CN110298106B - Optimal positioning and mounting method for displacement sensor of static pressure rotary table under unbalanced load working condition - Google Patents
Optimal positioning and mounting method for displacement sensor of static pressure rotary table under unbalanced load working condition Download PDFInfo
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- CN110298106B CN110298106B CN201910560706.6A CN201910560706A CN110298106B CN 110298106 B CN110298106 B CN 110298106B CN 201910560706 A CN201910560706 A CN 201910560706A CN 110298106 B CN110298106 B CN 110298106B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B21/00—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant
- G01B21/02—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness
- G01B21/08—Measuring arrangements or details thereof, where the measuring technique is not covered by the other groups of this subclass, unspecified or not relevant for measuring length, width, or thickness for measuring thickness
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/17—Mechanical parametric or variational design
Abstract
An optimal positioning and mounting method for a displacement sensor of a static pressure rotary table is disclosed, wherein the optimal position of the sensor is determined by combining theoretical calculation and a simulation process. When thermal deformation is not considered, the thickness of the oil film is smaller as the radius is larger in the radial direction of the offset load, when the thermal deformation is considered, the thermal deformation is different due to different offset load working conditions, the thickness of the simulated oil film is obtained according to the thermo-hydro-solid coupling theory and ANSYS simulation, and the minimum position of the thickness of the oil film on the oil pad is determined by an oil film thickness matrix comparison method. When the sensor is optimally positioned on the oil sealing edge, the width of the oil sealing edge of the oil pad where the sensor is positioned is enlarged, and the effective bearing area of the static pressure rotary worktable is increased. A novel oil pad and a sensor mounting hole are designed, and the mounting position and the mounting method of the displacement sensor under the unbalance loading working condition are determined. The displacement sensor probe is ensured to be slightly lower than the outer surface of the oil sealing edge, and finally high-temperature-resistant sealant is coated on the mounting position to block a gap between the sensor and the oil pad, so that the hydraulic oil is prevented from leaking from the mounting hole to cause inaccurate measurement.
Description
Technical Field
The invention relates to an optimal positioning and mounting method for a static pressure rotary table displacement sensor under an offset load working condition, in particular to an optimal positioning and mounting method for a double-rectangular-cavity static pressure rotary table sensor under an offset load working condition.
Background
The hydrostatic pressure rotary worktable is a key part of a heavy high-precision vertical lathe of large numerical control equipment because of the advantages of low friction power consumption, long service life, stable operation, high machining precision and the like. With the proposals of concepts such as ' china wisdom 2025 ', industrial 4.0 ' and the like, higher and higher requirements are put forward on aspects such as machine tool machining precision, machining size, machining speed, bearing capacity and the like, and in recent years, the influence of an unbalance loading condition on the performance of a static pressure rotary table is more important. The static pressure rotary worktable under the unbalance loading working condition bears unevenly, so that the oil film thickness, the oil cavity pressure and the oil film temperature of each oil pad are uneven, local high pressure and high temperature occur, the oil film deforms unevenly, the static pressure rotary worktable works unstably, the alarm of the displacement sensor can be triggered when the oil film thickness is minimum, and finally the machine is stopped. In addition, the oil film thickness of the static pressure rotary worktable is different under different unbalance loading working conditions, the traditional displacement sensor is arranged in the oil cavity, the oil film thickness possibly reaches the designed limit value under the unbalance loading working condition, the displacement sensor cannot detect the oil film thickness at the thinnest part, and the displacement sensor in the oil cavity does not give an alarm when the fluid lubrication fails due to dry friction at the oil sealing edge. Aiming at the problem, the embodiment of the invention takes a double-rectangular-oil-cavity static pressure rotary worktable as a research object, researches the thickness of an oil film of the static pressure rotary worktable according to tribology and a lubrication theory, determines the position of the thinnest oil film, and provides an optimal positioning and mounting method suitable for a displacement sensor under an unbalance loading working condition.
