動靜態(tài)液壓試驗臺液壓系統(tǒng)設計
動靜態(tài)液壓試驗臺液壓系統(tǒng)設計,靜態(tài),液壓,試驗臺,系統(tǒng),設計
沈陽化工大學科亞學院本科畢業(yè)設計題 目: 動靜態(tài)液壓試驗臺液壓系統(tǒng)設計 專 業(yè): 機械設計制造及其自動化 班 級: 機制1203 學生姓名: 侯鵬程 指導教師: 王志成 論文提交日期: 年 月 日論文答辯日期: 年 月 日畢業(yè)設計(論文)任務書 機械設計制造 專業(yè) 1203班學生:侯鵬程畢業(yè)設計(論文)題目:動靜態(tài)液壓試驗臺液壓系統(tǒng)設計 畢業(yè)設計(論文)內(nèi)容: 針對液壓阻尼器的特性,設計同時滿足其靜態(tài)性能和動態(tài)性能測試的試驗臺,要求最大輸出動態(tài)力為200KN,頻率范圍0.0133Hz。設計液壓系統(tǒng)的原理圖;選擇液壓元件,主要包括電動機、液壓泵、伺服閥、比例閥、電磁換向閥、單向閥等;對系統(tǒng)進行性能驗算。 畢業(yè)設計(論文)專題部分:液壓振動試驗臺的現(xiàn)狀和發(fā)展趨勢分析。液壓振動試驗臺的功能分析:包括靜態(tài)性能和動態(tài)性能分析,建立液壓振動試驗臺的數(shù)學模型。擬定動靜態(tài)液壓試驗臺的液壓原理圖:包括油源回路,由比例閥控制的壓力回路、由電液伺服閥控制的動靜態(tài)加載回路、卸荷回路等。選擇液壓元件:主要包括電液伺服閥和作動器(伺服液壓缸),比例溢流閥,電磁換向閥,電磁單向閥,油箱,蓄能器等。液壓系統(tǒng)性能的驗算:包括壓力損失計算,溫升計算,各壓力調(diào)節(jié)閥調(diào)節(jié)壓。伺服液壓缸機械設計。液壓系統(tǒng)原理圖,液壓缸裝配圖檢查和完善。起止時間:2016/3/5到2016/5/28指導教師: 簽字 年 月 日摘要阻尼器是一種能夠吸收、衰減沖擊與振動的控制裝置,隨著設計和制造技術的不斷提高,其應用越來越廣泛鑒于阻尼器如此廣泛的使用,且其對系統(tǒng)的安全性起著至關重要的作用,必須確保阻尼器具備合格的性能指標和制造質(zhì)量。因此,研制阻尼器振動試驗臺對測試阻尼器性能,保證產(chǎn)品質(zhì)量具有重要意義。本文調(diào)研了阻尼器振動試驗臺的發(fā)展現(xiàn)狀,在分析了各類振動試驗臺性能特點的基礎上,提出使用液壓振動試驗臺檢測阻尼器的方法,并針對國內(nèi)外液壓振動試驗臺研究中存在的不足,研究開發(fā)了一套具備高精度、大載荷、寬頻響等特點的百噸級液壓振動試驗臺系統(tǒng),并完成了系統(tǒng)具體設計。對液壓振動試驗臺的系統(tǒng)原理進行闡述,根據(jù)試驗臺的技術指標,對試驗臺 液壓系統(tǒng)主要元件和試驗臺機架進行設計,并針對試驗臺設計中的技術難點進行 分析。關鍵詞:阻尼器;液壓試驗臺;性能檢測;伺服控制AbstractDamper as an absorption and attenuation of shock and vibration control device, as the design and manufacturing technology The continuous improvement of operation, its application is more and more widely. In view of the damper is so widely used, and the system Security plays an important role, must ensure that the damping apparatus for manufacturing quality and qualified performance indicators. Therefore, the development to test the tester damper vibration damper performance, ensure the quality of products is of great significance. In this paper, the research of vibration damper test bench development present situation, the analysis of the various characteristics of vibration table Based on the analysis of using hydraulic method to detect damper vibration test rig, and in view of the hydraulic vibration test at home and abroad Test platform of the insufficiency in research, the research developed a high precision, large load, bandwidth, etc The tonnage hydraulic vibration test system, and completed the system design. On the system principle of hydraulic vibration test bench, according to the technical index of the test bench, main components and hydraulic system on test bench test bed frame design, and in view of the technical difficulties in the design of test bed are analyzed. Based on the above research results, the tonnage hydraulic vibration damper test rig is developed, and in jiangsu electric power Run the installation for co., LTD The damper test showed that this paper developed test rig, Load control accurate, reliable test data, fully meet the needs of enterprises on the damper performance test.Key words: damper; Hydraulic test bench; Performance testing; Servo control目 錄緒論1第一章 液壓振動試驗臺的現(xiàn)狀和發(fā)展趨勢分析21.1 國外液壓振動試驗臺的發(fā)展現(xiàn)狀21.2阻尼器性能檢測方法4第二章 液壓振動試驗臺的功能分析71.1 液壓振動試驗臺研制方案的提出71.2 本文的主要研究內(nèi)容81.3 論文組織架構91.4液壓振動試驗臺的設計9第三章 擬定動靜態(tài)液壓試驗臺的液壓原理圖103.1 試驗臺架功能和組成103.2 液壓系統(tǒng)103.3 效率問題103.4 動靜態(tài)試驗問題11第四章 選擇液壓元件134.1分類154.2 用途174.3分類功能17第五章 液壓系統(tǒng)性能的驗算195.1 系統(tǒng)沖擊問題195.2 主機設計20第六章 伺服液壓缸機械部分設計236.1 試驗臺的技術指標236.2 供油壓力的選擇236.3 機架的設計說明27總結28參考文獻29致謝30沈陽化工大學科亞學院學士學位論文 緒論緒論阻尼器是一種對速度反應靈敏的振動控制裝置,它能夠吸收、沖擊能量與衰減振動,減少結構的動力反應,控制沖擊性的流體振動(如主汽門快速關閉、安全閥排放、水錘、破管等沖擊激擾)和地震激擾的管系振動,主要適用于核電廠、火電廠、化工廠、鋼鐵廠等的管道及設備的減振。阻尼器是利用充滿液壓油的液壓缸,借助液壓缸內(nèi)活塞上的小孔來獲得阻 尼作用。