CN113705033B - Lightweight design method of electromagnetic automatic balancing device - Google Patents
Lightweight design method of electromagnetic automatic balancing device Download PDFInfo
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Abstract
The invention discloses a lightweight design method of an electromagnetic automatic balancing device, which belongs to the field of electromagnetic automatic balancing of rotary machinery. The invention has the advantages that the structural design is combined with electromagnetic simulation, firstly, the size boundary of the electromagnetic automatic balancing device is determined according to the installation space, and a finite element model is initially established in electromagnetic simulation software; secondly, electromagnetic simulation is carried out on structural parameters such as the thickness of the excitation magnetic ring, the thickness of the permanent magnet, the number of teeth and the tooth length, the shape of the permanent magnet, the ampere-turns and the like, and the axial thickness and the radial thickness of related structures of the electromagnetic automatic balancing device are reduced on the premise of meeting the self-locking and driving functions of the counterweight plate; finally, based on electromagnetic simulation results, the electromagnetic automatic balancing device is light in weight with the aid of structural design.
Description
Technical Field
The invention provides a lightweight design method of an electromagnetic automatic balancing device, and belongs to the technical field of automatic balancing of rotary machinery.
Background
With the development of modern industry at a high speed, the rotation speed of a rotor of a rotary machine is continuously increased, and the vibration problem caused by the rotation speed is more remarkable. Vibration faults are important factors influencing the safety and stable operation of equipment, reflect the operation condition of the equipment to a great extent, and are main indexes for evaluating the safety of the equipment. An effective way to solve the vibration problem of rotary machines is to dynamically balance the rotor. Compared with manual balancing, automatic balancing effectively reduces manual labor and downtime, greatly reduces equipment maintenance cost, and improves industrial production efficiency.
Vegte first proposed the concept of online automatic balancing in 1964, and developed to date, various online automatic balancing systems composed of automatic balancing actuators with different structures and corresponding control methods have been proposed. The basic structure and operation of an electromagnetically driven automatic balancing apparatus was described by Dyer et al, basance Dynamics, inc. in 1998. The electromagnetic automatic balancing is variable mass distributed automatic balancing based on permanent magnet self-locking and electromagnetic driving principles, and an electromagnetic automatic balancing actuator is usually an electromagnetic balancing head. The electromagnetic balance head consists of a movable ring and a stationary ring, and can be divided into an inner excitation balance head, an outer excitation balance head and a side excitation balance head according to the relative positions of the excitation coil and the counterweight disc. The exciting coil is positioned at the radial inner side of the counterweight plate and is an inner exciting balance head, the exciting coil is positioned at the radial outer side of the counterweight plate and is an outer exciting balance head, and the exciting coil is positioned at the axial two sides of the counterweight plate and is a side exciting balance head. The electromagnetic automatic balancing has the advantages of high precision, quick response and the like, and is widely applied to the technical field of automatic balancing.
However, since the electromagnetic automatic balancing apparatus is difficult to install and use on equipment having a narrow space and a strict mass limit, such as a main shaft of a propeller engine, due to the limitations of the size and mass of the electromagnetic automatic balancing apparatus itself, the development of the electromagnetic automatic balancing apparatus is significant for the study of the weight saving of the electromagnetic automatic balancing apparatus. But the weight of the electromagnetic automatic balancing device cannot be reduced blindly, the electromagnetic automatic balancing device is designed in a light-weight manner by combining electromagnetic simulation and structural design on the premise that the balance capacity, self-locking of a counterweight disc and driving reach requirements, and the following related patents are referred to:
in 2016, beijing university of chemical industry (publication No. CN 106312821A) discloses an integrated side excitation electromagnetic slip ring type automatic balancing device, and the device adopts a side excitation balancing head structure with a movable ring and a static ring which are connected into a whole. In 2019, on the basis of the patent (publication number: CN 106312821A), the Beijing university discloses a radial excitation electromagnetic slip ring type automatic balancing device (publication number: CN 110829711A), and the device is characterized in that side excitation rings are positioned on two radial sides of a counterweight disc, so that the problems of deflection and friction with the excitation rings in the rotation process of the counterweight disc are solved. The difference with the patent is that the radial thickness and the axial thickness of the device are larger, the required installation space is larger, and the whole mass is heavier.