Disclosure of Invention
A method for determining and installing the optimal installation position of a displacement sensor of a static pressure rotary table under the condition of unbalance loading. Because the radius of the rotary worktable is large, under the condition of unbalance loading, the oil film thickness is not uniformly distributed, and a position with the minimum oil film thickness needs to be found for installing the displacement sensor. The displacement sensor positioning under the unbalanced load working condition can calculate theoretical oil film thickness without considering thermal deformation and simulated oil film thickness obtained by considering thermal fluid-solid coupling under the thermal deformation through mechanical modeling and analysis, respectively divide areas with equal dimensions for two conditions, respectively calculate the oil film thickness of each area under the two conditions, respectively establish an oil film thickness matrix and then superpose the oil film thickness matrix, find the position with the thinnest oil film thickness through comparison, namely the mounting position of the displacement sensor, and the height difference between the sensor and the oil sealing edge horizontal plane during mounting is mainly determined according to the working attributes of the displacement sensor and the machining condition of the mounting hole. In the aspect of optimal positioning, an oil film thickness matrix comparison method is provided; in the aspect of installation of the displacement sensor, the width of the oil sealing edge is widened when the displacement sensor is positioned on the oil sealing edge, the effective bearing area of an oil film is increased, the displacement sensor is installed by taking the optimal positioning and the oil sealing edge horizontal plane as reference, and an installation gap is sealed.
Effects of the invention
According to the method, the thickness of each oil pad oil film of the static pressure rotary table under the condition of unbalance loading is deduced according to a lubrication theory, a tribology principle and theoretical mechanics, and the thickness distribution condition of each oil pad oil film under the condition of unbalance loading under the condition of considering thermal deformation is simulated according to a thermo-hydro-solid coupling principle. The optimal installation position of the displacement sensor of the static pressure rotary worktable is found, a technical basis is laid for timely detecting the minimum oil film thickness and improving the safety early warning and reliability of the static pressure rotary worktable under the condition of unbalance loading of the static pressure thrust bearing, and an important reference basis is provided for the positioning and installation of the sensor of the static pressure rotary worktable. The method is also suitable for oil film thickness detection and early warning under the central loading working condition, the stability of the static pressure rotary worktable designed by the method is greatly improved, and the safe operation time is improved. When the sensor is optimally positioned on the oil sealing edge, the oil sealing edge is widened, so that the effective bearing area of the oil film is increased, the bearing capacity of the workbench is enhanced, and the operation reliability is improved by 20%.
Drawings
FIG. 1 is a flow chart of the optimal positioning method of the displacement sensor according to the present invention.
Fig. 2 is a schematic diagram illustrating a static pressure rotary table deflected by an offset load according to an embodiment of the present invention.
Fig. 3 is a schematic diagram of an optimal position of a displacement sensor on a single oil pad according to an embodiment of the present invention.
Fig. 4 is a partially enlarged schematic view of a mounting height difference of a displacement sensor according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. In the embodiment of the invention, the displacement sensor is an eddy current displacement sensor, the static pressure rotary worktable adopts an open structure, 12 oil pads in a circumferential array are arranged, and the oil pad structure is a double-rectangular-cavity oil pad.
The method can be realized by the following technical scheme:
the evaluation of the oil film thickness under the condition of unbalance loading is divided into: 1. the workbench and the oil pad are ideal rigid bodies, thermal deformation is not considered, and the thickness of the oil film is in ideal distribution; 2. the thermal deformation of the oil film, the oil pad and the workbench is considered, the working conditions are different, and the oil film thickness distribution is not uniform. The invention respectively calculates the oil film thickness distribution under the ideal unbalance loading working condition in the embodiment and carries out the heat flow solid coupling simulation in the embodiment, and the final oil film thickness under the unbalance loading working condition is jointly evaluated by the two results. The flow chart of the optimal positioning method of the sensor of the invention is shown in figure 1.
When the workbench and the oil pad are ideal rigid bodies and thermal deformation is not considered, the oil film thickness is divided into two parts under the unbalance loading working condition for calculation: 1. the situation when only axial forces are being borne; 2. only the case of the overturning moment of couple. The oil film thicknesses of the two cases were then superimposed. The schematic deflection diagram of the static pressure rotary table under the action of the offset load in the embodiment of the invention is shown in fig. 2. The oil film thickness is an important index for showing the lubricating performance of the oil pad, and the oil film thickness of each oil pad is the same when the oil pad is loaded at the center, so that only one oil film thickness is calculated. Obtaining the relation among the flow, the oil film thickness and the oil cavity pressure during the central loading, and obtaining the flow formula and the oil film thickness formula of a single oil pad during the central loading after finishing:
where p is the average pressure of the oil chamber, k is a structural parameter of the oil pad, related to the oil pad geometry, and μ t The kinematic viscosity of the hydraulic oil.