其基本工作原理是,當阻尼器的活塞受到外力沖擊時,通過阻尼 控制閥和阻尼節(jié)流孔,在液壓缸兩腔產(chǎn)生壓力差,從而對外產(chǎn)生阻尼力, 該阻尼力的大小與負載速度有關。近年來,隨著阻尼器的設計和制造技術的不斷改進,各種各樣的測試和檢驗阻尼器的測試技術的改進,應用越來越廣泛。不僅現(xiàn)在,阻尼器應用于重要軍事工程,并已大量應用于土木工程。針對阻尼器的使用廣泛,系統(tǒng)安全起著至關重要的作用。因此,為了測試和保證阻尼器的技術性能指標和產(chǎn)品制造質(zhì)量,必須建立相應的阻尼器進行測試系統(tǒng),阻尼性能測試和質(zhì)量檢驗。33沈陽化工大學科亞學院學士學位論文 第一章 液壓振動試驗臺的現(xiàn)狀和發(fā)展趨勢分析第一章 液壓振動試驗臺的現(xiàn)狀和發(fā)展趨勢分析液壓振動臺的殘余,長沖程,承載能力強的優(yōu)點,阻尼器測試領域獲得了極其廣泛的應用。隨著計算機技術的發(fā)展,計算機振動臺可以預先設置參數(shù),如振幅、頻率、負載測試方法和起止時間等等。這使得液體壓力振動臺具有更好的可操作性和較高的工作效率,成為最廣泛使用的阻尼器方法。國內(nèi)外對液壓振動試驗臺進行了廣泛而深入的研究,具體的研究接口紹如下:1.1 國外液壓振動試驗臺的發(fā)展現(xiàn)狀液壓振動試驗臺在國外企業(yè)技術方面的研究和應用起步較早,到20世紀九十年代初,國外試驗臺行業(yè)幾大公司比較知名的,如美國的MTS、英國的Iasdn、德國的Shenck、日本島津等,已推出其代表性的數(shù)字控制試驗臺系統(tǒng)。這些公司在其原有??丶夹g的基礎上,采用了計算機控制與電液伺服相結合的技術,提高了試驗精度和增強了系統(tǒng)功能。目前,液壓振動試驗臺生產(chǎn)主要以美國、英國和德國為主,另外日本島津制作所也有少量的產(chǎn)品f。美國的MTS公司作為世界上液壓振動試驗臺生產(chǎn)、銷售量最大的廠商,其產(chǎn)品在技術和品種方面處于絕對的領先地位。MTS數(shù)字控制系統(tǒng)TeSt star具有靈活的多參量控制補償功能,實現(xiàn)了P、I、D參數(shù)數(shù)字設定和對系統(tǒng)的非線性修正,配置靈活、適應面廣,性能指標很高。減小摩擦力方面,MTS公司采用的方式有:靜壓支撐、動壓支撐、特殊噴涂技術等。伺服作動器滑動配合表面采用非金屬噴涂處理,實現(xiàn)了較小的阻尼。在標準液壓振動試驗臺產(chǎn)品上,MTS公司擁有全系列的標準振動試驗臺產(chǎn)品。該公司生產(chǎn)的824系列液壓振動試驗臺除有MTs通用的液壓伺服系統(tǒng)外還有諧振系統(tǒng),對試樣施加平均載荷,并以其固有頻率激勵質(zhì)量振動,以便提供和控制動載荷。英國的Insaon公司的液壓振動試驗臺有1300系列、8000系列和8500系列等。在8000系列中,原有的全部電子控制柜被一臺計算機系統(tǒng)取代。所有的試驗程序均錄于微型盒式磁帶上,通過按鍵指令的操作,可快速自動完成整個試驗過程。而8500系列可以連接計算機,使用數(shù)字信號處理器和動態(tài)響應自適應控制,具有P、I、D參數(shù)數(shù)字設定和測量系統(tǒng)自動調(diào)零,對材料試驗全過程進行32位全數(shù)字化閉環(huán)控制和高速數(shù)據(jù)采集。由于引入了各種功能附件及計算機,其功能、可靠性、測試精度大大提高。但由于其量程小,價格昂貴,在國內(nèi)應用較少嗍。德國的Schenck公司推出了諧振非諧振液壓振動試驗臺,這種試驗臺有雙作動器和單作動器兩種。其中750KN諧振非諧振液壓振動試驗臺為四立柱雙作動器。該試驗臺有兩個伺服控制通道,一是在試樣上產(chǎn)生平均載荷,另一是以其固有頻率激勵彈簧質(zhì)量系統(tǒng),諧振狀態(tài)工作完全是自動進行的以諧振狀態(tài)工作時,試驗臺在諧振曲線的峰值工作,此時只需低功率便可在高頻率下獲得高試驗負荷。伺服控制器的每個通道都有獨立的PID控制,具有最佳的伺服控制回路的響應特性。國內(nèi)液壓振動試驗臺的發(fā)展現(xiàn)狀國內(nèi)液壓振動試驗臺的研制起步較晚,技術儲備與研究水平落后于國外先進企業(yè)。直至上世紀七十年代,長春試驗機研究所以及甘肅天水紅山試驗機廠研制出液壓振動試驗臺,才邁出我國動態(tài)試驗臺研制的步伐。上世紀八十年代后期,國內(nèi)許多單位加強了相關方面的研究。如天津大學研制了PwS100A液壓振動試驗臺,開發(fā)的預拉應力橫梁央緊結構、非金屬支撐高速作動器、拉壓對稱循環(huán)的液壓強迫夾頭等多項技術屬國內(nèi)首創(chuàng)?,F(xiàn)已開發(fā)出lOKN。1000l(選擇法蘭接口,根據(jù)用戶的需求自由選擇。根據(jù)流體參數(shù)選擇電磁閥:材料、溫度組1)腐蝕性液體:宜選用耐腐蝕電磁閥,不銹鋼;超級清潔液:宜選用食品級不銹鋼材料電磁閥;2)高溫液體,應選擇使用耐高溫的電氣電磁閥材料和密封材料,和選擇活塞結構類型;3)流體狀態(tài):氣體,液體或混合狀態(tài),尤其是當直徑大于DN25必須區(qū)分;4)流體的粘滯性:通常在50個春秋國旅可以任意選擇,如果超過這個值,應該選擇高粘度電磁閥。根據(jù)參數(shù)選擇壓力電磁閥:品種的原理和結構1)公稱壓力:這個參數(shù)的意義與其他通用閥是一樣的,是根據(jù)管道公稱壓力;2)工作壓力:如果低工作壓力必須選擇或一步一步的直接代理原則;最低工作壓力差連續(xù)超過0.04 Mpa,一步一步直接表演,指導類型都可以選擇。電氣選擇:電壓規(guī)格應盡量優(yōu)先選用AC220V、DC24較為方便。根據(jù)持續(xù)工作時間長短來選擇:常閉、常開、或可持續(xù)通電1)當電磁閥需要長時間開啟,并且持續(xù)的時間多于關閉的時間應選 用常開型;2)要是開啟的時間短或開和關的時間不多時,則選常閉型;3)但是有些用于安全保護的工況,如爐、窯火焰監(jiān)測,則不能選常開的,應選可長期通電型。根據(jù)環(huán)境要求選擇輔助功能:防爆、止回、手動、防水霧、水淋、潛水。工作原理:電磁閥封閉空腔,打開一個孔在不同的位置,每個孔連接不同的油管,腔中間是活塞,兩邊是兩個電磁鐵,將吸引磁鐵線圈電身體哪邊,通過控制閥體的移動來打開或關閉不同放電的油孔、油孔永遠是敞開的,液壓油就會進入不同4.的排油管,然后通過油的壓力來推動油缸的活塞,活塞推動活塞桿,活塞桿驅(qū)動機制。這個流的電力通過控制電磁鐵斷層控制了機械運動。電磁單向閥:只有一個方向氣流,不能反向流動的方向控制閥門。它的工作原理和液壓單向閥。壓縮空氣從入口,克服彈簧力和摩擦力使單向閥口打開,單向閥應用于不允許空氣流通,如空氣壓縮機,膨脹水箱,水箱和安裝一個止回閥之間的空氣壓縮機,壓縮機停止工作時,可以防止壓縮空氣罐回空氣壓縮機。止回閥通常是結合節(jié)流閥,順序閥用單向節(jié)流閥,單向順序閥更換。蓄能器:工作原理:液壓油是不可壓縮液體,因此它是不可能積累的壓力可以使用液壓油,必須依靠其他媒體來變換,儲層壓力。例如,利用氣體(氮氣)開發(fā)的可壓縮特性包式空氣蓄電池設備的液壓油箱。皮囊式蓄能器由石油和天然氣中的組件與氣體密封部分,位于石油和周圍的皮膚油循環(huán)。壓力油進入蓄電池時,氣體被壓縮,系統(tǒng)管路壓力不再上升;當壓縮空氣管路壓力降低通貨膨脹,液壓油會進入電路,以減緩線路壓降。4.1分類彈簧式這取決于壓縮彈簧液壓系統(tǒng)壓力過剩可以轉(zhuǎn)化為彈簧勢能存儲,在必要的時候。其結構簡單,成本低。但是因為彈簧伸縮的數(shù)量有限和規(guī)模擴張壓力的變化不敏感,消振功能差,所以只適合小容量和低壓系統(tǒng)(1.0 1.2 MPa P),或用作緩沖裝置。活塞式它通過提高密封活塞上的負載質(zhì)量塊的液壓系統(tǒng)的壓力能轉(zhuǎn)化為重力勢能積蓄。其結構簡單、穩(wěn)定的壓力。缺陷設置限制,只有垂直安裝,不容易密封,慣性大,質(zhì)量不敏感。這種類型的蓄能器僅供臨時使用。圖4.1活塞式蓄能器這兩個蓄電池因為其局限性是很少使用。但值得注意的是,一些研究從經(jīng)濟的觀點在兩個蓄電池的結構做新的東西,在某種程度上,克服其缺點。如國內(nèi)工廠改進的彈簧式蓄能器的結構。