CN101046420A - On-line detection method for transmission torque required by PFC (Power factor correction) of mechanical press - Google Patents
On-line detection method for transmission torque required by PFC (Power factor correction) of mechanical press Download PDFInfo
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Abstract
本发明公开了一种机械压力机PFC所需传递扭矩的在线检测方法,该方法采用滑块力程间接测量法检测PFC所需传递的扭矩Ma,根据机械压力机实际加工的有关信息,采用滑块力程特性获取Ma的值的方法进行研究。当由滑块上的力程特性得到曲轴的所需扭矩MRa后,可方便地由公式确定Ma的值,利用力传感器、A/D板及计算机等在线实测变形力数值及其时刻,采用软件可自动计算出工件变形阶段中不同时刻的扭矩MRa,并输出不同时刻的MRa值和最大值MRm,该方法具有迅速、可靠等良好特性,可以在生产中推广应用。
The present invention discloses an online detection method for the torque required to be transmitted by a mechanical press PFC. The method adopts a slider force range indirect measurement method to detect the torque Ma required to be transmitted by the PFC. According to the relevant information of the actual processing of the mechanical press, a method for obtaining the value of Ma by using the slider force range characteristics is studied. After the required torque M Ra of the crankshaft is obtained by the force range characteristics on the slider, the value of Ma can be conveniently determined by a formula. The deformation force value and its time are measured online by using a force sensor, an A/D board, a computer, etc., and the torque M Ra at different times in the deformation stage of the workpiece can be automatically calculated by using software, and the M Ra values at different times and the maximum value M Rm are output. The method has good characteristics such as rapidity and reliability, and can be promoted and applied in production.
Description
技术领域
本发明属于锻压设备之机械压力机领域的传递扭矩检测方法,具体涉及一种PFC所需传递扭矩的在线检测方法及装置。The invention belongs to a transmission torque detection method in the field of mechanical presses of forging equipment, and in particular relates to an online detection method and device for PFC required transmission torque.
背景技术 Background technique
当机械压力机进行锻冲工作时,需要气动摩擦离合器(PneumaticFriction Clutch,以下简称PFC)摩擦副能输出足够大的扭矩Mq≥Ma,否则PFC摩擦面产生打滑而发生闷车事故。通过电气比例压力阀给PFC气缸提供合适的气压来满足Mq≥Ma的正常工作要求,很显然必须预先知道Ma的大小。When the mechanical press performs forging work, the friction pair of the pneumatic friction clutch (PFC) needs to be able to output a large enough torque M q ≥ M a , otherwise the PFC friction surface will slip and cause a stuffy car accident. Provide proper air pressure to the PFC cylinder through the electric proportional pressure valve to meet the normal working requirements of M q ≥ M a , obviously the size of M a must be known in advance.
目前在国内外的所有机械压力机中,不管工件变形每次需要PFC传递多大的扭矩Ma(如齿轮热模锻进行第1工步的镦粗力往往仅为第2工步终锻力的1/3,相应的第1工步所需的Ma1不到第2工步的1/2),但每次PFC气缸都进最大的气压pmax,相应地PFC所能提供的扭矩总为最大值Mqmax,既造成了压缩空气能量的浪费又使PFC的排气噪声增大对环境的污染加重,因此本发明提供一种对PFC所需传递的扭矩的大小进行在线测量的方法。并详细论述了如何通过该测量装置检测得到PFC所需传递的扭矩Ma,PFC又是如何依据Ma的大小,提供足够大的扭矩Mq来满足工作变形的需要的。At present, in all mechanical presses at home and abroad, no matter how much torque M a needs to be transmitted by the PFC each time the workpiece is deformed (for example, the upsetting force of the first step of the gear hot die forging is often only 100% of the final forging force of the
由于塑性变形过程及机械压力机的复杂性,给理论计算带来当大的难度,为此这里采用在线实测的方法来确定Ma的大小,通常PFC轴上实际的扭矩的测试方法有用扭矩传感器直接测量、使用荷重传感器间接测量、使用电动机电流间接测量和利用滑块力程间接测量四种方法,本文先对这四种方法分别进行论述。Due to the complexity of the plastic deformation process and the mechanical press, it brings considerable difficulty to the theoretical calculation. Therefore, the online actual measurement method is used to determine the size of Ma . Usually, the actual torque test method on the PFC shaft is useful. Torque sensor There are four methods: direct measurement, indirect measurement using load cell, indirect measurement using motor current and indirect measurement using slider force distance. This paper first discusses these four methods respectively.
1.扭矩传感器直接测量方法1. Torque sensor direct measurement method
直接测量转动轴上扭矩的传感器有以下两种类型:Transducers that directly measure torque on a rotating shaft are of two types:
a.应变式扭矩传感器:a. Strain torque sensor:
采用电阻应变片将机械应变转换成正比于扭矩的电信号。由于其从转轴上输出信号,装置复杂,或可靠性差、或成本太高,使用不便。The mechanical strain is converted into an electrical signal proportional to the torque by using a resistance strain gauge. Because it outputs signals from the rotating shaft, the device is complicated, or the reliability is poor, or the cost is too high, and it is inconvenient to use.
b.扭转角相位差式扭矩传感器b. Torsion angle phase difference torque sensor
如JCZ型转矩转速传感器的转矩测量原理就是相位差式原理,即在弹性轴的两端安装两只信号齿轮,在两齿轮的上方各装有一组信号线圈,在信号线圈内均装有磁缸,与信号齿轮组成磁电信号发生器。当信号齿轮随弹性轴转动时,由于信号齿轮的齿顶及齿谷交替周期扫过磁缸的底部,使气隙磁导产生周期性的变化,线圈内部的磁通量亦产生周期性变化,使线圈中感生出近似正弦波的交流电信号。在弹性轴受扭时,将产生扭转变形,使两组交流电信号之间的相位差发生变化,在弹性变形范围内,相位差变化的绝对值与转矩的大小成正比。For example, the torque measurement principle of the JCZ torque speed sensor is the principle of phase difference, that is, two signal gears are installed at both ends of the elastic shaft, and a set of signal coils are respectively installed above the two gears. The magnetic cylinder and the signal gear form a magnetoelectric signal generator. When the signal gear rotates with the elastic shaft, since the tooth top and tooth valley of the signal gear alternately sweep across the bottom of the magnetic cylinder, the air-gap permeability will change periodically, and the magnetic flux inside the coil will also change periodically, making the coil The medium induction produces an alternating current signal that approximates a sine wave. When the elastic shaft is twisted, it will produce torsional deformation, which will cause the phase difference between the two sets of AC signals to change. Within the elastic deformation range, the absolute value of the phase difference change is proportional to the magnitude of the torque.
