耐高压高速开关电—机械转换器关键技术研究
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摘要
随着计算机技术的日益完善和广泛应用,电液数字控制技术已成为机械行业实现机电一体化的一种重要手段,是实现对液压系统高速、高精度控制的理想方法之一,已广泛应用于国防及民用如航空航天、汽车、冶金、武器控制、农业机械和工程机械等领域。其中,高速开关电—机械转换器是其核心技术。高速开关电—机械转换器可直接与微机相连而无需D/A转换装置,与传统的伺服阀和比例阀阀用电—机械转换器相比,具有结构简单、工艺性好、成本低、抗污染能力强、重复精度高、工作稳定可靠、能耗低等优点,目前已成为电—机械转换器的一个研究热点。对耐高压高速开关电—机械转换器的研究,能够提高电液数字控制系统的整体性能指标,更好地满足生产生活需要,进而推动相关领域理论、技术和装备的发展。
论文以耐高压高速开关电—机械转换器为研究对象,采用理论分析、数值仿真和实验研究相结合的方法,对耐高压高速开关电—机械转换器关键技术进行了系统、深入的研究。基于耐高压动铁式高速开关电—机械转换器,对大行程时的吸合性能和释放性能综合考虑,分析了动态过程中的磁路变化,探讨了主要结构参数对静、动态特性的影响,完成了平面形磁极和圆锥形磁极耐高压大行程高速开关电—机械转换器的研制,仿真与实验表明这两种耐高压大行程高速开关电—机械转换器因匹配不同的负载弹簧特性以适用不同的工作行程；针对导磁套一体式耐高压高速开关电—机械转换器漏磁的问题,提出了永磁屏蔽式耐高压高速开关电—机械转换器的结构方案,并进行了仿真分析和实验研究,结果表明,采用永磁屏蔽策略可形成永磁磁通和线圈磁通相互约束的磁场状态,从而在减少漏磁的同时避免永磁体极化磁通的自锁力问题,能有效地增加电磁力并大幅提升吸合性能；作为应用的实例,将耐高压高速开关电—机械转换器应用于电液振动冲击系统,从而用高速开关阀替代了原系统所用的电液伺服阀,仿真与实验表明新系统性能满足设计要求,降低了成本。
有关各章内容分述如下：
第一章,从电液数字控制和高速开关阀技术应用的角度出发,探讨了高速开关电—机械转换器关键技术的研究进展,分析总结了阀用电—机械转换器的结构和高速响应特点以及发展趋势。
第二章,介绍了电—机械转换器的作用、分类及结构特点；针对广泛应用的耐高压动铁式高速开关电—机械转换器,介绍了其典型结构、工作原理和性能指标；建立了电—机械转换器的动态数学模型,围绕电磁力的计算,分别介绍了磁路分析法和有限元分析法,并指出它们的各自特点和应用场合；通过仿真深入研究了高速开关电—机械转换器的动态特性,阐明了动态过程的进行规律和分析设计方法。
第三章,研制了平面形磁极和圆锥形磁极耐高压大行程高速开关电—机械转换器,详细分析了其结构与工作原理；针对大行程的工作特点,结合磁路分析法和有限元分析法,分析了动态过程中的磁场/磁路变化以及磁场／磁路变化对静、动态特性的影响,阐述了结构参数的作用机理,明确了两种耐高压大行程高速开关电—机械转换器的具体结构参数值；介绍了静态特性测试系统和动态特性测试系统的原理、组成和实验方法；基于搭建的静、动态特性实验系统,实验研究了这两种电—机械转换器,并与仿真结果进行了对比。
第四章,提出并介绍了新型永磁屏蔽式耐高压高速开关电—机械转换器的结构和工作原理,采用磁路分析和有限元仿真相结合的方法,探讨了其主要结构参数对静、动态特性的影响；阐述了电磁铁动态过程的功能转换分析和导磁套受压的失效形式,利用有限元工具分别进行了温升分析和强度分析,结果表明均在许可范围内；搭建了静、动态特性实验系统,进行了实验研究,并与仿真结果进行了对比；与导磁套一体式耐高压高速开关电—机械转换器进行了对比实验,结果验证了永磁屏蔽策略的有效性。
第五章,作为耐高压高速开关电—机械转换器的应用实例,研制了基于高速开关阀的电液振动冲击系统,并应用于剁挫机；建立了耐高压高速开关电—机械转换器、高速开关阀和电液振动冲击系统的仿真模型,通过仿真获得其静、动态特性,并探讨了耐高压高速开关电—机械转换器的性能对电液振动冲击系统的影响；建立了冲击能测试系统,获得了基于高速开关阀的电液振动冲击系统的冲击力实验结果,并进行了实验研究和仿真对比。
第六章,概况了全文的主要研究工作和成果,并展望了今后需要进一步研究的工作和方向。
With increasingly sophisticated and extensively used computer technology, the digital electro-hydraulic control technology becomes an important mean for achieving electro-mechanical machinery industry and is widely used in many sections of national economy and social surroundings, such as aerospace, automotive, metallurgy, arms control, agricultural machinery, and construction machinery, due to its advantages of high-speed, high-precision control of hydraulic systems. The high-speed on-off electro-mechanical converter is the core technology. Compared with the conventional converters for servo valves or proportional valves, the high-speed on-off electro-mechanical converters can be directly connected with the computer without the need for D/A converters and has the advantages of low cost, easy processing, strong anti-pollution, high repeatability, high stability, high reliability, and low energy consumption. So the high-speed on-off electro-mechanical converter has come to a hot topic of researches on the electro-mechanical converters. Researches on high-pressure high-speed on-off electro-mechanical converters would improve the overall performance index of digital electro-hydraulic control systemes and promote the theory, technology and equipment of related areas, to better meet the ever-increasing productions and livings.