(如圖2所示,增加彈簧直徑大于液壓室直徑),合格的春天之旅(將彈簧最大負載限制在容許極限載荷)方法提高了工作壓力,和蓄電池的容量,降低成本。圖4.2外彈簧式蓄能器氣體式它以波義爾定律(PVn=K=常數(shù))為基礎,通過壓縮氣體完成能量轉(zhuǎn)化,使用時首先向蓄能器充入預定壓力的氣體。當系統(tǒng)壓力超過蓄能器內(nèi)部壓力時,油液壓縮氣體,將油液中的壓力轉(zhuǎn)化為氣體內(nèi)能;當系統(tǒng)壓力低于蓄能器內(nèi)部壓力時,蓄能器中的油在高壓氣體的作用下流向外部系統(tǒng),釋放能量。選擇適當?shù)某錃鈮毫κ沁@種蓄能器的關鍵。這類蓄能器按結構可分為管路消振器、氣液直接接觸式、活塞式、隔膜式、氣囊式等。4.2 用途有兩種類型的蓄電池。(1)當?shù)退龠\動負載流量小于液壓泵流量、液壓泵冗余流量累加器,當負載流量大于液壓泵流量的需求,從蓄電池集流體,以彌補短缺的液壓泵的流量。(2)當停機,但仍需要保持一定的壓力,能阻止泄漏的液壓泵和蓄電池的補償系統(tǒng),為了保證系統(tǒng)的壓力。蓄電池也可以用來吸收壓力脈動的液壓泵或吸收液壓沖擊壓力系統(tǒng)。蓄電池可以使用壓縮氣體的壓力,重錘或彈簧生產(chǎn),因此蓄電池分為氣體類型、錘式和彈簧。氣體和液體氣體蓄電池直接接觸,稱為接觸,其結構簡單,容量大,但容易在氣液混合,通常用于液壓機。氣體和液體接觸不叫隔離類型,常用的皮和隔膜隔離,皮的大量的體積變化,隔膜體積變化量很小,通常用于吸收壓力脈動。重錘式容量較大,常用于軋機等系統(tǒng),能源存儲。4.3分類功能蓄能器的種類主要分為:彈簧式和充氣式。蓄能器的功用(1)短期大量供油(2)系統(tǒng)保壓(3)應急能源(4)緩和沖擊壓力(5)吸收脈動壓力蓄能器的功能主要分為存儲能量、吸收液壓沖擊、消除脈動和回收能量四大類。第一類:儲存能量。這種功能在實際使用,可以分為:1)作為輔助電源,減少裝機容量;(2)補償泄漏;(3)熱膨脹補償;(4)對應急電源;(5)恒壓油源。第二類:吸收液壓沖擊。換向閥換向突然突然停止,執(zhí)行機構運動將在液壓系統(tǒng)沖擊壓力,系統(tǒng)壓力在短時間內(nèi)迅速增加,造成儀器的損壞,組件和密封裝置,并產(chǎn)生振動和噪聲。為了確保吸收的影響,蓄電池應設置在碰撞點附近,所以蓄電池通常是安裝在控制閥和液壓缸的影響源之前,是一個很好的方式來吸收和緩沖液壓沖擊。第三類:消除脈動,降低噪音。柱塞泵和液壓系統(tǒng),少量的柱塞泵流量周期變化使系統(tǒng)產(chǎn)生振動??梢蕴峁┬铍姵?大量吸收脈動壓力和流量的能量,在流量脈動的一個周期。瞬時流量高于平均的一部分石油被蓄能器吸收,低于平均流量的一部分蓄電池,它吸收的能量脈沖,降低紋波,減少損傷敏感的儀器和設備常規(guī)精液。第四類:回收能量。與回收能源蓄電池是目前更多的研究領域。能量回收可以提高能源的利用率是節(jié)能的重要途徑。蓄電池可以儲存能量,因為它已經(jīng)結束,所以可以用來回收多種功能,位置勢能。該領域的主要研究有:(1)回收車輛制動能量;(2)回收工程機械動臂機構的人;(3)復蘇的液壓挖掘機轉(zhuǎn)臺制動能量;(4)回收石油修井機和鉆機的下落的重力勢能;(5)回收電梯向下的重力勢能。沈陽化工大學科亞學院學士學位論文 第五章 液壓系統(tǒng)性能的驗算第五章 液壓系統(tǒng)性能的驗算5.1 系統(tǒng)沖擊問題系統(tǒng)在動態(tài)試驗的過程中 ,從蓄能器和泵源獲 得的峰值流量為 1 704 L /min,如果按此指標來設計 整個系統(tǒng) ,顯然不經(jīng)濟也沒有必要。但如果僅僅按照 油泵的流量來選擇管道、過濾器和冷卻器等 ,則峰值 流量將會對系統(tǒng)產(chǎn)生沖擊和破壞。為此 ,在系統(tǒng)的回 油路增設了蓄能器組。 蓄能器組的最高工作壓力為 回油路管道和元件能耐受的最高壓力。設冷卻器進油管通徑為 50 mm ,油流速度按 2 m /s計算 ,則 5 s內(nèi)通過的流量為 19. 6 L,作動器在 5 s內(nèi)排出的最大流量為V =1704 0. 64 /60 5 =90. 88 (5-1)需要蓄能器的有效容積為V = 90. 88 - 19. 6=71. 28 (5-2)選用氣囊式折合型蓄能器。 出口的壓力不超過0. 63 M Pa,即蓄能器的最高工作壓力為 P1 = 0. 63 M Pa,最低工作壓力為油液回油過程中克服管道、冷 卻器、過濾器等需要的壓力 ,其中過濾器的阻力為最 主要的部分 ,取 P3= 0. 35 M Pa,則蓄能器充氣壓力為:P1=(0.80.85)P3=0.28*106 (5-3)則蓄能器的總?cè)莘e為: = (5-4)選取 3個容積為 100 L的蓄能器可以滿足要求。 這樣可以避免回油管路中流量過大而造成的對低壓 元器件的破壞。5.2 主機設計主機安裝阻尼器和測試樣本,結構原理如圖2所示。主機為臥式結構,主要部件包括前軸承、軸承、移動橫梁后,指導的帖子,和夾緊缸體執(zhí)行機構,等。試驗過程中,阻尼器安裝在連接法蘭之間。在前軸承、軸承、橫梁、導柱,形成一個剛性的盒子。阻尼力等于框架的內(nèi)力,兩個指南列和橫梁前后軸承,軸承是主要的承載部件,因此,變形很容易控制,低要求的平臺和基礎。阻尼器的自尊的執(zhí)行機構承擔。通過磁位移傳感器位移測量,內(nèi)置的致動器的活塞。輪輻式負荷傳感器,安裝阻尼器和梁之間。執(zhí)行機構由伺服閥控制。伺服閥和閥塊安裝在傳動裝置上,以減少連接的閥門和執(zhí)行機構之間的距離,提高頻率響應。圖5.1試驗臺主機結構原理圖主機的設計,以確保足夠的剛度,有利于提高測試精度。同時,主機系統(tǒng)的固有頻率,以避免工作頻率,以免引起共鳴。這些是主機的總體設計需要注意的問題。在主人面前,軸承,軸承將固定的驅(qū)動器,梁可以沿導柱滑動,并根據(jù)需要調(diào)整測試空間。調(diào)整位置后,依靠液壓夾緊裝置將梁和柱是固定的。與普通螺母固定方式相比,液壓夾緊空間調(diào)整更方便,導柱兩光束同時,消除預應力安裝時無需添加線程間隙。液壓夾緊可靠,不是由于選擇高工作壓力和過度的夾緊缸和浪費資源,液壓夾緊裝置的合理設計是至關重要的。橫梁與導向柱的夾緊過程如圖 3所示 ,圖 3( a) 為初始狀態(tài) ,假設導向柱正好在孔的中心。當橫梁受到夾緊力 P 的作用后 ,橫梁產(chǎn)生懸臂 梁變形 ,最先變形的是橫梁最薄弱的位置 ,即沿孔的 中心縱向截面處。 夾緊的第一步是橫梁和導向柱兩 點接觸 ,如圖 3( b)所示。由于導向柱的一端基本處于自由狀態(tài) ,在夾緊 力的進一步作用下 ,立柱被推向右端 ,最終近似為圖 3( c)所示的 3點夾持狀態(tài)。 此時導向柱的受力狀況 如圖 3( d)所示。橫梁受到的力與圖 3( d)所示的力方 向相反。選取夾緊缸的直徑為 D,活塞桿的直徑為 d ,則夾緊缸產(chǎn)生的夾緊力為 F = ( D2 - d2 ) (5-5)選擇橫梁與導向柱之間的最大配合間隙為 y。 在橫梁與導向柱處于夾緊狀態(tài) (如圖 3( c) )時 ,沿作 用力 P 的方向橫梁的變形量約為 2y ,此變形量需要消耗一部分夾緊力 Ft ,根據(jù) 2y= 可計算得到 Ft ,其中: I 為橫梁的極慣性矩 ,則作用在導向柱上的力 為 P= F- Ft。對橫梁的最先變形點 B 取力矩 ,可得 MB =0 Pl = (5-6)則每個立柱每側(cè)的正壓力 N =p (5-7)夾緊力為橫梁與導向柱產(chǎn)生的摩擦力為 Ff = 2Ff= 2_ N (5-8)其中: _ 為橫梁與導向柱間的摩擦系數(shù)。 根據(jù)此計算方法 ,液壓夾緊裝置選擇每側(cè) 3個 夾緊缸 ,每個夾緊缸產(chǎn)生的夾緊力為 0. 46 106 N , 則兩根導向柱產(chǎn)生的夾緊力為 F = 6 Ff =2. 22 106 =2 220 kN (5-9)取摩擦系數(shù)為 0. 1,則橫梁與導向柱之間的摩擦 力為 2 220 kN ,可以滿足 1 000 kN 試驗力的要求 (安 全系數(shù)為 2. 22)。