In 2015, lord corporation (patent number: US8961140B 2) discloses an electromagnetic driving type automatic balancing device for a propeller plane, wherein 200 permanent magnets are embedded on a counterweight plate of the device, and the balancing precision is high, but the structure of the device is complex due to the fact that an internal excitation structure is realized by using a slip ring, and the service life of the whole machine is influenced.
In 2018, beijing university of chemical industry (publication No. CN 109625246A) discloses an internal excitation automatic balancing device for a propeller, which is characterized in that the device structurally adopts a transition sleeve type compact structural design to reduce the structural complexity of a balancing head; the dynamic ring is designed to be external, the static ring is of an internal structure, and the balancing capacity is improved. The balance head is characterized in that the problem of large mass of the balance head is considered, a hard aluminum material with lower density is adopted on the balance weight disc, and the mass ratio of the bearing in the balance head is reduced by adopting an ultrathin bearing on the structure; the difference with the patent lies in that the large steel deep groove ball bearing is used for supporting, and the transition sleeve type compact structure and the design of the supporting plate increase the whole quality of the balance head.
In 2020, patent (publication number: CN 112417611A) proposes an automatic balance structure design method based on magnetic circuit optimization, which is similar to the method in this patent in that the whole performance of the magnetic circuit is optimized through finite element software modeling simulation calculation and analysis, and an electromagnetic automatic balance device with stable stepping of a counterweight disc and stable vibration suppression and precision is designed; the difference from this patent is that the method does not consider the weight reduction of the electromagnetic automatic balancing device yet.
At present, domestic scholars have developed researches on lightweight design methods in a plurality of technical fields. Patent (publication number: CN109063409 a) discloses a lightweight design method and apparatus for a vehicle; patent (publication number: CN109255144 a) discloses a lightweight design method for landing gear brake members; patent (publication number: CN111783333 a) discloses a method of integrating a lightweight car and a lightweight car; patent (publication No. CN 110991035A) discloses a design method of a lightweight structure of a palm mattress. The idea of the above-mentioned 4 patents is similar to that of the present patent in that the finite element method is adopted to perform optimization calculation by using at least one performance target as a boundary condition and using the lightweight structure of the whole device as an optimization object, the lightweight structure design is performed by obtaining the position with the surplus variable through the theoretical data, and the lightweight material is optimized at the same time, and the lightweight structure is endowed with the lightweight material attribute, so that the lightweight of the device is realized. The idea of the above 4 patents is different from that of the present patent in that the present patent not only considers electromagnetic simulation and structural light-weight design, but also realizes light weight on the quality of the assembly tool of the device, further reduces the mass ratio of the assembly part in the whole device, and reduces the quality of the whole device.
The research on the electromagnetic automatic balancing device in China focuses on realizing stable self-locking and electromagnetic driving of the counterweight plate, and no intensive research on a lightweight design method of the electromagnetic automatic balancing device is available. The invention provides a lightweight design method of an electromagnetic automatic balancing device, which fills up the blank effectively, reduces the size and the quality of the electromagnetic automatic balancing device on the premise of ensuring the self-locking and driving requirements of a counterweight disc, and enables the installation occasion to be wider.
Disclosure of Invention
The invention aims to provide a lightweight design method of an electromagnetic automatic balancing device, which mainly optimizes a balancing head structure and reduces the mass of the balancing head by combining structural design and electromagnetic simulation. The electromagnetic simulation is based on electromagnetic simulation software, and the minimum axial thickness and the minimum radial thickness of the related structure of the electromagnetic balance head under the premise of meeting the self-locking and driving functions of the counterweight disc are obtained through simulation analysis aiming at the structural parameters such as the thickness, the tooth number and the tooth length of the side excitation magnetic ring and the permanent magnet, the permanent magnet shape and the ampere-turns and the like; the structural design is based on the electromagnetic simulation result, and light weight is realized from the structure and the assembly tool, so that the overall quality of the electromagnetic balance head is reduced to the maximum extent, and the light weight of the electromagnetic automatic balance device is realized.