锻压生产的工业现场环境恶劣,且不宜对机械压力机的曲轴进行破坏性处理(如在曲轴上打磨、钻孔等)和破坏曲轴的动平衡(如在曲轴上安装传感器及其附件),因此,上述直接测量转动轴上的扭矩的方法在机械压力机FPC扭矩测试中应用较难。The industrial site environment of forging production is harsh, and it is not suitable for destructive treatment of the crankshaft of the mechanical press (such as grinding, drilling, etc.) , the above-mentioned method of directly measuring the torque on the rotating shaft is difficult to apply in the FPC torque test of the mechanical press.
2.荷重传感器间接测量扭矩方法2. Load sensor indirect torque measurement method
在机械压力机上安装和使用荷重传感器都是比较方便的,在西安交通大学模具与塑性加工研究所的PFCB-82型机械压力机气动摩擦离合器与制动器综合智能试验台(如附图1所示)上安装的荷重传感器则可以测出PFC轴上的扭矩与时间的变化关系。图2为该实验台上安装荷重传感器的情况,制动器的固定座有左右两凸台,在一侧安装荷重传感器,通过测量荷重传感器的输出的力,通过扭矩计算公式Ma=F×L间接计算得到作用于PFC轴上的扭矩。It is more convenient to install and use the load sensor on the mechanical press. In the PFCB-82 mechanical press pneumatic friction clutch and brake comprehensive intelligent test bench of the Mold and Plastic Processing Research Institute of Xi'an Jiaotong University (as shown in Figure 1) The load sensor installed on the PFC shaft can measure the relationship between the torque on the PFC shaft and the time. Figure 2 shows the installation of the load cell on the test bench. The fixed seat of the brake has two bosses on the left and right, and the load cell is installed on one side. By measuring the output force of the load cell, the torque calculation formula M a =F×L is used indirectly Calculate the torque acting on the PFC shaft.
3.电动机电流间接测量轴上扭矩方法3. Method of indirect measurement of shaft torque by motor current
机械压力机一般由三相异步电动机驱动,当PFC轴上所需的扭矩越大时,则相应的电动机所需输出转矩也越大,这样可间接地通过对电动机输出转矩的测量结果,推算出PFC轴上Ma。由异步电动机的运行原理可知,转子绕组中的电流在旋转磁场的作用下,产生了作用在电动机转子上的电磁转矩。由电动机学可知,电动机的平均电磁转矩M为:The mechanical press is generally driven by a three-phase asynchronous motor. When the torque required on the PFC shaft is greater, the corresponding output torque of the motor is also greater. In this way, the measurement of the output torque of the motor can be indirectly obtained. Calculate Ma on the PFC axis. According to the operating principle of the asynchronous motor, the current in the rotor winding produces an electromagnetic torque acting on the rotor of the motor under the action of the rotating magnetic field. According to electromechanics, the average electromagnetic torque M of the motor is:
M=K·Φm·I2·cosΦ2(N·m) (1)M=K·Φ m ·I 2 ·cosΦ 2 (N·m) (1)
式中:K-与电动机结构参数有关的系数,称为转矩系数;In the formula: K-coefficient related to the structural parameters of the motor, called the torque coefficient;
Φm-气隙每极磁通量(Wb);Φ m - magnetic flux per pole of the air gap (Wb);
I2-转子绕组相电流(A);I 2 - rotor winding phase current (A);
cosΦ2-转子绕组的功率因数 cosΦ2 - power factor of the rotor winding
由式(1)可看出,异步电动机电磁转矩M的大小与气隙每极磁通量Φm、转子相电流I2以及转子的功率因数cosΦ2成正比。但由于这个关系比较复杂,而在实际生产中,电动机在正常范围内运转时电动机的转差率很小,其气隙磁通Φm可视为额定值,功率因数cosΦ2≈1,这样电磁转矩M的大小仅与转子电流I2成正比。但因为转子电流不便于测量,根据电动机的等值电路,把转子各量进行匝数、相数和转子位置的折合后,可以得到定子电流 转子折合电流 与电动机的励磁电流 的关系:It can be seen from formula (1) that the magnitude of the electromagnetic torque M of the asynchronous motor is proportional to the magnetic flux Φ m of each pole of the air gap, the rotor phase current I 2 and the power factor cos Φ 2 of the rotor. But because this relationship is more complicated, and in actual production, the slip rate of the motor is very small when the motor is running in the normal range, its air gap flux Φ m can be regarded as the rated value, and the power factor cosΦ 2 ≈ 1, so the electromagnetic The magnitude of the torque M is only proportional to the rotor current I2 . But because the rotor current is not easy to measure, according to the equivalent circuit of the motor, the stator current can be obtained after converting the rotor quantities into the number of turns, the number of phases and the position of the rotor Rotor equivalent current With the field current of the motor Relationship:
式中
4.滑块力程间接测量方法:4. Indirect measurement method of slider force distance:
实际中机械压力机的PFC所需传递的扭矩Ma是由其滑块通过模具使工件产生变形时所需力和变形高度确定的,在工业生产实际中有些机械压力机上安装有自动检测锻冲变形力及变形高度的装置,这样,用这两种信号的大小就可获得曲轴上作用的扭矩MRa In practice, the torque M a required to be transmitted by the PFC of the mechanical press is determined by the force and deformation height required when the slider passes through the mold to deform the workpiece. In actual industrial production, some mechanical presses are equipped with automatic detection forging punches. The device of deformation force and deformation height, so that the torque M Ra acting on the crankshaft can be obtained by using the magnitude of these two signals
MRa=Pmq (3)M Ra = Pm q (3)
式中P为作用到滑块上的工件变形力(N),mq为曲柄连杆机构的当量力臂(m)。In the formula, P is the workpiece deformation force (N) acting on the slider, and m q is the equivalent force arm (m) of the crank linkage mechanism.