圖5.2夾緊過程示意圖沈陽化工大學科亞學院學士學位論文 第六章 伺服液壓缸機械部分設計 第六章 伺服液壓缸機械部分設計6.1 試驗臺的技術指標為了在一定頻率的交變載荷作用下,進行液壓阻尼器的動態(tài)性能試驗,測試液壓阻尼器在振動狀態(tài)下的動態(tài)響應特性,本試驗臺須達到以下技術指標: 1)振動方向:水平雙向;2)最大動態(tài)載荷:1000KN;3)工作頻率范圍:0133Hz;4)最大振幅:33Hz時,3mm;5)液壓缸有效行程:25mm(活塞中位固定);6)試驗波形:正弦波、三角波和方波;7)被測阻尼器最大質(zhì)量:750Kg;8)系統(tǒng)具有數(shù)據(jù)采集、存儲、查詢和打印等功能。6.2 供油壓力的選擇供油的選擇是非常重要的,石油供應的壓力,靜態(tài)和動態(tài)參數(shù)的液壓動力元件和液壓設備的大小,還與功率組件和負載匹配是否合理。選擇高石油供應的壓力,輸出功率相同的情況下,可以減少液壓設備和管道的大小和質(zhì)量,使液壓削弱了系統(tǒng)結構緊湊,與空氣中的油混合體積彈性模量的影響,有利于改善系統(tǒng)速度,選擇低油壓,可以降低設備成本,有利于延長液壓系統(tǒng)和元件的壽命,泄漏的生活,低溫度、低噪音和易于維護。液壓系統(tǒng)的供油壓力與液壓設備的工作環(huán)境、精度要求等有關,常用的液壓系統(tǒng)供油壓力推薦如表6.1所示表6.1各類液壓常用的供油壓力根據(jù)本液壓振動試驗臺的具體工作情況,參考現(xiàn)有同類試驗臺的供油壓力,選擇供油壓力B=3lMPa。液壓缸主要參數(shù)的確定 液壓缸是試驗臺的執(zhí)行元件,負責輸出位移、力、速度等運動參量。液壓缸的設計在滿足動態(tài)出力、位移行程要求的基礎上,還要考慮液壓動力源的設計、伺服閥的匹配等系統(tǒng)因素,以及解決液壓缸的安裝、連接、密封等具體問題。液壓缸按基本結構可分為活塞缸(單桿活塞缸和雙桿活塞缸)、柱塞缸和擺動缸(單葉片式和雙葉片式)。按作用方式可分為單作用和雙作用兩種,單作用缸是一個方向的運動靠液壓油驅(qū)動,反向運動必須靠外力(如彈簧或重力)來實現(xiàn);雙作用缸是兩個方向的運動均靠液壓油驅(qū)動由于本試驗臺提供水平雙向振動,水平兩方向須靠液壓油驅(qū)動,因而本試驗臺采用雙活塞桿雙作用式液壓缸。接著對試驗臺液壓缸進行設計。伺服閥輸出功率為最大值時的負載壓力最與供油壓力只的關系為:式(2-1)可以計算此時的負載壓力PL=21MPa上式中,F(xiàn)為最大動態(tài)負載力。根據(jù)試驗臺的技術指標可得,F(xiàn)=1000KN。經(jīng)由式(2-2)計算得 A=47619mm2??紤]到本試驗臺振動方向為水平雙向,正負方向輸出的特性要求一致,因而采用雙作用雙桿液壓缸。按GB/T2348-1993液壓缸缸內(nèi)內(nèi)徑和活塞桿直徑系列的標準,對液壓缸內(nèi)徑D、活塞桿直徑d進行圓整,確定液壓缸內(nèi)徑D=320mm,活塞桿直徑d=200mm。這樣液壓缸的實際作用面積為: A=(D2-d2)/4(2.經(jīng)計算得液壓缸實際作用面積A=48984mm。由上可得,液壓缸主要參數(shù)為: 液壓缸內(nèi)徑D:320mm; 活塞桿直徑d:200mm; 活塞行程三:50mm。結合考慮試驗臺液壓缸的安裝、連接、密封等情況,完成試驗臺液壓缸的設計,其結構示意如下圖所示:圖6.2 伺服液壓缸裝配圖電液伺服閥選擇液壓振動試驗臺的核心組件,既是電液轉(zhuǎn)換元素和功率放大器,試驗臺的設計是很重要的。電液伺服閥的輸入微小電信號的大功率液壓壓力和流量的輸出。伺服閥試驗臺的電氣與液壓系統(tǒng)可以連接的一部分,實現(xiàn)電動和液壓信號轉(zhuǎn)換和液壓執(zhí)行機構(活塞桿)控制。首先,根據(jù)試驗臺的技術指標計算活塞的最大速度Vmax“,其計算公式為: Vmax=APP=2AP=fP (6-1)式中,AP為頻率最大時的最大振幅,國P為頻率最大時的角速度,為試驗最大頻率。本試驗臺中,AP=3mm,fP=33Hz式(2-4)可得Vmax=622mm/s。其次,計算試驗臺系統(tǒng)的最大負載流量Qmax,由此確定伺服閥的選型。最大負載流量級的計算如下: Qmax=Avmax (6-2)其中,液壓缸實際作用面積A=48984mm2,最大速度Vmax=622mm/s,計算得Qmax=1826L/min最后,根據(jù)最大負載流量Qmax。及系統(tǒng)供油壓力Ps,并參考美國MOOG公司的伺服閥技術資料,最終選定MOOG公司的D792-S99JR06VSA0-P型伺服閥。該閥的額定流量為1000Lmin、額定壓力為35MPa,結構圖如圖23所示MOOG公司 D792 - S99JR06vSA0- P是一個兩級伺服閥,閥芯。閻套結構,主閥芯提供了一個線性位置閉環(huán)反饋控制。主要的燕在關閉位置四通閥的產(chǎn)出水平。導閥是機械反饋式兩級伺服閥,雙噴嘴擋板閥的流量控制。伺服閥將放大器和相關路集成到身體,使設計簡單,耐用,可以提供可靠和長期運行順利??紤]到最大負載流Qmax = 1828升/分鐘,為了滿足交通系統(tǒng)的需求,測試臺上2臺 D792 S99JR06VSA0 - P型伺服燕并行操作。提供線性的主閥閥芯閉環(huán)控制,通過伺服控制器的信號設置函數(shù)修正階段兩個伺服閥操作,確保兩個閥高頻率的同步操作條件。液壓泵的選擇 液壓泵作為液壓系統(tǒng)的動力元件,將原動機(電動機、柴油機等)輸入的機械能(轉(zhuǎn)矩和角速度)轉(zhuǎn)換為液壓能(壓力和流量)輸出,為系統(tǒng)的執(zhí)行元件提 供液壓油。因而液壓液壓控制系統(tǒng)的設計 作為現(xiàn)代機械設備實現(xiàn)傳動與控制的重要技術手段,液壓技術在國民經(jīng)濟各領域得到了廣泛的應用。與其他傳動控制技術相比,液壓技術具有能量密度高配置靈活方便調(diào)速范圍大工作平穩(wěn)且快速性好易于控制并過載保護易于實現(xiàn)自動化和機電液一體化整合系統(tǒng)設計制造和使用維護方便等多種顯著的技術優(yōu)勢,因而使其成為現(xiàn)代機械工程的基本技術構成和現(xiàn)代控制工程的基本技術要素。 液壓鑿巖機是礦上機械的一種,作為開采礦山的主要設備,適用于各類礦石的開采。本文根據(jù)液壓鑿巖機的用途特點和要求,利用液壓傳動的基本原理,擬定出合理的液壓系統(tǒng)圖,再經(jīng)過必要的計算來確定液壓系統(tǒng)的參數(shù),然后按照這些參數(shù)來選用液壓元件的規(guī)格和進行系統(tǒng)的結構設計。液壓鑿巖機的液壓系統(tǒng)呈長方形布置,外形新穎美觀,動力系統(tǒng)采用液壓系統(tǒng),結構簡單、緊湊、動作靈敏可靠。該機并設有腳踏開關,可實現(xiàn)半自動工藝動作的循環(huán)。液壓傳動和氣壓傳動稱為流體傳動,是根據(jù)17世紀帕斯卡提出的液體靜壓力傳動原理而發(fā)展起來的一門新興技術,是工農(nóng)業(yè)生產(chǎn)中廣為應用的一門技術。如今,流體傳動技術水平的高低已成為一個國家工業(yè)發(fā)展水平的重要標志。第一個使用液壓原理的是1795年英國約瑟夫布拉曼(JosephBram,以水壓機的形式將其應用于工業(yè)上,誕生了世界上第一臺水壓機。1905年他又將工作介質(zhì)水改為油,進一步得到改善。我國的液壓工業(yè)開始于20世紀50年代,液壓元件最初應用于機床和鍛壓設備。60年代獲得較大發(fā)展,已滲透到各個工業(yè)部門,在機床、工程機械、冶金、農(nóng)業(yè)機械、汽車、船舶、航空、石油以及軍工等工業(yè)中都得到了普遍的應用。當前液壓技術正向高壓、高速、大功率、高效率、低噪聲、低能耗、長壽命、高度集成化等方向發(fā)展。同時,新元件的應用、系統(tǒng)計算機輔助設計、計算機仿真和優(yōu)化、微機控制等工作,也取得了顯著成果。目前,我國的液壓件已從低壓到高壓形成系列,并生產(chǎn)出許多新型元件,如插裝式錐閥、電液比例閥、電液伺服閥、電業(yè)數(shù)字控制閥等。我國機械工業(yè)在認真消化、推廣國外引進的先進液壓技術的同時,大力研制、開發(fā)國產(chǎn)液壓件新產(chǎn)品,加強產(chǎn)品質(zhì)量可靠性和新技術應用的研究,積極采用國際標準,合理調(diào)整產(chǎn)品結構,對一些性能差而且不符合國家標準的液壓件產(chǎn)品,采用逐步淘汰的措施。