新型的节能型蓄能器快锻回路进行了仿真和试验研究,提出了计算选择蓄能器的依据,证明了利用蓄能器实现快锻节能的可行性,验证了蓄能器及蓄能器快锻回路数学模型的正确性。
Forging hydraulic press is one symbol which weighs a country machinery manufacturing level and ability. Forging oil press is considered as substitute of large type forging hammer and middle-small traditonal forging water press because of its fast forging speed, high control accuracy and high automatization etc. Developing the hydraulic control system essential characteristics research on the forging oil press has important theoretical significance and practical application value. It can provide the technical support for hydraulic system design optimization of the modernized forging oil press; it can improve hydraulic control system essential characteristics, structure parameters and system design of the existing forging oil press, optimize control technology, and then enhance forging oil press overall level.
Aming at modernization forging oil press rapid, non-impact and high precision, the influencing factors of forging oil press operating characteristics and the forging oil press control characteristics had been studied. This work around these two special subjects had been carried on as follows:
Using the mechanism modeling technology, based on hydraulic system dynamic modeling research of the forging oil press, the essential components mathematical model consist of the kind of cartridge directional valves, the kind of cartridge pressure valves, the triple-stage cartridge valves, the electro-hydraulic proportional cartridge valves, the accumulator, the pipeline, the executive mechanism, the hydraulic press vibration etc. were found. According to these, different hydraulic control system mathematical model of fast forging circuit were found. All above models are laying a theoretical foundation for the essential characteristics research of the forging oil press.
Based on the theoretical modeling foundation, through the massive simulations and the experimental study, comprehensive and systematic analysis of forging oil press rapid influencing factors, which include working speed, the essential components static and dynamic performance, the set-pressure time, the unloading pressure time, various valves coordination control and electro-hydraulic proportional control system design and so on, were carried out. From pressure relief and unloading impact, the pipeline pressure impact and sudden unloading impact vibration three aspects, the influencing key factors of forging oil press impact vibration were conducted. In combination with measured data of production progress, using simulation technology, the ideal release of pressure curve, the influence rules of pipeline to the system impact vibration in the different position, the measures of reducing unloading to lead to the press and the foundation vibration had been obtained, it has the practical significance and the application value.
The valve controlled cylinder characteristics of the forging oil press was studied. Through designing the controller parameters, the forging hydraulic press hydraulic control system control characteristics was optimized, the return cylinder pressure jump was reduced, the hydraulic system rapidity was enhanced. What is more important it was applied and verified in the actual forging oil press.
On the basis of the simulation and experimental study, the control characteristics of the switching type fast forging circuit, the differential overflow fast forging circuit and the proportional control fast forging circuit had been analyzed and compared. The corresponding computer fast forging procedures were given. The simulation and the experimental with emphasis on forging circuit using accumulator were studied, the basis of selecting calculation of accumulator was proposed, the simulation and test results had proved energy conservation of fast forging by using the accumulator is feasible and realized, and the mathematical model of the accumulator and the fast forging circuit using accumulator is accuracy.
引文
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