当在线已知曲轴上作用的扭矩MRa,相应地PFC轴上所需传递的扭矩Ma应为When the torque M Ra acting on the crankshaft is known on the line, the corresponding torque Ma that needs to be transmitted on the PFC shaft should be
式中i为PFC的轴至曲轴的传动比,η为PFC轴至曲轴之间的传动效率,对一级齿轮传动η=0.97,二级齿轮传动η=0.94。In the formula, i is the transmission ratio from the shaft of the PFC to the crankshaft, and η is the transmission efficiency between the PFC shaft and the crankshaft. For one-stage gear transmission, η=0.97, and for two-stage gear transmission, η=0.94.
发明内容Contents of invention
本发明的目的在于,提供一种机械压力机PFC所需传递扭矩的在线检测方法,该方法就是采用上述第四种方法来在线测试PFC轴上实际的扭矩以确定Ma的大小。The object of the present invention is to provide an online detection method for the required transmission torque of the PFC of a mechanical press, which uses the above fourth method to online test the actual torque on the PFC shaft to determine the size of Ma .
为了实现上述任务,本发明采取如下的技术解决方案:In order to realize above-mentioned task, the present invention takes following technical solution:
一种机械压力机PFC所需传递扭矩的在线检测方法,该方法采用滑块力程间接测量法检测PFC所需传递的扭矩Ma,其特征在于,具体包括下列步骤:An on-line detection method for the torque required to be transmitted by the PFC of a mechanical press, the method adopts the indirect measurement method of the slider force distance to detect the torque M a required to be transmitted by the PFC, and is characterized in that it specifically includes the following steps:
1)以PFC所能提供的扭矩Mq=βMa并且Mq与气缸气压成良好的线性关系MqC=kp,通过调节进入PFC气缸的气压p来达到对PFC所能产生的扭矩的控制;1) With the torque M q that can be provided by the PFC = βM a and M q has a good linear relationship with the cylinder air pressure M qC = kp, the control of the torque that can be generated by the PFC is achieved by adjusting the air pressure p entering the PFC cylinder;
2)利用滑块力程曲线确定PFC摩擦面上所需传递扭矩MRa的方法,包括了由工艺类型的最大变形力Pm和由在线实测P-t数值关系两种方式;2) The method of determining the required transmission torque M Ra on the PFC friction surface by using the force-distance curve of the slider includes two methods: the maximum deformation force P m of the process type and the online actual measurement of the Pt numerical relationship;
A.采用由工艺类型和最大变形力Pm的方式确定扭矩MRa时,首先应建立所完成工艺较为准确的工作负荷特性的数学表达式,然后计算出工件变形过程中各段的最大扭矩MRaim,最后通过各段的对比求出整个变形过程中的扭矩最大值MRm;A. When the torque M Ra is determined by the method of the process type and the maximum deformation force P m , the mathematical expression of the more accurate working load characteristics of the completed process should be established first, and then the maximum torque M of each section during the deformation process of the workpiece should be calculated Raim , and finally calculate the maximum torque M Rm in the whole deformation process through the comparison of each section;
B.采用由在线实测P-t数值关系是,利用力传感器、A/D板及计算机在线实测变形力数值及其时刻,计算机通过数据采集和输出卡进行控制,采用软件可自动计算出工件变形阶段中不同时刻的扭矩MRa,并输出不同时刻的MRa值和最大值MRm。B. The online measured value of Pt is used to measure the deformation force value and its time online by using the force sensor, A/D board and computer. The computer controls the data acquisition and output card, and the software can automatically calculate the workpiece deformation stage. Torque M Ra at different moments, and output M Ra value and maximum value M Rm at different moments.
为了验证本发明的方法的相关程序的正确性,选用上海第二锻压机床厂生产的JH23-63型机械压力机完成冷挤压时的典型工艺进行研究。假设某冷挤压工艺中Pm=3×105N,α0=30°,该机械压力机的参数为滑块行程s0=100mm,曲柄半径R=s0/2=50mm,do=115mm,dA=155mm,dB=120mm,μ=0.045,λ=0.1,Δα=1°,ε=0.5°,传动比I=5.353(为便于和角度增中中的i区别,将式(4)中的曲轴到PFC轴之间的传动比i在这里换成字母I),一级齿轮传动效率η=0.97,滑块行程次数n=50次/分,相应的曲柄旋转角速度为ω=2πn/60=5.236(rad/s),经过计算后的结果如图3所示,为了直观,将横坐标以压力角α(角度)表示,图中M′l、M′μ分别为折算到PFC轴上的理想扭矩和阻扭矩。In order to verify the correctness of the relevant procedures of the method of the present invention, the typical process of the cold extrusion of the JH23-63 type mechanical press produced by Shanghai No. 2 Forging Machine Tool Factory was selected for research. Assume that P m =3×10 5 N, α 0 =30° in a cold extrusion process, the parameters of the mechanical press are slider stroke s 0 =100mm, crank radius R=s 0 /2=50mm, d o = 115mm, d A = 155mm, d B = 120mm, μ = 0.045, λ = 0.1, Δα = 1°, ε = 0.5°, transmission ratio I = 5.353 (in order to facilitate the difference from i in the angle increase, the formula (4) The transmission ratio i between the crankshaft and the PFC shaft is replaced by letter I here), the first-stage gear transmission efficiency η=0.97, the number of strokes of the slider n=50 times/min, and the corresponding crank rotation angular velocity is ω =2πn/60=5.236(rad/s), the calculated result is shown in Figure 3, for the sake of intuition, the abscissa is represented by the pressure angle α (angle), and M′ l and M′ μ in the figure are converted Desired and resistive torque to the PFC shaft.