由此可見,隨著科學技術的迅速發(fā)展,液壓技術將獲得進一步發(fā)展,在各種機械設備上的應用將更加廣泛。本機器適用于各種各樣礦山的開采等,本機器具有獨立的動力機構和電氣系統(tǒng)。采用按鈕集中控制,可實現(xiàn)調(diào)整、手動及半自動三種操作方式。 19世紀問世以來發(fā)展很快,液壓機在工作中的廣泛適應性,使其在國民經(jīng)濟各部門獲得了廣泛的應用。由于液壓機的液壓系統(tǒng)和整機結構方面,已經(jīng)比較成熟,目前國內(nèi)外液壓機的發(fā)展不僅體現(xiàn)在控制系統(tǒng)方面,也主要表現(xiàn)在高速化、高效化、低能耗;機電液一體化,以充分合理利用機械和電子的先進技術促進整個液壓系統(tǒng)的完善;自動化、智能化,實現(xiàn)對系統(tǒng)的自動診斷和調(diào)整,具有故障預處理功能;液壓元件集成化、標準化,以有效防止泄露和污染等四個方面。作為液壓機兩大組成部分的主機和液壓系統(tǒng),由于技術發(fā)展趨于成熟,國無較大差距,主要差別在于加工工藝和安裝方面。良好的工藝使機器在過濾、冷卻及防止沖擊和振動方面,有較明顯改善。在油路結構設計方面,國內(nèi)外液壓機都趨向于集成化、封閉式設計,插裝閥、疊加閥和復合化元件及系統(tǒng)在液壓系統(tǒng)中得到較廣泛的應用。特別是集成塊可以進行專業(yè)化的生產(chǎn),其質(zhì)量好、性能可靠而且設計的周期也比較短。近年來在集成塊基礎上發(fā)展起來的新型液壓元件組成的回路也有其獨特的優(yōu)點,不需要另外的連接件其結構更為緊湊,體積也相對更小,重量也更輕無需管件連接,從而消除了因油管、接頭引起的泄漏、振動和噪聲。邏輯插裝閥具有體積小、重量輕、密封性能好、功率損失小、動作速度快、易于集成的從70年代初期開始出現(xiàn),至今已得到了很快的發(fā)展。我國從液壓機具有點動、手動和半自動等工作方式,操作方便;The design of hydraulic control system Beijing Institute of Aviation Technology Liu xin Ya introduced a concurrent engineering, agile manufacturing and sophisticated production, and other advanced manufacturing technology and the characteristics of the development of machine tools in the portfolio of applications, how to deepen and extend the application of specific measures.In the machine tool industry, with the social demands of the continuous improvement of products, along with the growing competition in the market to meet user requirements, including the improvement of product quality, shorten production cycles, reduce costs, improve service and win market has become a breakthrough. In order to achieve this goal and win market, it should be the introduction of modern and advanced manufacturing technology: concurrent engineering, agile manufacturing and sophisticated production, in order to promote the development of combination machine.Concurrent Engineering is also known as concurrent engineering, integrated, parallel to optimize product design and its related processes (including manufacturing and support) system approach, which guide the product development staff began to consider a product from concept to design to the demise of throughout the life cycle of all the factors, including quality, cost, programming and user needs.Concurrent Engineering is the first to shorten product development cycles as a means to develop. Products will be characterized by the development, production engineering involved in the acts broken down into a series of tasks, such as market analysis, design, process design, production plans and equipment purchases, processing, quality assurance, testing and after sales service. These sub-tasks as far as possible and consider synchronous parallel to achieve improved design to shorten the cycle and improve quality, reduce costs, optimize the design purpose. It stressed that integrated, coordinated and parallel, namely: (1) management, design, production, and service of all project-related personnel and product information integration as a whole, and stressed that all relevant departments and the interests of the overall goal line (2) to the establishment of a competent and reasonable charge of the project personnel structure of the working group coordinated management model, by the Working Group in the ministries responsible for project elements, and the promotion of the coordination of tasks, (3) parallel processing stages of the work. According to the project in the different tasks of the linkages between the different ministries mandate of the elements of the work process can be completely overlap or duplication. In accordance with these principles, formulate a reasonable, and optimize the