This patent electromagnetic type automatic balancing unit lightweight design content includes:
1) Electromagnetic simulation light weight of related parameters of the moving ring: the method comprises the steps of establishing a finite element model of a permanent magnet and two side excitation rings, determining an axial air gap, and comparing and analyzing to obtain two-step curves of the thickness of the excitation ring, the thickness of the permanent magnet, the shape of the permanent magnet, the number of teeth, the tooth length and the self-locking moment of the adjacent permanent magnet when the self-locking moment is maximum by utilizing electromagnetic simulation technology means, so that the thicknesses of the excitation ring and a counterweight disc are reduced as much as possible on the premise of ensuring that the self-locking moment is enough, and the quality of an electromagnetic balance head moving ring is reduced.
2) Electromagnetic simulation light-weight of static ring related parameters: based on 1) finite element model, adding a coil support and a finite element model of a coil, and comparing and analyzing to obtain the minimum coil ampere-turns number meeting the driving requirement of a counterweight disc by using electromagnetic simulation technology means, thereby reducing the axial thickness and the radial thickness of the coil support and realizing the mass reduction of the static ring of the electromagnetic balance head.
3) And the assembly structure is light: the small-sized and light ceramic bearing is adopted to replace the traditional large-sized steel deep groove ball bearing, so that the mass ratio of the bearing in the electromagnetic balance head is reduced; using an assembly tool to replace the assembly of the baffle plate and the screws to the split type balance weight disc; the permanent magnets are adopted to realize the functions of counterweight and self-locking, and the number of the permanent magnets is reduced, so that the electromagnetic automatic balancing device is light.
The specific technical scheme of the lightweight design method of the electromagnetic automatic balancing device is as follows:
the electromagnetic simulation calculation analysis and the verification are realized by three-dimensional modeling software Creo and electromagnetic analysis software Maxwell.
Firstly, determining the size boundary of an electromagnetic automatic balancing device according to an installation space, and initially establishing a finite element model of a movable ring magnetic circuit part (a permanent magnet, a middle side excitation ring and left and right side excitation rings) in Maxwell software; secondly, defining materials of all parts, and giving the magnetizing direction of the permanent magnet; thirdly, excitation and solving setting are added, excitation sources and boundary condition definition, loading and solving option parameters are required to be set, and solving setting is a key of electromagnetic simulation and influences the accuracy of electromagnetic simulation results; fourthly, analyzing self-checking, and starting iterative solution calculation after the self-checking passes; finally, post-processing analysis, which is the inspection of electromagnetic simulation and reflects the accuracy of the solving result. After each solution is completed, firstly, observing the solution condition, wherein the key is whether the observed data is converged or not, recording the data after convergence, and the above 5 steps are a complete electromagnetic simulation process.
The simulation calculation of the related parameters of the self-locking moment is related, and the software setting steps are the same as the above, except that the related parameters such as the thickness of an excitation ring, the thickness of a permanent magnet, the shape of the permanent magnet, the number of teeth, the tooth length and the like need to be changed during modeling; the software setup steps involved in the simulation calculation of the drive torque related parameters are substantially the same as described above, except that the model of the stationary ring magnetic circuit portion (coil and coil support) is added when modeling is required, and the related parameters, such as ampere-turns and current direction, are changed when excitation is added.
When the self-locking moment of the electromagnetic balance head is calculated in a simulation mode, a curve of 2 steps of rotation steps of adjacent permanent magnets with the horizontal coordinate being an angle and the vertical coordinate being moment is needed to be obtained, and the position with the largest self-locking moment in a single-step period is obtained; on the basis of the position, the parameters of the related structure, such as the thickness of an excitation ring, the thickness of a permanent magnet, the shape of the permanent magnet, the number of teeth and the tooth length, which influence the self-locking moment are changed during modeling, the axial dimension of the related structure is reduced on the premise of ensuring that the self-locking moment is as large as possible, and the optimal numerical value of the related structural parameter is obtained through simulation calculation and analysis, so that the stable self-locking of the balance weight disk is realized while the weight of the electromagnetic balance head is reduced.