附图说明Description of drawings
图1为PFC-B-82型机械压力机气动摩擦离合器与制动器综合智能试验台结构示意图。图中的标号分别表示:1.制动器气压比例阀 2.荷重传感器 3.制动器气缸上气压变送器 4.制动器壳体 5.制动器活塞 6.制动器活塞位移传感器 7.制动器运动盘 8.制动器摩擦块 9.滚动轴承 10.制动端支承架及轴承 11.转动惯量调节盘 12.从动轴测速盘 13.从动轴测速光电传感器及支架 14.从动惯量盘 15.离合器端支承架及轴承 16.飞轮 17.滚动轴承 18.离合器活塞位移传感器 19.活塞 20.飞轮测速盘 21.飞轮测速光电传感器及支架 22.离合器进排气管气压变送器 23.离合器气压比例阀 24.地面25.摩擦块 26.三角皮带槽 27.从动轴;Figure 1 is a schematic diagram of the structure of the PFC-B-82 mechanical press pneumatic friction clutch and brake comprehensive intelligent test bench. The labels in the figure respectively indicate: 1. Brake air pressure
图2为利用荷重传感器测试轴上扭矩的结构;Fig. 2 is the structure of utilizing the load cell to test the torque on the shaft;
图3为由Pm求取冷挤压工艺的扭矩变化特性曲线,其中曲线a为Ma,曲线b为M′l,曲线c为M′μ;Fig. 3 is the torque change characteristic curve obtained from P m for the cold extrusion process, wherein curve a is M a , curve b is M′ l , and curve c is M′ μ ;
图4为机械压力机PFC所需传递扭矩的计算机在线监测与控制系统;Fig. 4 is the computer online monitoring and control system of the required transmission torque of mechanical press PFC;
图5为在线实测的变形力特性曲线;Figure 5 is the deformation force characteristic curve measured online;
图6为在线计算的拉延工艺的扭矩变化曲线;Fig. 6 is the torque variation curve of the drawing process calculated online;
图7为拉延工艺变形力变化曲线。Figure 7 is the deformation curve of the drawing process.
以下结合附图对本发明作进一步的详细描述。The present invention will be described in further detail below in conjunction with the accompanying drawings.
具体实施方式 Detailed ways
如前所述,要使PFC摩擦副输出的扭矩Mq能满足工件变形的要求,就必须知道该工件变形时所需PFC摩擦面传递的扭矩Ma,这样才能实现根据PFC所需传递的Ma,通过智能化的气动系统以使PFC摩擦副能输出的扭矩满足:Mq≥Ma,自适应地实现可靠、高效能、低污染的锻冲加工。本发明就是根据机械压力机实际加工的有关信息来确定Ma的值。获得Ma的方法很多,本发明仅就采用滑块力程特性获取Ma的值的方法进行研究。当由滑块上的力程特性得到曲轴的所需扭矩MRa后,可方便地由公式确定Ma的值,为此,本发明仅就MRa是如何确定进行了研究。As mentioned above, in order to make the torque M q output by the PFC friction pair meet the requirements of workpiece deformation, it is necessary to know the torque M a transmitted by the PFC friction surface when the workpiece is deformed, so as to realize the M a , through the intelligent pneumatic system, the torque output by the PFC friction pair can satisfy: M q ≥ M a , and the reliable, high-efficiency, and low-pollution forging process can be adaptively realized. The present invention determines the value of Ma according to the relevant information of the actual processing of the mechanical press. There are many ways to obtain Ma , and the present invention only studies the method of obtaining the value of Ma by using the force characteristic of the slider. After the required torque M Ra of the crankshaft is obtained from the force characteristic on the slider, the value of Ma can be easily determined by the formula. For this reason, the present invention only studies how M Ra is determined.
在工业实际中的有些机械压力机上安装了可自动检测并显示滑块上作用的工件变形力的装置(以下简称为测力装置)。目前这种测力装置有两种输出方式,一种是仅能输出并显示最大工件变形力Pm,另一种是可输出不同时刻的变形力P的大小,并给出最大值,即可输出并显示P-t数值及曲线。为此,本发明首先对工艺类型已知但测力装置仅能输出最大工件变形力Pm的情况下如何得到MRa进行研究,然后依次对已知P-t的情况下得到MRa的值来论述。In some mechanical presses in industrial practice, a device that can automatically detect and display the deformation force of the workpiece acting on the slider (hereinafter referred to as the force measuring device) is installed. At present, this kind of force measuring device has two output methods, one is only able to output and display the maximum workpiece deformation force P m , the other is to output the size of deformation force P at different moments, and give the maximum value, that is, Output and display Pt value and curve. For this reason, the present invention first studies how to obtain M Ra when the process type is known but the force measuring device can only output the maximum workpiece deformation force P m , and then discusses the value of M Ra obtained under the known Pt .
