高速数字多功能土槽试验台车的设计
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以LabVIEW为合成橡胶弹簧试验机的液压控制博尔达 王旭永(机电研究所,上海交通大学,上海,200030,中国)摘录:该应用程序是一个液压缸同步运动控制运动。本文的主要目的是显示一个短的编程代 码中的LabVIEW来控制两个气缸与自动控制程序仅使用从压力传感器和线性位移传感器的模拟输入和从所述液压阀的数字输出的运动。这是专为这种合成橡胶弹簧试验机的试验之一。关键词:橡胶弹性;多层橡胶弹簧;层叠式顺序结构文献标识码:A简介合成橡胶试验机是检测地铁车的橡胶弹簧。实际使用这台机器是为了使预防维护,这样我们就可以准确了解橡胶弹簧的消费生活。每一个橡胶弹簧是一种周期或工作时间的主题,这一时期的弹簧橡胶测试必须根据制造商的规格,这种试验机是被用来测试四种橡胶弹簧;用于此测试的一个是所谓的多层橡胶弹簧。本试验的主要特征,与其它橡胶弹簧相比,是,这是结合了两个气缸的力成为唯一一个:一个垂直和一个水平。1. 结构组件这种试验机的结构组件是非常简单的。该测试平台具有上框架,移动框架,下框架,装框架试件垂直柱,卡盘框架支撑上的工作平台,液压系统安装下至工作平台。该平台最高液压为150KN,它是一个简单的机械结构,只需使用两个垂直列来支持它。同时,这个设计是在多层橡胶弹簧元件的刚性横向测量条件下。此外,也有不同的试件,测量是不一样的。这种卧式液压缸是固定到框架结构里的。该基地的高度可以通过试验件根据试验只是改变底座支撑来修改。它的垂直压力传感器被固定在垂直圆柱的头部。垂直缸的运动总是向下推施加压缩力成试片。垂直传感器被安装在底框结构中的一个固定位置正好平行于垂直列。垂直力传感器被安装在垂直缸的头部的基极,水平位移传感器安装在水平筒的右侧的这个底部(查看图1)的背面。一个多层橡胶弹簧的弹性试验期间,水平力必须申请65 kN然后水平缸必须移位土30毫米,在这个过程中,我们获得了从模拟信号的水平缸的力传感器,然后我们要衡量的橡胶弹簧常数K为使用此公式K =(F1 + F2)/ 60(牛顿/毫米)的这个原因。图1试验机的概貌1-上部框架;2-垂直缸;3-移动框架;4-垂直力传感器;5-力柱;6-垂直位移传感器;7-试件;8-工具板;9-下部框架;10-组件框架;11-水平力传感器;12-卧式圆筒;13-水平位移传感器2.压力系数压力系统的原理可以被视为在图2系统使用两个液压泵连接电机,所述液压泵不超16兆帕,6毫升/转和16毫升/转流的工作压力。泵站设计有一个压力表计,过滤器等。泵的工作压力(水平和垂直气缸)是通过四个电磁阀分开。泵1被设计为三个不同的工作压力(150,100,50 KN)。因此,为测定试验高频即液压泵的速度可以用一个阀门来调节。试验加载速度约为1mm/s,这也是在卸载工艺流程中。速度可以调整到大约2mm/ s,系统具有两个阀来关闭,这些也是用于保护液压泵。液压系统的示意图,可以理解在图2中,电磁阀的控制和改变可以在表1可以看出。图2液压原理图1,2,3,4-减压阀;5,6-电磁整流阀;7,8-单向收缩药;9-流量控制的单向阀,电磁阀;10,11,12-整流器;13-单向阀;14-闸阀;15-过滤器;16-压力计;17-空气滤清器 表1液压系统动作图标准态 主缸快速前进 主缸缓慢前进 主缸缓慢返回 主缸快速返回 卧式液压缸左前进 卧式液压缸右前进 主缸液压1 主缸液压2 主缸液压3 3.采集卡和驱动控制对于数据的控制和采集我们使用了两个不同的卡:一个模拟卡收集从传感器的信号以及另一个收集数字卡控制的开关阀信号。