When the driving moment of the electromagnetic balance head is subjected to simulation calculation and check, whether the installation space of the coil in the coil bracket is enough or not needs to be checked; counting the number of turns of the windable enameled wire of the coil bracket under different wire diameters of the enameled wire, and then referring to the maximum safe current capacity of the different wire diameters in the enameled wire specification table, and multiplying the maximum safe current capacity by the maximum safe current capacity to obtain the ampere-turns of the windable coil in the coil bracket; if the driving moment excited by the ampere-turns of the coil is larger than the eccentric moment of the split type balance weight disc, electromagnetic simulation enables the device to be light and basically completed, otherwise, the size of the coil support needs to be readjusted and designed, and electromagnetic simulation is conducted again until the driving moment excited by the ampere-turns of the coil which can be assembled by the coil support is larger than the eccentric moment of the split type balance weight disc, so that the stepping driving of the balance weight disc is met and the weight of the electromagnetic balance head is reduced.
When the balance capacity of the electromagnetic balance head is calculated, a model of a split type balance weight disc is required to be established in three-dimensional modeling software, tungsten copper locking plates with different sizes and permanent magnets with different numbers and directions are assembled on the split type balance weight disc, a section with the size of the balance capacity of the electromagnetic balance head is obtained, and meanwhile, the minimum balance capacity of the section is ensured to be larger than the preset balance capacity.
The electromagnetic balance head adopts a light assembly structure. Firstly, a plurality of small-sized light ceramic bearings are adopted to replace the traditional large-sized steel deep groove ball bearings to play a supporting role, so that the weight ratio of the bearings in the electromagnetic balance head is reduced; secondly, using a locking plate and a screw to form an assembly tool to replace the assembly of the baffle and the screw to the split type balance weight disc; thirdly, because the self-locking moment is large enough during electromagnetic simulation, the permanent magnet can realize stable self-locking without being fully assembled, and the permanent magnet simultaneously realizes the functions of counterweight and self-locking, the number of the permanent magnets and the size of the tungsten copper lock piece can be reduced, and the weight of the electromagnetic balance head is reduced by using a light structure.
The lightweight electromagnetic automatic balancing device designed by the method has the following structure:
when the movable ring is arranged outside and the stationary ring is arranged inside, the balance capacity is high, the electromagnetic balance head with the internal excitation structure is adopted in the patent, and the specific structure is shown in the attached drawings 2 and 3. The movable ring part is of an axially symmetrical structure, and the main components comprise a left sliding rail 1, a right sliding rail 2, a left side plate 2, a right side exciting ring 3, a split counterweight disc 4, an ultrathin bearing 6, a middle side exciting ring 5, a middle bracket 8 and a right symmetrical part in sequence from left to right; the static ring part is also of an axially symmetrical structure, and the main components are a ceramic bearing 9, a coil bracket, an exciting coil 15 and a right symmetrical part in sequence from left to right. The number of the ultrathin bearings is 2, and the number of the ceramic bearings is 9. The split type weight plate 4 of the core component is made of hard aluminum material with lower density, and is connected into a whole through a stainless steel thin locking plate 10 and a tungsten copper thick locking plate 14, as shown in fig. 4. Different numbers of oblong permanent magnets 11 and tungsten copper thick locking plates 14 with different sizes can be arranged on the split type balance weight disc 4, so that balance capacity adjustment is realized, and the trapezoidal magnets 13 are positioning references of the split type balance weight disc.
The invention relates to a lightweight design method and device for an electromagnetic automatic balancing device, which combines electromagnetic simulation and structural design, and has the following beneficial effects:
1. according to the invention, through electromagnetic simulation, the balance head still realizes stable self-locking and stepping driving under the condition of taking the self-locking moment and the driving moment of the balance weight disc as boundary conditions and guaranteeing the reduction of the related structure size.
2. The invention adopts a plurality of small-sized light ceramic bearings to replace the traditional large-sized steel deep groove ball bearings to play a supporting role, thereby greatly reducing the weight ratio of the bearings in the electromagnetic balance head.
3. The permanent magnet of the invention realizes the functions of counterweight and self-locking at the same time, and reduces the number of the required permanent magnets and the size of the tungsten copper thick locking plate.
4. The invention can carry out parameterized design according to the requirement of balance capability, and has flexibility of design and application.
5. According to the invention, the tool structure is considered in the design of each part, so that the concentricity of each part after assembly is ensured, and the problems of friction between the counterweight plate and the exciting ring and overlarge friction caused by assembly errors are reduced.
6. The invention can reduce the size and the mass of the electromagnetic automatic balancing device and enlarge the installation occasion range.