Based on theory analysis, numerical simulation and experimental study, the key technologies of high-pressure high-speed on-off electro-mechanical converters are systematically, deep researched in the thesis. Based on the research of moving-iron high-pressure high-speed on-off electro-mechanical converters, taking comprehensive consideration of closing performance and opening performance for long stroke condition, analyzing the dynamic process of magnetic changes, discussing the influence of structural parameters on the static and dynamic characteristics, and developing the planar-polar and conical-polar high-pressure high-speed on-off electro-mechanical converters are presented. And simulation and experimental results show that these two electro-mechanical converters match different characteristics of the spring load to apply to different working stroke. Aiming at the leakage problem of the single-piece high-pressure high-speed on-off electro-mechanical converters, a high-pressure high-speed on-off electro-mechanical converter with permanent magnet (PM) shielding is proposed, and the simulation analysis and experimental study are conducted. The results show that the PM shielding strategy can reduce the flux leakage, avoid self-locking force inherited from polarization of the permanent magnet flux, increase electromagnetic force, and enhance closing performance by forming a mutual constraint of the permanent magnet flux and the magnetic field coil flux. As an application instance, a high-pressure high-speed on-off electro-mechanical converter is applied to the electro-hydraulic vibration impact system, and the original servo valve is replaced by a high-speed on-off valve. And simulation and experimental results show that new system performance meets the design requirements with lower cost.
The main content of each chapter is summarized as following:
In chapter 1, from standpoints of the high-speed valves for the digital electro-hydraulic control technology, the research progress of the high-pressure high-speed on-off electro-mechanical converters is introduced. The structural and high-speed feature, development trend of the electro-mechanical converters for valves are summarized.
In chapter 2, the function, classification and structural characteristics of electro-mechanical converters are described. Future, the typical structure, the working principle and performances of the widely used moving-iron high-speed on-off electro-mechanical converters are introduced. The dynamic mathematical model of electro-mechanical converters is established. Taking the calculation of electromagnetic force as the central task, the magnetic circuit analysis and finite element analysis are introduced. The characteristics and applicable fields of the two analytical methods are pointed out.
In chapter 3, the planar-polar and conical-polar high-pressure high-speed on-off electro-mechanical converters are developed. Being conditional on long working stroke, the influences of dynamic process of magnetic field/magnetic field changes on the static and dynamic characteristics are analyzed as the design basis. By explaining the mechanism of structural parameters, the structure parameters of the two long working stroke electro-mechanical converters are specified. The principle, constitution and test methods of static and dynamic test systems are introduced. Based on the static and dynamic test systems, the static and dynamic characteristics of two long working stroke electro-mechanical converters are measured, and compared with simulation results.
In chapter 4, the structure and working principle of the new high-speed on-off electro-mechanical converter with permanent-magnet (PM) shielding are proposed. Using combined methods of magnetic circuit analysis and finite element simulation, the influences of main structure parameters on static and dynamic characteristics are discussed. Based on the energy conversion relations in dynamic process and the failure mode under oil pressure, temperature and strength analyses are carried out using the finite element tools and results are all within the limits permitted. Compared the PM shielding type high-pressure high-speed on-off electro-mechanical converters with the single-piece type high-pressure high-speed on-off electro-mechanical converters, the experimental results verify the effectiveness of PM shielding strategy.