这两种卡是研华卡,这些卡都是台湾制造,他们也控制使用LabVIEW,该驱动程序的LabVIEW必须下载从Advantechl公司的网站。这种模拟卡是由PCL 818 L16路单端或8路差分模拟量输入,40千赫,12比特的A/ D转换器(转换时间25微秒)。可编程增益对于每个输入通道(最多8个)与DMA的自动通道/增益进行扫描。这种数字I/O卡有32个隔离的PCL-730 DIO信道(16个输入和16个输出),硬件结构,你可以在图3看出。 显示屏 模拟传感器 PCL818LS 控制计算机输出 16频 A/D PCL730(I/O 16频) AVDAM3920 ADAM3920 数字输入 24伏 4频 AVDAM3920 AVDAM3920 数字输出 数字输出 24伏 4频 24伏 4频图3硬件系统结构4.控制程序的编程一旦我们安装驱动程序为研华卡程序可以启动。该程序的配置是以LabVIEW为它显示在图4的一种基本的控制。 垂直圆柱体 最后阶段 开始阶段 第二阶段 第三阶段 第一阶段 卧式圆筒 初始点图4. 气缸的控制过程视图在开始阶段,垂直气缸压缩橡胶弹簧,到它检测的65千牛的力,然后卧式筒体必须移动+ 30毫米到右侧,然后返回到左边-60mm的,然后移动到右边+30毫米和停止,和垂直气缸回到它原来的点(图4看到)。在这个组合过程中的难点之一是控制运动,因为这种运动必须同步,以避免两个油缸碰撞。在这种情况下,我们将只显示气缸控制由于这个程序的完全控制,也扩展到本报告中表明我们也只会显示背面板程序控制测试。这LabVIEW程序主要是通过使用所谓的层叠顺序结构的元件,该元件由一个或更多的子图或帧,即按顺序执行设计的。使用堆叠式顺序结构以确保一个子图的另一个子图的之前或之后执行。4.1起步阶段你可以在图5中看到,在第一阶段,在当垂直圆筒下来直到垂直力传感器获得的力65KN相对于橡胶弹簧则气缸停止,并保持在这个位置,直到测试完成时(参见图4)。4.2第一阶段对于水平缸的控制,我们必须首先使用水平位移传感器获得初始位置,然后我们可以标记在这个初始点我们的起点和基础,可以使我们的位移与气缸数有+ 30毫米(查看图6)的控制。4.3第二阶段在第二阶段的水平气缸的返回必须扩展 - 60mm到左侧然后停止,在这个过程中,我们必须取得气缸施加在橡胶弹簧(参见图7)力的测量。4.4第三阶段在第三阶段,气缸必须返回+30mm到右边,然后停止到原始点(第一阶段)(参见图8)。4.5最后阶段一旦水平气缸已经返回到原始点(第一阶段)并且程序已关闭水平圆柱所有的阀门,然后垂直油缸必须开始工作。在这种情况下,垂直气缸使用的垂直位移传感器,使气缸回到原来的工作点,但在开始时,因为我们需要控制施加到弹簧橡胶的力,我们必须使用力传感器来做到这一点(参见图9)。图5.立式汽缸的开始阶段图6.卧式气缸的第一阶段图7.卧式气缸的第二阶段图8.卧式气缸的第三阶段图9.立式气缸的最后阶段堆叠的序列结构为多帧序列,以便序列的运行,我们用10序列在该程序过程中从0到9;在这篇报告中我们只显示主要的阶段,对于介质阶段主要是控制阀门最后阶段的关闭。这是因为我们使用的是阀的通断阀和保留的最后一个进程的内存,所以我们必须小心,当我们利用堆叠顺序结构来编程的时候。例如,你可以看到图10,这表明最后阶段9是当垂直缸停在初始点时。图10.立式气缸的最后一帧从水平位移传感器和水平力传感器获得的信号被用于绘制使用该橡胶弹簧的弹性的曲线,在测试过程中,我们可以测量橡胶弹簧的常数k。