Drawings
FIG. 1 is a flow chart of a lightweight design of an electromagnetic automatic balancing device;
FIG. 2 is an overall exploded schematic view of the excitation balance head;
FIG. 3 is a schematic diagram of an assembly of the excitation balance head;
FIG. 4 is a schematic diagram of a split weight plate assembly;
FIG. 5 is a schematic diagram of a finite element model of electromagnetic simulation software;
FIG. 6 is a schematic diagram of the self-locking torque as a function of the thickness of the excitation ring and the thickness of the permanent magnet;
FIG. 7 is a schematic diagram of self-locking torque of the excitation ring with different numbers of teeth.
In the figure: 1. left and right slide rails, 2, left and right side plates, 3, left and right side excitation magnetic rings, 4, split weight plates, 5, middle side excitation magnetic rings, 6, ultrathin bearings, 7, coil brackets, 8, middle brackets, 9, ceramic bearings, 10, stainless steel thin locking plates, 11, permanent magnets, 12, cylindrical pins, 13, trapezoidal magnets, 14, tungsten copper thick locking plates, 15, excitation coils
Detailed Description
The invention is described in further detail below with reference to the drawings and the specific examples.
The lightweight design flow chart of the electromagnetic automatic balancing device is shown in the attached figure 1, and the lightweight design method of the electromagnetic automatic balancing device comprises two parts of electromagnetic simulation and structural design.
The electromagnetic simulation steps are as follows:
first, build a model
And determining the size boundary of the internal excitation balance head according to the installation space, and establishing a finite element model of the related structure. Finite element models can be built in three-dimensional modeling software before importation, or modeled directly in Maxwell. In order to facilitate parameterization calculation of the relevant structural parameters of the balance head, the patent adopts a mode of modeling in Maxwell directly. The finite element model for calculating the driving moment is shown in figure 5, and the axial air gap between the excitation ring and the permanent magnet defaults to 1mm;
second, material definition and distribution
1) Default to solve for the material properties of domain geometry model Region-vacuum,
2) Defines the material properties of the field coil 15-coater,
3) Defining the material properties of the middle side excitation ring 5, the left and right side excitation rings 3 and the coil support 7-ion,
4) The permanent magnet 11 is defined as NdFe35, and the magnetizing mode is parallel magnetizing;
third, excitation source loading
Creating a section on the exciting coil, and loading a current excitation source on the section;
fourth, solve the parameter setting of the option
Selecting two adjacent permanent magnet models, and selecting and solving the moment born by the two adjacent permanent magnet models;
fifthly, adding solving setting and selecting default setting;
sixthly, setting parameterized solution, and adding variables for parameterized calculation. For example, the thickness of the excitation ring, the thickness of the permanent magnet, the shape of the permanent magnet, the number of teeth, the length of the teeth and the like are structural parameters when a model is built, and the ampere turns, the current direction and the like are carried out when an excitation source is loaded;
seventh, analyzing self-checking, calculating and checking results. The key to looking at the results is to see if the data is converging, which is not recordable.
Thus, the electromagnetic simulation process is completed once through the seven steps.
In the electromagnetic simulation process, the self-locking moment and the driving moment are used as performance indexes, and structural parameters such as the thickness of an excitation ring, the thickness of a permanent magnet, the shape of the permanent magnet, the number of teeth, the tooth length, the ampere turns and the current direction when an excitation source is loaded are used as optimization objects to execute optimization calculation, and the positions with surplus variables are obtained through theoretical data to carry out light structural design on the positions, such as the reduction of the thickness of the excitation ring, the reduction of the number of the permanent magnets and the like.
After the electromagnetic simulation is finished, two important accounting needs to be performed.