1.PFC的扭矩与气压大小的关系1. The relationship between PFC torque and air pressure
前面叙述了在机械压力机工作过程中,如何在线地获得PFC轴上的扭矩Ma的方法。在已知了Ma的大小之后,接下来的问题就是要让PFC的摩擦副能够提供足够大的扭矩Mq,使Mq≥Ma,否则将会在工件变形过程中发生摩擦面打滑,摩擦材料磨损、过热,甚至发生严重的“闷车”事故。但若不管Ma的大小,每次工作时都取最大值Mqmax,虽然工作可靠,但如前所述会造成极大的压缩空气能量的浪费,这是目前的PFC气路系统存在的不足,也正是本发明要改善之处。The foregoing describes how to obtain the torque Ma on the PFC shaft online during the working process of the mechanical press. After the size of Ma is known, the next problem is to make the friction pair of PFC provide enough torque M q so that M q ≥ M a , otherwise the friction surface will slip during the deformation of the workpiece. The friction material wears out, overheats, and even serious "stuffy car" accidents occur. However, if the maximum value M qmax is taken every time regardless of the size of Ma , although the work is reliable, it will cause a huge waste of compressed air energy as mentioned above, which is the deficiency of the current PFC air circuit system , which is exactly what the present invention will improve.
考虑到工作过程中存在摩擦运动阻扭矩,为了正常工作Mq≥Ma,但为了节能又不能大很多,这里定义在进行扭矩智能控制时取:Considering the existence of friction motion resistance torque in the working process, in order to work normally M q ≥ M a , but in order to save energy and can not be much larger, the definition here is taken when performing torque intelligent control:
Mq=βMa (5)M q =βM a (5)
式中β定义为PFC扭矩储备系数。它是考虑到PFC摩擦副之间所能传递的扭矩Mq受到PFC气缸内气压的波动、摩擦系数的稳定性、真实摩擦接触面积的变化等情况下仍能使PFC正常工作而得到的。这里取β=1.1~1.3,本申请取β=1.2。where β is defined as the PFC torque reserve coefficient. It is obtained by considering that the torque M q that can be transmitted between the PFC friction pairs is affected by the fluctuation of the air pressure in the PFC cylinder, the stability of the friction coefficient, and the change of the real friction contact area, etc., so that the PFC can still work normally. Here, β=1.1-1.3 is taken, and in this application, β=1.2.
对PFC摩擦副来讲,其所能输出的扭矩Mq应为For the PFC friction pair, its output torque M q should be
Mq=mμqF0Rμ (6)M q =mμqF 0 R μ (6)
式中,m为摩擦面数,μ为摩擦系数,对机械压力机通常所使用的摩擦材料及对磨元件μ=0.3~0.4。Rμ为当量摩擦半径,F0为单面摩擦面积,q为摩擦面上的比压,该摩擦面上作用的总的压紧力Q为In the formula, m is the number of friction surfaces, μ is the friction coefficient, and for the friction materials and anti-wear elements usually used in mechanical presses, μ=0.3~0.4. R μ is the equivalent friction radius, F 0 is the single-sided friction area, q is the specific pressure on the friction surface, and the total pressing force Q acting on the friction surface is
Q=qF0 (7)Q=qF 0 (7)
Q通常是由气缸内的活塞产生的,活塞是依靠压缩空气驱动的,这样当设PFC活塞面积为S,压缩空气压强为p,当忽略活塞与气缸之间的摩擦时,可得:Q is usually generated by the piston in the cylinder, and the piston is driven by compressed air. In this way, if the area of the PFC piston is S and the pressure of the compressed air is p, when the friction between the piston and the cylinder is neglected, we can get:
Q=pS (8)Q=pS
因为式(6)和式(8)中的μ、F、Rμ及S很难人为调节,这样由式(5)可知,为了使Mq能跟随Ma而变化,只能通过调节气压p的大小。在本申请中气压p的大小,在本文中气压p依靠电气比例电磁阀在线调节,由气压传感器来反馈检测调试结果从而构成闭环系统。Because μ, F, R μ and S in formulas (6) and (8) are difficult to adjust artificially, it can be seen from formula (5) that in order to make M q change with Ma , only by adjusting the air pressure p the size of. The size of the air pressure p in this application, in this paper, the air pressure p is adjusted online by the electric proportional solenoid valve, and the air pressure sensor is used to feedback and detect the debugging results to form a closed-loop system.
通常PFC的摩擦副形式有盘式和浮动镶块式两种。本申请中的PFC-B-82型试验台采用的浮动镶块式结构形式,其所能产生的摩擦扭矩为Generally, there are two types of friction pairs of PFC: disc type and floating insert type. The PFC-B-82 test bench in this application adopts the floating insert type structure, and the friction torque it can produce is
Mq=2μqzFiRμ (9)M q =2μqzF i R μ (9)
式中:z为浮动镶块数目;In the formula: z is the number of floating inserts;
Fi为一个浮动镶块的单边摩擦面积。F i is the unilateral friction area of a floating insert.
也就是说,对该种浮动镶快结构,存在下式That is to say, for this kind of floating fast structure, there is the following formula
F0=zFi (10)F 0 =zF i (10)
m=2 (11)m=2 m=2 (11)
由式(7)~(11)可得:From formula (7) ~ (11) can get:
Mq=2μpSRμ (12)M q = 2μpSR μ (12)
在本发明的实验中,PFC和PFB摩擦面的尺寸为z=10,Rμ=0.210m,μ=0.3~0.35,Fi=7.7117×10-3m2,SB=0.2366m2,SC=0.2686m2。其中SB、SC分别为PFC和PFB活塞的面积。In the experiment of the present invention, the size of the friction surface of PFC and PFB is z=10, R μ =0.210m, μ=0.3~0.35, F i =7.7117×10 -3 m 2 , S B =0.2366m 2 , S C = 0.2686m 2 . Where S B , S C are the areas of the PFC and PFB pistons, respectively.
