【摘要】：超塑成形技術(shù)是指利用金屬在特定加工條件下呈現(xiàn)出的低強(qiáng)度、大伸長(zhǎng)率的特性對(duì)金屬進(jìn)行加工,以獲得尺寸精密、形狀復(fù)雜以及晶粒組織均勻且細(xì)小的薄壁制件,是先進(jìn)制造技術(shù)的一種。隨著我國(guó)航天事業(yè)的發(fā)展和國(guó)防科技的進(jìn)步,大噸位超塑成形設(shè)備的研究顯得越來(lái)越重要。超塑成形設(shè)備中的氣壓控制系統(tǒng)會(huì)影響零件成形的精度,尤其在大噸位超塑成形設(shè)備中,材料的形變會(huì)使氣腔體積發(fā)生較大變化,導(dǎo)致系統(tǒng)難以實(shí)現(xiàn)對(duì)氣腔內(nèi)氣壓的準(zhǔn)確控制。本文重點(diǎn)研究了大噸位超塑成形設(shè)備的氣壓控制方法,進(jìn)而開發(fā)了一種具有可視化操作與遠(yuǎn)程控制功能的氣壓控制系統(tǒng)。分析了超塑成形設(shè)備氣壓控制系統(tǒng)的需求,利用機(jī)理法構(gòu)建了氣壓控制系統(tǒng)中上、下氣腔的數(shù)學(xué)模型,利用實(shí)驗(yàn)法修正了模型結(jié)構(gòu)并確定了模型參數(shù),推導(dǎo)出了氣腔的時(shí)變模型。研究了傳統(tǒng)PID控制、神經(jīng)網(wǎng)絡(luò)控制、模糊控制以及模糊PID控制的理論,利用MATLAB/Simulink仿真軟件分別搭建了針對(duì)固定體積的氣腔模型與體積勻速膨脹10倍的氣腔模型的控制系統(tǒng)。研究了不同控制方法下系統(tǒng)的階躍響應(yīng)與梯形波信號(hào)響應(yīng),仿真結(jié)果的對(duì)比表明,將模糊PID控制應(yīng)用到本系統(tǒng)時(shí),系統(tǒng)階躍響應(yīng)與梯形波信號(hào)響應(yīng)的超調(diào)量更小,調(diào)整時(shí)間更短,符合控制要求。完成了氣壓控制系統(tǒng)的硬件及軟件設(shè)計(jì),硬件設(shè)計(jì)主要包括需求分析、總體設(shè)計(jì)、硬件選型與基于以太網(wǎng)通訊協(xié)議的系統(tǒng)搭建。軟件設(shè)計(jì)主要包括基于組態(tài)王的主控界面的設(shè)計(jì)、基于FTP傳輸協(xié)議的文件備份的設(shè)計(jì)和基于MATLAB軟件的氣壓控制方法的設(shè)計(jì)。其中,主控界面主要包括氣壓參數(shù)設(shè)置界面、實(shí)時(shí)狀態(tài)顯示界面、報(bào)警界面和歷史數(shù)據(jù)報(bào)表界面等。基于OPC通信技術(shù)實(shí)現(xiàn)了氣壓控制系統(tǒng)中各環(huán)節(jié)的數(shù)據(jù)交換,將模糊PID控制方法應(yīng)用到了實(shí)際的超塑成形設(shè)備中,并對(duì)該設(shè)備的氣壓控制系統(tǒng)進(jìn)行了功能測(cè)試與精度測(cè)試。加壓測(cè)試證明了基于模糊PID控制的氣壓控制系統(tǒng)具有較高的準(zhǔn)確性和實(shí)時(shí)性,零件加工測(cè)試表明了應(yīng)用本系統(tǒng)的超塑成形設(shè)備加工出的零件符合工藝要求。
[Abstract]:Superplastic forming technology is to use the characteristics of low strength and large elongation of metal under certain processing conditions to process metal to obtain thin wall parts with precise size, complex shape and uniform and fine grain structure. Is a kind of advanced manufacturing technology. With the development of China's aerospace industry and the progress of national defense science and technology, the research of large-tonnage superplastic forming equipment is becoming more and more important. The air pressure control system in the superplastic forming equipment will affect the forming accuracy of the parts. Especially in the large-tonnage superplastic forming equipment, the deformation of the material will make the volume of the gas chamber change greatly, which makes it difficult for the system to realize the accurate control of the air pressure in the gas chamber. In this paper, the air pressure control method of large-tonnage superplastic forming equipment is studied, and a kind of air pressure control system with visual operation and remote control function is developed. The requirement of air pressure control system of superplastic forming equipment is analyzed. The mathematical model of upper and lower air chamber in the air pressure control system is constructed by using mechanism method. The model structure is modified by the experimental method and the model parameters are determined. The time-varying model of the gas chamber is derived. The theories of traditional PID control, neural network control, fuzzy control and fuzzy PID control are studied. The control systems for the fixed volume gas cavity model and the uniform volume expansion 10 times gas cavity model are built by using MATLAB/Simulink simulation software. The step response and trapezoidal signal response of the system under different control methods are studied. The simulation results show that the overshoot between the step response and the trapezoid signal response of the system is smaller when the fuzzy PID control is applied to the system. The adjustment time is shorter and meets the control requirements. The hardware and software design of the pneumatic control system is completed. The hardware design mainly includes the requirement analysis, the overall design, the hardware selection and the system construction based on Ethernet communication protocol. The software design mainly includes the design of the main control interface based on Kingview, the file backup based on FTP transfer protocol and the air pressure control method based on MATLAB software. Among them, the main control interface mainly includes air pressure parameter setting interface, real-time state display interface, alarm interface and history data report interface. Based on the OPC communication technology, the data exchange in each link of the pneumatic control system is realized. The fuzzy PID control method is applied to the actual superplastic forming equipment, and the function and precision of the pneumatic control system of the equipment are tested. The pressure test proves that the air pressure control system based on fuzzy PID control has high accuracy and real-time performance. The part processing test shows that the parts processed by the superplastic forming equipment of this system meet the requirements of technology.
【學(xué)位授予單位】：哈爾濱工業(yè)大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG305;TH138

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