work plan, and the location in which the necessary settings assessment, the Working Group by the project implementation so that all sub-tasks in parallel, to move forward in an orderly manner, so as to ensure the smooth implementation of the whole project .According to the traditional methods of work, the work of the various stages in a row serial. In such a product development approach, divorced from each other at various stages, are not related, resulting in increased design error, and difficult to discover such a design rework, to lengthen the development cycle, adding to the costs.Parallel working methods used, the process will be integrated with parallel consideration, the work can be carried out duplication. Problems can be promptly coordinate the changes so that the follow-up stage left to increase the difficulty of correction And costs. Thus, the application of concurrent engineering can significantly shorten the product development cycle, reduce costs, it is suitable for the development of professional portfolio machine.Concurrent engineering methods will be applied to product development, the effect was very significant. March 1997, Beijing Institute of Aviation Technology with a motorcycle design and manufacturing plants to sign the 6-crank machine project contract for delivery end of the year, and the requirements of machine tools in the past quite different. In the project using a concurrent engineering approach, in parallel, cross-operation , greatly reducing the design, manufacture period, the successful completion of the tasks.Parallel development of the combination of machine specific methods are:(1) the establishment of a multi-composed of professionals to develop working groups. By the Working Group of the specific part of the implementation of the project, members of the Working Group in collaboration division of duties, timely and coordinated in order to achieve optimization of the design. Such as a machine tool demand in the clamping fixture parts to the process of floating, if separate consideration from the mechanical structure to meet this requirement more difficult, complex structure of the fixture. Later, with the hydraulic design of electrical control and coordinate, control procedures proposed amendments to change the order clamping action, adjusting the hydraulic pressure of solutions to meet the requirements of the clamping.(2) in the formulation of programmes, the signing of the contract stage, on the preliminary identified a number of standard components.(3) Multiple Multi-accreditation programme. Machine Tool Technology in determining the overall programme, key components in the overall design process, many times by the Solidworks committee to review the design plan, and put into production before the user in the design plan joint trials. Thus, from the design to take into account the beginning of a process design, tooling design, manufacturing, assembly and other downstream various stages of debugging problems that may arise, thus greatly reducing the number of design changes Rated meet user requirements, to achieve design best.(4) a design pre-release method. Machine overall plans in a formal drawing ago, has been released in stages set by the main structure and the major components of data, process design, tooling design can be carried out ahead of schedule. In the design of the machine tool to determine some components such as fixtures, tools such as the coordination of size, and at the same time began to design and tool fixture, and, also identified slider, mobile workstations and other components, these components have the choice as far as possible Standard components, in the design of its operation will be completed. And the overall design of the various components such as fixtures, and timely coordination between the tool, linked to changes in the size of each other timely coordination so that the size of other relevant drawings are promptly corrected.