And analyzing the condition that the static pressure rotary working table only bears the overturning moment of couple. The invention takes 12 circular array double rectangular cavity oil pads as an example, under the action of an overturning moment of couple M, a workbench deflects an inclination angle psi by taking a rotating main shaft as a center, the thickness of each oil film is also changed, and the average value of the oil film thickness of each oil pad under the condition of unbalance loading is as follows:
h 1 ＝h 0 +e M ＝h 0 (1+ε M ) (3)
h 7 ＝h 0 -e M ＝h 0 (1-ε M ) (4)
in the formula:
ε M the displacement rate of the maximum displacement position of the oil film under the action of the overturning moment of couple M is more than 0 and less than epsilon M ＜1，e M Is biased toDisplacement that varies when loaded; h is 0 In order to obtain the initial oil film thickness,
is the angle between the oil pads.
The comparison finds h 7 ＜(h 6 ＝h 8 )＜(h 5 ＝h 9 )＜(h 4 ＝h 10 ) In the direction of the unbalance loading radius, the larger the radius is, the smaller the oil film thickness is, and according to the method, the position where the oil film thickness on the oil pad is the minimum is obtained preliminarily at the intersection angle of the outer sealing oil edge of the oil cavity outside the oil pad with the double rectangular cavities. The average value of each oil pad can only be obtained by the formula, the installation position of the eddy current displacement sensor on the oil pad needs to be determined, the thickness distribution of the oil film on the oil pad needs to be required, and the displacement rate formula and the deflection angle formula are derived according to the couple balance principle as follows:
wherein n is the number of oil pads, A e R is the distance from the center point of the oil pad to the center of the main shaft.
After the parameters are determined, the theoretical oil film thickness of any point of the oil film under the eccentric load working condition can be calculated according to the position of any point of the oil film on the oil pad relative to the center of the main shaft and by combining a geometric principle. The oil film is divided into equal-area areas, the oil film is divided into x equal parts in the length direction and y equal parts in the width direction, the central point of each small area with the equal area is taken as a reference, the average oil film thickness in each equal-area is calculated, and the oil film thickness values of each area are arranged into a matrix or an Excel table.
In engineering practice, the oil film can generate heat because of shearing and extrusion of the workbench under the working condition of central loading, the same is true under the working condition of unbalance loading, the generated heat can be unevenly distributed because of different linear speeds in the radius direction, and the heat generated under different working conditions is different. The oil pad is fixed on a base of the static pressure rotary workbench and does not move, the eccentric workpiece is fixed on the workbench and rotates around the main shaft, the smooth guide rail and the oil pad below the workbench are separated by the middle pressure oil film to form oil film lubrication, the oil film generates a large amount of heat in the rotating process, the heat is unevenly distributed on the oil film, meanwhile, the pressure distribution at each position on the oil film is uneven, and at the moment, the oil film, the oil pad and the workbench guide rail are easy to form thermo-fluid-solid coupling deformation.
Firstly, simulating a physical field of an oil film under an unbalance loading condition, establishing an oil pad three-dimensional model by using three-dimensional software according to the unbalance loading condition and structural parameters of the oil pad, solving boundary conditions required by simulation in advance, dividing a grid for the oil film by using grid dividing software, introducing the grid into CFX fluid simulation software under an ANSYS simulation platform, setting the required boundary conditions, selecting a corresponding solver, and solving a temperature field and a pressure field of the oil film. The oil film thickness distribution is finally determined by the shapes of the workbench guide rail and the oil pad, so that the deformation simulation of the oil pad and the workbench guide rail is performed step by step.
In order to obtain a deformation distribution rule in the vertical direction of a guide rail of a Workbench, a Workbench model is built by using three-dimensional software and is led into Workbench software under an ANSYS simulation platform, grids are divided by using grid division software, simulated boundary conditions are determined according to structural parameters and material properties of a static pressure rotary Workbench, the temperature of a surrounding medium and the heat exchange rule between a boundary surface and the surrounding air medium are determined, numerical simulation is carried out by adopting a third type of boundary mode, an oil film temperature field and an oil film pressure field are used as loads and loaded to a static pressure support friction pair, an eccentric load is applied to the Workbench, a solver is set for simulation solution, and finally the vertical direction deformation field at the guide rail of the Workbench is obtained. And calculating the rotary worktable under different unbalance loading conditions through Workbench to obtain a deformation field.