将上述数据代入式(12)并取μ=0.31可得:Substitute the above data into formula (12) and take μ=0.31 to get:
MqB=0.0308p(N·m) (13)M qB =0.0308p(N·m) (13)
MqC=0.0350p(N·m) (14)M qC =0.0350p(N·m) (14)
可见对其它尺寸的PFC仍存在It can be seen that PFCs of other sizes still exist
MqC=kp (15)M qC = kp (15)
也就是说摩擦离合器能够产生的摩擦扭矩大小与气缸内的气压大小成正比,这样由式(5)和式(15)可知,在已直接检测到PFC所需传递的摩擦扭矩Ma的情况下,可以根据Ma而调节气缸内气压的大小,从而达到节约压缩空气的目的。That is to say, the friction torque that the friction clutch can produce is directly proportional to the air pressure in the cylinder, so it can be seen from formula (5) and formula (15) that under the condition that the friction torque M a required to be transmitted by the PFC has been directly detected , the air pressure in the cylinder can be adjusted according to Ma , so as to achieve the purpose of saving compressed air.
2.使用在线实测的滑块力程特性确定Ma 2. Determine M a using the online measured force-range characteristics of the slider
由文献可知,当已知工件变形力P时,还无法确定作用到曲轴上的扭矩MRa,必须知道力臂的大小,在最大变形力Pm处往往力臂未必取最大值,两者之间的关系对不同的工艺存在较大差异。要想得到MRa的值,必须知道任意力臂长度mq下的变形力P,两者相乘才能获得MRa的值,然后才能由式(4)求得PFC轴上的Ma。现在任意时刻的MRa值无法知道而仅知道Pm的值,如何求出MRa呢?It can be seen from the literature that when the deformation force P of the workpiece is known, the torque M Ra acting on the crankshaft cannot be determined. The size of the moment arm must be known. The moment arm may not always take the maximum value at the maximum deformation force P m . There are great differences in the relationship between different processes. In order to obtain the value of M Ra , the deformation force P under any arm length m q must be known, and the value of M Ra can be obtained by multiplying the two together, and then Ma on the PFC axis can be obtained from formula (4). Now the value of M Ra at any time cannot be known but only the value of P m , how to calculate M Ra ?
虽然任意时刻的P无法获得,但机械压力机实际所完成的工艺类型如冲裁、拉深、热模锻、冷挤压是确定的,每种工艺都有其独特的力程特性,特别在已知Pm和变形高度时,其它时刻的力的变形规律可推算出来,这里的工件变形高度对确定的加工毛坯及模具也是已知,这样就在已知工艺类型、Pm及h情况下,就可获得任意时刻的MRa值,由此可看出这种方法存在一定的近似性。Although P cannot be obtained at any time, the types of processes actually completed by mechanical presses such as blanking, deep drawing, hot die forging, and cold extrusion are determined. Each process has its unique force characteristics, especially in When the P m and the deformation height are known, the deformation law of the force at other times can be calculated, and the deformation height of the workpiece here is also known to the determined processing blank and mold, so that when the process type, P m and h are known , the M Ra value at any time can be obtained, which shows that there is a certain approximation in this method.
为此,本发明先对不同工艺类型的变形力程规律进行论述,然后再研究如何由已知工艺的变形力程确定出MRa。如前所述,因为MRa已知,由式(4)可知,Ma就可求得,所以下面仅研究如何获得MRa。For this reason, the present invention first discusses the law of deformation force ranges of different process types, and then studies how to determine M Ra from the deformation force ranges of known processes. As mentioned above, since M Ra is known, it can be known from formula (4), that M a can be obtained, so the following only studies how to obtain M Ra .
根据文献,考虑摩擦作用后,机械压力机的曲轴(或偏心轮)所需传递的扭矩可以表示为:According to the literature, after considering the friction effect, the torque required to be transmitted by the crankshaft (or eccentric wheel) of the mechanical press can be expressed as:
MRa(α)=Ml(α)+Mμ(a) (16)M Ra (α)=M l (α)+M μ (a) (16)
式中Ml(α)为理想扭矩,Mμ(α)为摩擦扭矩,P(α)为工件变形力,μ为机械转动系统摩擦系数,对开式压力机μ=0.04~0.05,对闭式压力机μ=0.045~0.055,dA、dB和do分别为连杆大端、小端和曲轴支承轴颈的直径。考虑到前述五种典型工艺均由不同斜率的折线构成,为使P(α)表达式更具通用性,参考前述各工艺力程特性方程的讨论,P(α)可写成:In the formula, M l (α) is the ideal torque, M μ (α) is the friction torque, P (α) is the deformation force of the workpiece, μ is the friction coefficient of the mechanical rotation system, the split press μ=0.04~0.05, and the closed press Type press μ = 0.045 ~ 0.055, d A , d B and d o are the diameters of the connecting rod big end, small end and crankshaft bearing journal respectively. Considering that the aforementioned five typical processes are all composed of broken lines with different slopes, in order to make the expression of P(α) more general, referring to the discussion of the force characteristic equations of the aforementioned processes, P(α) can be written as:
P(α)=k(α-a0)+P0 (19)P(α)=k(α-a 0 )+P 0 (19)
式中k=(P1-P0)/(a1- a0)为负荷线段的斜率;(a0,P0)和(a1,P1)分别为该线段两端点的坐标,这两点的坐标由各个典型工艺的参数确定,在具体求解过程中,需先根据工艺参数确定这两点的坐标,然后才能进一步求解。In the formula, k=(P 1 -P 0 )/(a 1 - a 0 ) is the slope of the load line segment; (a 0 , P 0 ) and (a 1 , P 1 ) are the coordinates of the two ends of the line segment respectively, which The coordinates of the two points are determined by the parameters of each typical process. In the specific solution process, the coordinates of the two points need to be determined according to the process parameters before further solution.