In chapter 5. as an application instance of high-pressure high-speed on-off electro-mechanical converters, the electro-hydraulic vibration impact system based on high-speed valves is developed. The simulation models of the high-pressure high-speed on-off electro-mechanical converter, the high-speed valve, and the electro-hydraulic vibration impact system are established to obtain their static and dynamic characteristics. The influences of the high-pressure high-speed on-off electro-mechanical converter on the electro-hydraulic vibration impact system are conducted. Through the impact energy test system for the electro-hydraulic vibration impact system, the impact forces are measured and compared with the simulation results.
In chapter 6, all achievements of the dissertation are summarized and the further research work is put forward.
论文以耐高压高速开关电—机械转换器为研究对象,采用理论分析、数值仿真和实验研究相结合的方法,对耐高压高速开关电—机械转换器关键技术进行了系统、深入的研究。基于耐高压动铁式高速开关电—机械转换器,对大行程时的吸合性能和释放性能综合考虑,分析了动态过程中的磁路变化,探讨了主要结构参数对静、动态特性的影响,完成了平面形磁极和圆锥形磁极耐高压大行程高速开关电—机械转换器的研制,仿真与实验表明这两种耐高压大行程高速开关电—机械转换器因匹配不同的负载弹簧特性以适用不同的工作行程；针对导磁套一体式耐高压高速开关电—机械转换器漏磁的问题,提出了永磁屏蔽式耐高压高速开关电—机械转换器的结构方案,并进行了仿真分析和实验研究,结果表明,采用永磁屏蔽策略可形成永磁磁通和线圈磁通相互约束的磁场状态,从而在减少漏磁的同时避免永磁体极化磁通的自锁力问题,能有效地增加电磁力并大幅提升吸合性能；作为应用的实例,将耐高压高速开关电—机械转换器应用于电液振动冲击系统,从而用高速开关阀替代了原系统所用的电液伺服阀,仿真与实验表明新系统性能满足设计要求,降低了成本。
有关各章内容分述如下：
第一章,从电液数字控制和高速开关阀技术应用的角度出发,探讨了高速开关电—机械转换器关键技术的研究进展,分析总结了阀用电—机械转换器的结构和高速响应特点以及发展趋势。
第二章,介绍了电—机械转换器的作用、分类及结构特点；针对广泛应用的耐高压动铁式高速开关电—机械转换器,介绍了其典型结构、工作原理和性能指标；建立了电—机械转换器的动态数学模型,围绕电磁力的计算,分别介绍了磁路分析法和有限元分析法,并指出它们的各自特点和应用场合；通过仿真深入研究了高速开关电—机械转换器的动态特性,阐明了动态过程的进行规律和分析设计方法。
第三章,研制了平面形磁极和圆锥形磁极耐高压大行程高速开关电—机械转换器,详细分析了其结构与工作原理；针对大行程的工作特点,结合磁路分析法和有限元分析法,分析了动态过程中的磁场/磁路变化以及磁场／磁路变化对静、动态特性的影响,阐述了结构参数的作用机理,明确了两种耐高压大行程高速开关电—机械转换器的具体结构参数值；介绍了静态特性测试系统和动态特性测试系统的原理、组成和实验方法；基于搭建的静、动态特性实验系统,实验研究了这两种电—机械转换器,并与仿真结果进行了对比。
第四章,提出并介绍了新型永磁屏蔽式耐高压高速开关电—机械转换器的结构和工作原理,采用磁路分析和有限元仿真相结合的方法,探讨了其主要结构参数对静、动态特性的影响；阐述了电磁铁动态过程的功能转换分析和导磁套受压的失效形式,利用有限元工具分别进行了温升分析和强度分析,结果表明均在许可范围内；搭建了静、动态特性实验系统,进行了实验研究,并与仿真结果进行了对比；与导磁套一体式耐高压高速开关电—机械转换器进行了对比实验,结果验证了永磁屏蔽策略的有效性。
第五章,作为耐高压高速开关电—机械转换器的应用实例,研制了基于高速开关阀的电液振动冲击系统,并应用于剁挫机；建立了耐高压高速开关电—机械转换器、高速开关阀和电液振动冲击系统的仿真模型,通过仿真获得其静、动态特性,并探讨了耐高压高速开关电—机械转换器的性能对电液振动冲击系统的影响；建立了冲击能测试系统,获得了基于高速开关阀的电液振动冲击系统的冲击力实验结果,并进行了实验研究和仿真对比。
第六章,概况了全文的主要研究工作和成果,并展望了今后需要进一步研究的工作和方向。
With increasingly sophisticated and extensively used computer technology, the digital electro-hydraulic control technology becomes an important mean for achieving electro-mechanical machinery industry and is widely used in many sections of national economy and social surroundings, such as aerospace, automotive, metallurgy, arms control, agricultural machinery, and construction machinery, due to its advantages of high-speed, high-precision control of hydraulic systems. The high-speed on-off electro-mechanical converter is the core technology. Compared with the conventional converters for servo valves or proportional valves, the high-speed on-off electro-mechanical converters can be directly connected with the computer without the need for D/A converters and has the advantages of low cost, easy processing, strong anti-pollution, high repeatability, high stability, high reliability, and low energy consumption. So the high-speed on-off electro-mechanical converter has come to a hot topic of researches on the electro-mechanical converters. Researches on high-pressure high-speed on-off electro-mechanical converters would improve the overall performance index of digital electro-hydraulic control systemes and promote the theory, technology and equipment of related areas, to better meet the ever-increasing productions and livings.