And (3) performing physical field simulation on the oil pad by adopting a method similar to the deformation simulation of the guide rail of the workbench to obtain the deformation of the oil pad in the vertical direction.
After simulation results of deformation at the guide rail of the workbench and deformation of the oil pad are obtained, data post-processing is carried out on the simulation results, the simulated deformation is led out to Matlab mathematical software, numerical post-processing is carried out on the deformation of the guide rail of the workbench and the deformation of the oil pad, the thickness of the thermo-fluid-solid coupling simulation oil film at any point on the oil film can be obtained, the oil film is divided into equal-area areas according to the method for solving the thickness of the oil film, the oil film is divided into x equal parts in the length direction and y equal parts in the width direction, the average thickness of the oil film in each equal-area is obtained through post-processing of the simulation results, and the thickness of the thermo-fluid-solid coupling simulation oil film in each area is arranged into a matrix or an Excel table.
The two oil film thickness matrixes have the same dimension, a theoretical oil film thickness matrix without considering the thermo-fluid-solid coupling condition and an oil film thickness matrix subjected to thermo-fluid-solid coupling simulation are added to obtain a new matrix, the numerical values of all the numbers in the new matrix are compared, the number with the minimum numerical value represents that the average oil film thickness of an oil pad area corresponding to the number is the thinnest, the area with the minimum oil film thickness is the optimal positioning area of the displacement sensor, and in order to ensure the positioning accuracy, the dimension of the matrix can be increased, namely the values of x and y are increased.
According to the embodiment of the invention, the inventor is in a more common unbalanced load condition in engineering practice, through calculation and simulation of the embodiment of the invention, the optimal installation position of the displacement sensor is the intersection angle of the outer sealing oil edges of the outer oil cavity of the double-rectangular cavity oil pad, the schematic installation position diagram of the displacement sensor is shown in fig. 3, and the partial enlarged position diagram of the sensor is shown in fig. 4. Obviously, if the offset load condition is changed, the calculated value of the ideal oil film thickness without the thermo-fluid-solid coupling and the simulated oil film thickness without the thermo-fluid-solid coupling of the invention are different from the embodiments of the invention, so the optimal positioning of the displacement sensor is also different from the position of the embodiments of the invention.
The design and manufacturing process of the embodiment of the invention comprises the following steps: use three-dimensional software Solidworks to design out the three-dimensional structure of oil pad, other sizes are unchangeable when the project organization, increase the outer oil blanket width of sealing, the increase width has the effect that the intensity that the mounting hole caused was beaten to balanced oil blanket, guarantee that oil blanket bulk strength does not reduce, increase the effective bearing area of oil pad simultaneously, two screw thread mounting holes of size design according to displacement sensor in outer oil blanket crossing angle proximal region, again according to the oil blanket three-dimensional structure preparation be used for machining's two-dimensional engineering drawing, make the oil pad through traditional lathe processing at last.
Supplementary explanation here is made: for the optimal positioning obtained by adopting other working conditions, the optimal positioning is probably not on the oil sealing edge of the oil pad, namely when the optimal positioning is in the oil cavity, the installation of the sensor is similar to the traditional method, and the oil sealing edge does not need to be widened; if the optimal positioning is performed in an oil discharge groove of the oil pad or at the junction of the oil sealing edge and the oil cavity, the displacement sensor is uniformly arranged on the oil sealing edge, so that the normal discharge of oil and the flow of the oil in the oil cavity are prevented from being influenced by the arrangement of the displacement sensor; in order to prevent one sensor from failing due to uncontrollable factors, the displacement sensors are arranged at two symmetrical positions with the thinnest oil film thickness, so that the working reliability of the displacement sensors is ensured.