为了后面计算的方便性,可令:For the convenience of calculation later, it can be ordered:
这样,式(17)和(18)可分别写成:In this way, equations (17) and (18) can be written as:
Ml(α)=P(α)f1(α) (22)M l (α)=P(α)f 1 (α) (22)
Mμ(α)=P(α)f2(α) (23)M μ (α)=P(α)f 2 (α) (23)
再结合式(16)可见,MRa(α)是关于α的函数,这样由式(16)和(19)~(23)可方便地使用计算机求出MRa(α)的值并得到其最大值。另外由相关文献中各典型工艺的力程图可知,对于力程图的每一段,Mq(α)均连续,即每一段均有极值出现,此极值即为这一段的扭矩的最大值。Combined with formula (16), it can be seen that M Ra (α) is a function of α, so from formulas (16) and (19) to (23), it is convenient to use a computer to find the value of M Ra (α) and obtain its maximum value. In addition, it can be seen from the force diagrams of typical processes in relevant literature that for each section of the force diagram, M q (α) is continuous, that is, each section has an extreme value, and this extreme value is the maximum torque of this section value.
因为对PFC输出扭矩Mq的智能控制是在线实时的,所以要求快速自动地根据在线实测所得的Pm值和所完成的工艺类型输出MRa的值,便于对系统进行控制。因此须编程在线求得MRa的值,进而由式(4)得到Ma的值。Because the intelligent control of the PFC output torque M q is online and real-time, it is required to output the value of M Ra quickly and automatically according to the online measured P m value and the completed process type, so as to facilitate the control of the system. Therefore, the value of M Ra must be obtained online by programming, and then the value of Ma is obtained from formula (4).
按照上述技术方案,本发明机械压力机PFC所需传递扭矩的在线监测系统采用计算机通过数据采集变形力传感器信号,利用在线实测的P-t数值关系确定MRa。如图4所示为机械压力机PFC所需传递扭矩的计算机在线监测与控制系统示意图。According to the above technical solution, the online monitoring system of the mechanical press PFC required transmission torque of the present invention uses a computer to collect deformation force sensor signals through data, and determines M Ra by using the online measured Pt numerical relationship. Figure 4 is a schematic diagram of the computer on-line monitoring and control system for the transmission torque required by the PFC of the mechanical press.
如前所述,有些机械压力机上安装的变形力传感器可输出任意时刻的变形力P值的模拟信号,通过A/D数据采集及计算机就可得到P-t数据关系。考虑到α=ωt,经把时间t转化为曲柄转角关系α和数字滤波后就可得到如图5所示的P-α关系及数值。下面就来讨论如何由图5来确定MRa的大小。As mentioned above, the deformation force sensor installed on some mechanical presses can output the analog signal of the deformation force P value at any time, and the Pt data relationship can be obtained through A/D data acquisition and computer. Considering α=ωt, the P-α relationship and value shown in Figure 5 can be obtained after converting the time t into the crank angle relationship α and digital filtering. Let's discuss how to determine the size of M Ra from Figure 5.
3.转角步长Δα的选取3. Selection of corner step size Δα
首先对如图5中的微小区间[αi,αi+1],αi+1=αi+Δα,Δα为计算MRa的步长,在该微小区间内,设P变化很小可忽略不计,因而可看成常数,并取作微区间左侧的数值Pi,即P=P(αi)(αi≤α≤αi+Δα)。这样图5中的连续曲线就可由高低不同的阶梯(αi,Pi)所代替,实际上在计算机通过A/D卡获得图5中的曲线时,也是由很密集的离散点光滑而得。所以为提高运算速度也可不必先获得图5的曲线(当然在控制系统带有P-α显示功能的情况例外),当已知A/D卡的采样周期Δt时,计算扭矩MRa时的转角步长Δα可按下式进行选取:Firstly, for the micro-interval [α i , α i+1 ] as shown in Figure 5, α i+1 = α i + Δα, Δα is the step size for calculating M Ra , in this micro-interval, it is possible to assume that the change of P is small Negligible, so it can be regarded as a constant, and taken as the value P i on the left side of the micro-interval, that is, P=P(α i )(α i ≤α≤α i +Δα). In this way, the continuous curve in Figure 5 can be replaced by steps (α i , P i ) with different heights. In fact, when the computer obtains the curve in Figure 5 through the A/D card, it is also smoothed by very dense discrete points . Therefore, in order to improve the calculation speed, it is not necessary to obtain the curve in Fig. 5 first (except in the case of the control system with P-α display function, of course), when the sampling period Δt of the A/D card is known, the torque M Ra when calculating The corner step size Δα can be selected according to the following formula:
Δα=ωΔt (24)
很显然Δα越小,精确度越高,但在线控制扭矩的实时性会受到一定程度的影响,因此Δα的选取应兼顾上述两个方面。Obviously, the smaller Δα is, the higher the accuracy is, but the real-time performance of online torque control will be affected to a certain extent, so the selection of Δα should take into account the above two aspects.