First, balance ability accounting
Establishing a model of a split type balance weight disc in Creo, and assembling tungsten copper locking plates with different sizes and permanent magnets with different numbers and directions on the split type balance weight disc to obtain a section with the balance capacity of an electromagnetic balance head, wherein the minimum balance capacity of the section is ensured to be larger than a preset balance capacity;
second, drive torque accounting for excitation of excitation coil
When checking the driving moment of the electromagnetic balance head, checking whether the installation space of the coil in the coil bracket is enough or not is needed; counting the number of turns of the windable enameled wire of the coil bracket under different wire diameters of the enameled wire, and then referring to the maximum safe current capacity of the different wire diameters in the enameled wire specification table, and multiplying the maximum safe current capacity by the maximum safe current capacity to obtain the ampere-turns of the windable coil in the coil bracket; if the driving moment excited by the ampere-turns of the coil is larger than the eccentric moment of the split type balance weight disc, electromagnetic simulation enables the device to be light and basically completed, otherwise, the size of the coil support needs to be readjusted and designed, and electromagnetic simulation is conducted again until the driving moment excited by the ampere-turns of the coil which can be assembled by the coil support is larger than the eccentric moment of the split type balance weight disc, so that the stepping driving of the balance weight disc is met and the weight of the electromagnetic balance head is reduced.
The method completes the optimization design of the related structural parameters of the internal excitation balance head through electromagnetic simulation, and then considers the light-weight design on an assembly tool. The quality of standard components in the balance head is reduced, and the adoption of the tool structure for reducing assembly errors is a good design idea.
Example 1
The thickness of the exciting ring and the thickness of the permanent magnet are optimally designed; when Maxwell modeling is carried out, the thickness of the excitation ring is set to be 2-8mm, the thickness of the permanent magnet is set to be 1-5mm, and the self-locking moment is calculated and solved in a parameterized mode. The solving result is shown in figure 6, and in the interval, the thicker the permanent magnet is, the larger the self-locking moment is; and as the thickness of the exciting ring increases, the self-locking moment is increased first and then is basically unchanged. Considering the self-locking moment and the whole size of the balance head, the electromagnetic simulation structure adopts a 5mm permanent magnet and a 4mm excitation ring.
Example 2
Optimizing the number of teeth of the excitation ring; during Maxwell modeling, excitation ring models of 50 teeth, 60 teeth, 75 teeth, 90 teeth and 100 teeth are respectively built, and the change of self-locking moment and the total self-locking moment (sum of self-locking moments of all permanent magnets) of stable self-locking positions in the stepping two-step process of a single permanent magnet are solved.
The result of the solution is shown in fig. 7, in the two steps, the change curve of the self-locking moment of each single permanent magnet is similar to a sinusoidal curve, but the change curves of the self-locking moment of the two steps are different because the permanent magnet respectively undergoes a step from the solid part of the exciting ring to the blank part of the exciting ring and a step from the solid part of the exciting ring to the solid part of the exciting ring. The more the number of teeth is, the larger the fluctuation of the self-locking moment is in the two steps, which is not beneficial to the stable stepping of the counterweight disc; the fewer the number of teeth is, the larger the self-locking moment for stabilizing the self-locking position is, which is favorable for permanent magnet self-locking, but with the reduction of the number of teeth, the phenomenon that the self-locking moment is approximately 0 in the stepping process appears, and whether the counterweight plate advances or retreats in the stepping process cannot be determined, so the number of teeth cannot be selected too much or too little. Thus, when the stable self-locking position is further calculated, the change trend of the total self-locking moment under different tooth numbers is shown as a right chart of fig. 7. In the tooth number interval, the total self-locking moment is increased and then reduced, and a 60-tooth excitation ring structure is adopted by combining the two-step change of the self-locking moment of a single permanent magnet.