The installation process of the displacement sensor comprises the following steps: firstly, an appropriate displacement sensor is selected according to the design requirement of a workbench, external threads are arranged on the displacement sensor, internal threads matched with the external threads are arranged in a mounting hole, and the displacement sensor is fixed on an oil pad through threaded connection. The working attributes of the displacement sensor are combined, the normal work of the displacement sensor is guaranteed, accidents are prevented, it is necessary to guarantee that a probe of the displacement sensor is slightly lower than the horizontal plane of the oil sealing edge, the height difference of the two planes is h =0.1mm, the height difference is adjusted by changing the matching length of the internal thread pair and the external thread pair, the height difference is detected by a dial indicator, the height difference is adjusted for multiple times until the designed height difference is reached, the height difference is the installation and positioning of the displacement sensor relative to the horizontal plane of the oil sealing edge, and the height difference is indicated in figure 4. And finally, coating high-temperature-resistant sealant at the mounting position to block a gap between the sensor and the oil pad, so as to prevent the inaccurate measurement caused by the leakage of the hydraulic oil from the mounting hole.
The positioning of the sensor is determined by combining theoretical calculation and software simulation, the reason of uneven oil film thickness under the unbalanced load working condition is determined, the size of an oil seal edge is designed, the mounting position of the sensor is determined, and the positioning method has a reference function for improving the stability, the safety and the bearing capacity of the static pressure rotary worktable. When the deformation of the heat-fluid-solid coupling is not considered, the oil film thickness of each oil pad is the same when the center is loaded, and the simulation condition is simpler when the heat-fluid-solid coupling is considered compared with the offset load simulation of the invention, so the invention is also suitable for the oil film thickness detection and early warning under the condition of the center loading.
Claims (3)
1. An optimal positioning and mounting method for a displacement sensor of a static pressure rotary table under an unbalance loading working condition is characterized by comprising the following steps: the optimal position of the sensor is determined by combining theoretical calculation and a simulation process, the theoretical oil film thickness is calculated in the unbalanced load radius direction without considering thermal deformation, the oil film thickness is smaller when the radius is larger, the oil film thickness minimum position on an oil pad is determined by combining the thermo-hydro-mechanical coupling theory and ANSYS simulation when the thermal deformation is considered, the method for determining the optimal position of the displacement sensor and the method for installing the displacement sensor are provided, the lowest position of the oil film thickness calculated in combination is the optimal position for installing the displacement sensor, the oil film thickness with the largest radius is calculated theoretically when the thermal deformation is not considered, the simulated oil film thickness is obtained by performing thermo-hydro-mechanical coupling simulation when the thermal deformation is considered, the equal-area of the oil film is divided, an oil film thickness matrix comparison method is provided, the theoretical oil film thickness matrix without considering the thermo-hydro-mechanical coupling condition is added with the thickness matrix after the thermo-hydro-mechanical coupling simulation to obtain a new matrix, the numerical value of each number in the new matrix is compared, the minimum number represents the average oil film thickness of the corresponding oil pad area, the minimum area is the optimal positioning area of the eddy current displacement sensor, and the displacement sensor is provided.
2. The optimal positioning and mounting method of the hydrostatic rotary table displacement sensor under the condition of unbalance loading as claimed in claim 1, wherein: when the displacement sensor is integrally positioned on the oil sealing edge, the width of the oil sealing edge outside the double-rectangular oil pad is enlarged, the effective bearing area of the static pressure rotary worktable is increased, novel oil pads and sensor mounting holes are designed, the mounting position and the mounting method of the eddy current displacement sensor under the unbalance loading working condition are determined, and the reference function is achieved for improving the stability and the safety of the static pressure rotary worktable and improving the bearing capacity.
3. The optimal positioning and mounting method of the hydrostatic rotary table displacement sensor under the unbalanced load condition according to claim 2, characterized in that: ensure that the displacement sensor probe is slightly lower than the horizontal plane on oil seal limit, the difference in height on two planes is h =0.1mm, the difference in height is through changing the vice cooperation length adjustment of internal and external screw thread, the difference in height passes through the amesdial to detect, adjust the back many times until reaching the design difference in height, this is also the local position of sensor at the oil blanket installation, scribble high temperature resistant sealed glue at the mounted position at last, plug up the clearance between sensor and the oil blanket, prevent that hydraulic oil from revealing from the mounting hole and cause the measurement inaccurate.
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| CN115673783B (en) * | 2022-11-02 | 2023-09-12 | 武汉重型机床集团有限公司 | Method and system for detecting and compensating unbalance of machining part of static pressure workbench |
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| CN102980755B (en) * | 2012-11-16 | 2015-05-20 | 北京工业大学 | Quantitive type experimental device for dynamic and static performances of static-pressure rotary table |
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