Based on theory analysis, numerical simulation and experimental study, the key technologies of high-pressure high-speed on-off electro-mechanical converters are systematically, deep researched in the thesis. Based on the research of moving-iron high-pressure high-speed on-off electro-mechanical converters, taking comprehensive consideration of closing performance and opening performance for long stroke condition, analyzing the dynamic process of magnetic changes, discussing the influence of structural parameters on the static and dynamic characteristics, and developing the planar-polar and conical-polar high-pressure high-speed on-off electro-mechanical converters are presented. And simulation and experimental results show that these two electro-mechanical converters match different characteristics of the spring load to apply to different working stroke. Aiming at the leakage problem of the single-piece high-pressure high-speed on-off electro-mechanical converters, a high-pressure high-speed on-off electro-mechanical converter with permanent magnet (PM) shielding is proposed, and the simulation analysis and experimental study are conducted. The results show that the PM shielding strategy can reduce the flux leakage, avoid self-locking force inherited from polarization of the permanent magnet flux, increase electromagnetic force, and enhance closing performance by forming a mutual constraint of the permanent magnet flux and the magnetic field coil flux. As an application instance, a high-pressure high-speed on-off electro-mechanical converter is applied to the electro-hydraulic vibration impact system, and the original servo valve is replaced by a high-speed on-off valve. And simulation and experimental results show that new system performance meets the design requirements with lower cost.
The main content of each chapter is summarized as following:
In chapter 1, from standpoints of the high-speed valves for the digital electro-hydraulic control technology, the research progress of the high-pressure high-speed on-off electro-mechanical converters is introduced. The structural and high-speed feature, development trend of the electro-mechanical converters for valves are summarized.
In chapter 2, the function, classification and structural characteristics of electro-mechanical converters are described. Future, the typical structure, the working principle and performances of the widely used moving-iron high-speed on-off electro-mechanical converters are introduced. The dynamic mathematical model of electro-mechanical converters is established. Taking the calculation of electromagnetic force as the central task, the magnetic circuit analysis and finite element analysis are introduced. The characteristics and applicable fields of the two analytical methods are pointed out.
In chapter 3, the planar-polar and conical-polar high-pressure high-speed on-off electro-mechanical converters are developed. Being conditional on long working stroke, the influences of dynamic process of magnetic field/magnetic field changes on the static and dynamic characteristics are analyzed as the design basis. By explaining the mechanism of structural parameters, the structure parameters of the two long working stroke electro-mechanical converters are specified. The principle, constitution and test methods of static and dynamic test systems are introduced. Based on the static and dynamic test systems, the static and dynamic characteristics of two long working stroke electro-mechanical converters are measured, and compared with simulation results.
In chapter 4, the structure and working principle of the new high-speed on-off electro-mechanical converter with permanent-magnet (PM) shielding are proposed. Using combined methods of magnetic circuit analysis and finite element simulation, the influences of main structure parameters on static and dynamic characteristics are discussed. Based on the energy conversion relations in dynamic process and the failure mode under oil pressure, temperature and strength analyses are carried out using the finite element tools and results are all within the limits permitted. Compared the PM shielding type high-pressure high-speed on-off electro-mechanical converters with the single-piece type high-pressure high-speed on-off electro-mechanical converters, the experimental results verify the effectiveness of PM shielding strategy.
In chapter 5. as an application instance of high-pressure high-speed on-off electro-mechanical converters, the electro-hydraulic vibration impact system based on high-speed valves is developed. The simulation models of the high-pressure high-speed on-off electro-mechanical converter, the high-speed valve, and the electro-hydraulic vibration impact system are established to obtain their static and dynamic characteristics. The influences of the high-pressure high-speed on-off electro-mechanical converter on the electro-hydraulic vibration impact system are conducted. Through the impact energy test system for the electro-hydraulic vibration impact system, the impact forces are measured and compared with the simulation results.
In chapter 6, all achievements of the dissertation are summarized and the further research work is put forward.
引文
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