(5) components in the design of the processing cycle can be long specific parts such as folders, such as casting stereotypes as soon as possible to advancing the process design, production.(6) completion of the various components of a design, process design and ready to enter the production stage. Therefore, the various components of the parts is in the workshop, parallel processing.Adopt this approach, the Working Group 4 were used only four weeks time on the part of generic components such as the slider, mobile platforms and power first went into operation at the same time, the completion of the mechanical design of the machine and outsourcing of orders. Machine tool production process, the various components in the Beijing Institute of Aviation Technology Association, and several manufacturers at the same time. In the machine, installation and debugging, but also several machine at the same time, through these work, and machine tools for the timely delivery of valuable time.Agile manufacturing in the United States of the Caspian Sea, the 21st century manufacturing strategy in the report of a new manufacturing paradigm. After development, the United States lacocca Institute will be defined as: a company that is agile in the market for the unpredictable changes in the competitive environment in the development and prosperity of a capability, that is rapidly changing global market a rapid response capability, with the company computer network and the global production system, the market, competitors to link up in the high-quality, high-performance, low-cost, customer product configuration settings, such as user demand-driven market situation demonstrated a capability. Characterized by the flexible production technology, flexible organization management and professional skills of the staff have integrated into a coordinated, interconnected systems, in order to achieve the strategic goal of reunification, the same industry in different enterprises through joint infrastructure links, past life-and-death competition will become friendly and cooperative competition, thereby changing market faster response. Therefore, this technology is suitable for the development of professional portfolio machine.(1) promote the Agile first modular products, reflected in the composition of the machine is in the machine tool components and the standardization of serialization. Crankshaft Machine Tool in the development and design, can greatly shorten the design cycle, the application of concurrent engineering is a factor, large number of standard components, the application of common components is a key element.(2) In the Agile Manufacturing, must reflect the people and organizations is the most valuable asset. In the production of large quantities, people are always Solidworks solution as manufacture and sale of the crux of the problem, and in Agile Manufacturing, the best use of people is the key to solve the problem, technology is only a method or means. Therefore, the need for the Project Working Group organizational model advocated hard working, give full play to their initiative.Sophisticated production is the United States in the 1990s, Japans Toyota Motor Corporation summed up production management