1.MRa的确定1. Determination of M Ra
由式(16)、(17)和(18),在任一转角αi处的曲轴上所需传递的扭矩MRai为According to equations (16), (17) and (18), the torque M Rai required to be transmitted on the crankshaft at any rotation angle α i is
MRai=Ml(αi)+Mμ(αi) (25)M Rai =M l (α i )+M μ (α i ) (25)
Ml(αi)=P(αi)f1(αi) (26)M l (α i )=P(α i )f 1 (α i ) (26)
Mμ(αi)=P(αi)f2(αi) (27)M μ (α i )=P(α i )f 2 (α i ) (27)
然后增加一个Δα,求出下一个转角αi+1=αi+Δα处的MRa(i+1)的值,依次进行直到计算出全部(0~α0)范围内的MRa的值,然后比较求出最大值MRm。再利用式ωti=αi就可得到不时刻ti的扭矩MRai的值。将以上计算步骤编制成程序可实现在线计算,并迅速为后面的控制系统提供数据。为了验证该程序的正确性,仍选用前面举例时所采用到的JH23-63型机械压力机进行对具有典型拉延工艺的近似半个正弦波形的力变形图进行仿真,即Then add a Δα, calculate the value of M Ra(i+1) at the next corner α i+1 =α i +Δα, and proceed in turn until the value of M Ra in the entire (0~α 0 ) range is calculated , and then compare to obtain the maximum value M Rm . The value of the torque M Rai at different times t i can be obtained by using the formula ωt i =α i . Compiling the above calculation steps into a program can realize online calculation and quickly provide data for the subsequent control system. In order to verify the correctness of the program, the JH23-63 mechanical press used in the previous example is still used to simulate the force deformation diagram of an approximate half sine wave with a typical drawing process, namely
P(α)=4×105sin 2α(N) (0≤α≤90°) (28)P(α)=4×10 5 sin 2α(N) (0≤α≤90°) (28)
如前所述对该机械压力机因其滑块行程s0=100mm,曲柄半径R=s0/2=50mm,d0=115mm,dA=155mm,dB=120mm,μ=0.045,λ=0.1,Δα=1°,传动比I=5.353,一级齿轮传动效率η=0.97,滑块行程次数n=50次/分,相应地曲柄旋转角速度ω=2πn/60=5.236(rad/s)。将上述已知数据输入到所编制的程序中,可得到如图6和图7所示的仿真结果,图6为扭矩变化曲线,图7为变形力曲线。由图6可求得在压力角α=53.1°(t=0.177s)时取得PFC轴所需的最大扭矩Ma=3493(N·m)。从图6和图7可看出,Ma的最大值和力P的最大值出现的时刻是不同的(变形力P在45处取的最大值),因此不能简单地认为最大变形力Pm处就是扭矩最大处。As mentioned above, for the mechanical press because of its slider stroke s 0 =100mm, crank radius R=s 0 /2=50mm, d 0 =115mm, d A =155mm, d B =120mm, μ=0.045, λ = 0.1, Δα = 1°, transmission ratio I = 5.353, primary gear transmission efficiency η = 0.97, slider stroke times n = 50 times/min, corresponding crank rotation angular velocity ω = 2πn/60 = 5.236 (rad/s ). Input the above known data into the compiled program, and the simulation results shown in Figure 6 and Figure 7 can be obtained, Figure 6 is the torque change curve, and Figure 7 is the deformation force curve. From Fig. 6, it can be obtained that the maximum torque Ma = 3493 (N·m) required to obtain the PFC shaft at the pressure angle α = 53.1° (t = 0.177s). It can be seen from Figure 6 and Figure 7 that the maximum value of Ma and the maximum value of force P appear at different times (deformation force P takes the maximum value at 45), so it cannot be simply considered that the maximum deformation force P m where the torque is greatest.
利用力传感器、A/D板及计算机等在线实测变形力数值及其时刻,采用软件可自动计算出工件变形阶段中不同时刻的扭矩MRa,并输出不同时刻的MRa值和最大值MRm,这种方法具有迅速、可靠等良好特性,值得在生产中推广应用。Using the force sensor, A/D board and computer to measure the deformation force value and its time on-line, the software can automatically calculate the torque M Ra at different times in the deformation stage of the workpiece, and output the M Ra value and the maximum value M Rm at different times , this method has good characteristics such as rapidity and reliability, and it is worth popularizing and applying in production.
按照上述技术方案申请人已完成一系列试验,结果证明达到了本发明的目的。The applicant has completed a series of tests according to the above technical solution, and the results prove that the object of the present invention has been achieved.
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Cited By (5)
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CN102252790A (en) * | 2011-05-31 | 2011-11-23 | 上海交通大学 | Flow adjustable reciprocating pump crankshaft impact load on-line real-time detection device |
CN104100606A (en) * | 2013-04-11 | 2014-10-15 | 比尔克特韦尔克有限公司 | Pneumatic drive and process for gathering the performance of a pneumatic drive |
CN107269632A (en) * | 2017-06-15 | 2017-10-20 | 柳州上汽汽车变速器有限公司 | Speed changer press-fits control device |
CN110757878A (en) * | 2019-10-31 | 2020-02-07 | 济宁科力光电产业有限责任公司 | Pressure fault detection system and method of servo press |
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Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
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US4520680A (en) * | 1982-04-26 | 1985-06-04 | Mitsubishi Denki Kabushiki Kaisha | Torque measuring apparatus |
JP3213227B2 (en) * | 1995-11-21 | 2001-10-02 | 本田技研工業株式会社 | Automatic transmission torque detection and control device |
KR100283294B1 (en) * | 1998-05-13 | 2001-03-02 | 장태환 | Real time measurement system of car engine torque |
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CN102252790A (en) * | 2011-05-31 | 2011-11-23 | 上海交通大学 | Flow adjustable reciprocating pump crankshaft impact load on-line real-time detection device |
CN102252790B (en) * | 2011-05-31 | 2012-11-28 | 上海交通大学 | On-line real-time detection device for the impact load of the crankshaft of the flow-adjustable reciprocating pump |
CN104100606A (en) * | 2013-04-11 | 2014-10-15 | 比尔克特韦尔克有限公司 | Pneumatic drive and process for gathering the performance of a pneumatic drive |
CN107269632A (en) * | 2017-06-15 | 2017-10-20 | 柳州上汽汽车变速器有限公司 | Speed changer press-fits control device |
CN110757878A (en) * | 2019-10-31 | 2020-02-07 | 济宁科力光电产业有限责任公司 | Pressure fault detection system and method of servo press |
CN111859661A (en) * | 2020-07-17 | 2020-10-30 | 西门子(中国)有限公司 | Inertia determination method for eccentric mechanism of press machine |
CN111859661B (en) * | 2020-07-17 | 2023-07-14 | 西门子(中国)有限公司 | Inertia determination method for eccentric mechanism of press |
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Assignee: Zhejiang Grande Machinery Co.,Ltd. Assignor: Xi'an Jiaotong University Contract record no.: 2010330001851 Denomination of invention: On-line detection process for torque transfer of mechanical press air operated friction clutch Granted publication date: 20090506 License type: Exclusive License Open date: 20071003 Record date: 20100915 |
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