Claims (8)
1. A lightweight design method of an electromagnetic automatic balancing device is characterized in that: the electromagnetic automatic balance is variable mass distributed automatic balance based on permanent magnet self-locking and electromagnetic driving principles, and an electromagnetic automatic balance actuator is usually an electromagnetic balance head; the electromagnetic balance head consists of a movable ring and a stationary ring, and can be divided into an inner excitation balance head, an outer excitation balance head and a side excitation balance head according to the relative positions of the excitation coil and the balance weight disc, wherein the excitation coil is positioned at the radial inner side of the balance weight disc and is positioned at the radial outer side of the balance weight disc and is positioned at the axial two sides of the balance weight disc and is positioned at the side excitation balance head; the lightweight design method of the electromagnetic automatic balancing device comprises electromagnetic simulation and structural design; the electromagnetic simulation is based on Maxwell software, and the minimum axial thickness and the minimum radial thickness of the related structure of the electromagnetic balance head under the premise of meeting the self-locking and driving functions of the balance weight disc are obtained through simulation analysis aiming at the structural parameters of the side excitation magnetic ring, the permanent magnet thickness, the tooth number, the tooth length, the permanent magnet shape and the ampere-turn number; the structural design is based on the electromagnetic simulation result, and the ceramic bearing and the hollow structure with smaller weight are adopted, and an assembly tool is used for replacing the assembly of the baffle and the screw to the split type balance weight disc, so that the overall weight of the electromagnetic balance head is reduced to the greatest extent, and the electromagnetic automatic balance device is light;
the lightweight design content of the electromagnetic automatic balancing device comprises:
1) Electromagnetic simulation light weight of related parameters of the moving ring: establishing a finite element model of a permanent magnet and two side excitation rings, determining an axial air gap, and comparing and analyzing to obtain a self-locking moment two-step curve of the thickness of the excitation ring, the thickness of the permanent magnet, the shape of the permanent magnet, the tooth number and the tooth length of the permanent magnet and the adjacent permanent magnet when the self-locking moment is maximum by utilizing an electromagnetic simulation technical means, so that the thicknesses of the excitation ring and a counterweight disc are reduced as much as possible on the premise of ensuring that the self-locking moment is enough, and the quality of an electromagnetic balance head moving ring is reduced;
2) Electromagnetic simulation light-weight of static ring related parameters: based on 1) a finite element model, a coil support and a finite element model of a coil are added, and the minimum coil ampere-turns number meeting the driving requirement of a counterweight disc is obtained by comparison analysis by utilizing electromagnetic simulation technical means, so that the axial thickness and the radial thickness of the coil support are reduced, and the quality of an electromagnetic balance head stationary ring is reduced;
3) And the assembly structure is light: the small-sized and light ceramic bearing is adopted to replace the traditional large-sized steel deep groove ball bearing, so that the mass ratio of the bearing in the electromagnetic balance head is reduced; using an assembly tool to replace the assembly of the baffle plate and the screws to the split type balance weight disc; the permanent magnets are adopted to realize the functions of counterweight and self-locking, and the number of the permanent magnets is reduced, so that the electromagnetic automatic balancing device is light.
2. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 1, wherein: firstly, determining the size boundary of an electromagnetic automatic balancing device according to an installation space, initially establishing finite element models of a permanent magnet, a middle side excitation ring and a left side excitation ring in Maxwell software, changing the thickness of the excitation ring, the thickness of the permanent magnet, the shape, the tooth number and the tooth length structural parameters of the permanent magnet, and obtaining the optimal numerical value of the structural parameters when the self-locking moment is maximum through electromagnetic simulation comparison analysis; on the basis of obtaining the optimal numerical value of the structural parameter, adding a finite element model of a coil and a coil bracket, and obtaining the minimum coil ampere-turns meeting the driving requirement of the split type balance weight disc through electromagnetic simulation comparison analysis; secondly, based on electromagnetic simulation conclusion, an electromagnetic balance head model is established in three-dimensional modeling software, whether the overall structure of the electromagnetic balance head is interfered or not is checked, whether a coil is installed in enough space or not is checked, if not, the relevant structure size of the electromagnetic balance head is readjusted and designed, and electromagnetic simulation is conducted again; if the balance capacity does not meet the expected requirement, the structural size of the split type balance weight disc is readjusted and designed until the balance capacity meets the expected requirement; to this end, electromagnetic simulation ends the device weight reduction; finally, the new assembly structure is added to enable the device to be light, a plurality of small and light ceramic bearings are adopted to replace the traditional large steel deep groove ball bearings to play a supporting role, and an assembly tool is used to replace the assembly of the baffle and the screws to the split type balance weight disc.
3. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein:
the permanent magnets are adopted to realize the functions of counterweight and self-locking, the number of the permanent magnets is reduced, and the weight of the electromagnetic balance head is reduced by adopting a light hollow structure.
4. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein:
the electromagnetic simulation calculation is realized by means of three-dimensional modeling software Creo and electromagnetic analysis software Maxwell; firstly, determining the size boundary of an electromagnetic automatic balancing device according to an installation space, and initially establishing a finite element model of a movable ring magnetic circuit part, namely a permanent magnet, a middle side excitation magnetic ring and left and right side excitation magnetic rings in Maxwell software; secondly, defining materials of all parts, and giving the magnetizing direction of the permanent magnet; thirdly, excitation and solving setting are added, the solving setting is the key of electromagnetic simulation, the accuracy of electromagnetic simulation results is affected, and excitation sources and boundary condition definition, loading and solving option parameters are required to be set;
fourthly, analyzing and self-checking, and starting iterative solution calculation after the self-checking is passed; finally, performing post-processing analysis, wherein the post-processing analysis is the inspection of electromagnetic simulation and reflects the accuracy of a solving result; after each solution is completed, firstly, observing the solution condition, wherein the key is whether the observed data is converged, recording the data after converging, and the above 5 steps are a complete electromagnetic simulation process; the simulation calculation of the related parameters of the self-locking moment is related, and the software is set up differently in that the related parameters such as the thickness of the exciting ring, the thickness of the permanent magnet, the shape of the permanent magnet, the number of teeth and the tooth length need to be changed during modeling; the simulation calculation of relevant parameters of driving moment is related, and the software setting steps are different in that a model of a static ring magnetic circuit part is added when modeling is needed, and the relevant parameters are changed when excitation is added.
5. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein: when the self-locking moment of the electromagnetic balance head is calculated in a simulation mode, a curve of 2 steps of rotation steps of adjacent permanent magnets with the horizontal coordinate being an angle and the vertical coordinate being moment is needed to be obtained, and the position with the largest self-locking moment in a single-step period is obtained; on the basis of the position, relevant structural parameters such as the thickness of an excitation ring, the thickness of a permanent magnet, the shape of the permanent magnet, the number of teeth and the length of teeth, which influence the self-locking moment, are changed during modeling, the axial dimension of a relevant structure is reduced on the premise of ensuring that the self-locking moment is large, and the optimal numerical value of the relevant structural parameters is obtained through simulation calculation and analysis, so that the stable self-locking of the counterweight disc is realized while the weight of the electromagnetic balance head is reduced.
6. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein: when the driving moment of the electromagnetic balance head is subjected to simulation calculation and check, whether the installation space of the coil in the coil bracket is enough or not needs to be checked; counting the number of turns of the windable enameled wire of the coil bracket under different wire diameters of the enameled wire, and then referring to the maximum safe current capacity of the different wire diameters in the enameled wire specification table, and multiplying the maximum safe current capacity by the maximum safe current capacity to obtain the ampere-turns of the windable coil in the coil bracket; if the driving moment excited by the ampere-turns of the coil is larger than the eccentric moment of the split type balance weight disc, electromagnetic simulation enables the device to be light and basically completed, otherwise, the size of the coil support needs to be readjusted and designed, and electromagnetic simulation is conducted again until the driving moment excited by the ampere-turns of the coil which can be assembled by the coil support is larger than the eccentric moment of the split type balance weight disc, so that the stepping driving of the balance weight disc is met and the weight of the electromagnetic balance head is reduced.
7. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein: when the balance capacity of the electromagnetic balance head is calculated, a model of a split type balance weight disc is required to be established in three-dimensional modeling software, tungsten copper locking plates with different sizes and permanent magnets with different numbers and directions are assembled on the split type balance weight disc, the interval of the balance capacity of the electromagnetic balance head is obtained, and meanwhile, the minimum balance capacity of the interval is ensured to be larger than the preset balance capacity.
8. The method for lightweight design of an electromagnetic automatic balancing apparatus according to claim 2, wherein: the electromagnetic balance head adopts a light assembly structure; a plurality of small-sized light ceramic bearings are adopted to replace the traditional large-sized steel deep groove ball bearings to play a supporting role, so that the weight ratio of the bearings in the electromagnetic balance head is reduced; the assembly tool consisting of the locking plate and the screw is used for replacing the assembly of the baffle and the screw to the split type balance weight disc; the self-locking moment is large enough during electromagnetic simulation, the permanent magnet can realize stable self-locking without being fully assembled, and the permanent magnet simultaneously realizes the functions of counterweight and self-locking, so the number of the permanent magnets and the size of the tungsten copper lock piece can be reduced, and the weight of the electromagnetic balance head is reduced by using a light structure.
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