methods on the basis of summing up by the production. It stressed that by improving the production of enterprises in the management of the activities, including the efficiency of various activities and cost accounting, to achieve the fastest speed of response to the market, the lowest cost of production, the optimal product design to design and Manufacturing of products needed by the market. Its features are user-God, a people-centred, as a means to streamline, to zero defect goal.Can be seen from the above analysis, and advanced manufacturing technology in the Beijing Institute of Aviation Technology Portfolio machine has been developed in a number of applications, but still need to further deepen and extend the application. In later work, Should pay attention to the following aspects:(1) Working Group on the further implementation of the project model, a responsibility to the people, by the use of concurrent engineering group responsible for the completion of the way from the machine tool technology programme to design, manufacture, testing and delivery of the work of the staff at the same time strengthen the knowledge and skills training, keep track machine tool industry at home and abroad combination of the latest developments.(2) market changes and the development of pre-study plan at the same time maintain close ties with users, users who regularly visit provides its users with quality after-sales service, and equipment operation and understanding of user needs, in order to improve the design.(3) high-quality products to win customers. Machine Tool in the development portfolio, in addition to enhancing the sense of quality, the new technology, the application of new technology in the market is also an important means. Now users generally require machine efficiency, flexibility, and adapt to small quantities and variety of processing. Portfolio Tool to enhance the efficiency of production and increase in the design should be cutting speed, the use of advanced tools, centralized processing consider three aspects.(4) attention to the development of products can be reconstructed so as to achieve the structure of modular machine. In the design, the use of group technology, and promote common machine combination of the development and application of functional modules, can be flexible coordinates NC unit model.(5) the application of agile manufacturing technology, the establishment of an effective Union dynamic virtual forms of cooperation. Further strengthen and outsourcing of production plants and factories, HS cooperation. Make full use of existing community technology, information equipment and personnel resources, strong - strong alliance, complementary advantages, the use of the virtual company model to expand our production capacity.(6) In combination with the design of machine tools to further promote the production of computer and information network technology applications. Promote the application of technology, the realization of a map designed to establish works Design environment.(7) to further strengthen Solidworks cooperation and exchanges and enhance my portfolio in the machine tool industry and the status of visibility, at the same time actively explore new markets and customers. Efforts should be made to explore the international market, such as the Toyota Motor Co., Japans exports to the body of the cars engine of vertical machining deep hole biaxial deep hole drilling machine, I have a combination of machine to enter the international market and made a good start.12
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