这让我们知道生命周期的同事也让我们知道了橡胶弹簧的情况,为了能够对这个程序有个清晰的理念,我们可以查看图11,如你所见,Fy,是水平方向的力信号(KN)和施水平位移信号(毫米),F1和F2分别是第一和第二级的测量结束时获得的最终的力。在程序的最后阶段能够告诉我们多层橡胶弹簧的状态,你可以在图12中看到 图11.橡胶弹簧的试验过程中的数据. 图12. 应用程序数据的橡胶弹性曲线最后的基址图5.总结虚拟仪器软件LabVIEW被用来液压缸的控制程序。这是一个简单而可靠的软件,而无需使用编码程序来做这个。我们必须注意,唯一的问题是有图书馆的采集卡,我们要使用,如果这些都不是NI控制卡采集卡。这台机器的发展有助于我们做出预防保养。控制的元素都不难获得,但该软件可能是一个艰难的一步来完成它。但是,使用LabVIEW这步是简单的一步。LabVIEW的其中一个优势就是在工作中可以以一种直观的方式看出,当我们使用Visual看到并纠正程序中的任何错误时,不需要调试主要代码C + +或其他编程语言。参考文献【1】 艾斯克J. 高级视图试验【M】. 纽约州,美国;Prentince Hall出版社.1999。【2】 理查德,马特,Lab VIEW:高级编程技术M。第二版博卡拉顿:CRS出版社,2001。【3】 王雄冰,王旭勇,谢文华。发展橡胶弹簧综合测试床研究J。电力机车与城轨车辆,2003,26(6):41-43。【4】 王雄兵,王煦勇,橡胶弹簧的数据测试和资料分析J,电力机车大众运输车辆,2003,26(4):56。参考文献【1】 刘CR,米塔尔S,单步超精加工硬切削:可行性与可行的切削条件研究J。机器人计算集成制造,1995,12(1):15-27。【2】 顿肖夫,阿伦特C,阿莫尔R B.切削淬硬钢J。机械工程研究所的活动年报,2000,49(2);547-566。【3】 刘CR。米塔尔s.单步执行超精加工用硬质加工造成表面完整性研究上。J制造系统,1995,14(2):124-133。【4】 瑞希,梅森,表面完整性的情况下完成硬车削淬硬钢J。国际机床与制造学报,2003,43(3):543-550【5】 阿布拉AM,阿斯平沃尔DK. 集体的表面完整性的车削和磨削淬硬轴承钢J。磨损,1996,196(2):279-284。【6】 周YK, 伊万斯C J。白层和硬车削表面的热建模研究J。国际机床与制造学报,1999,39(2):1863-1881。【7】 Sasahara H,Obikawa T,T有限元分析切削加工层J,力学特性的影响J。序列,材料的专业技术公司。1996.62(4):448-453。【8】 雅各布森M,达尔曼P,冈恩F。切割速度的影响在硬贝氏体钢表面完整性的研究J。材料科技,2002,128(3):318-323【9】 杨文华,Tarng Y S,设计优化车削操作的基于田口方法J,切削参数。难加工材料的加工技术,1998,84(1):122-129。Journal of Shanghai Jiao tong University ( Science ) , Vo 1E一 10,No .4 ,2005 ,381386 Article ID: 1 007 11 72( 2 0 05) 0 4 03 81 - 06 The Hydraulic Control Using LabVIEW for a Synthetic Rubber Spring Testing Machine Alejandro Borda( 博尔达) , WANG Xu yong ( 王旭永 ) ( Mechatronic Inst ,Shanghai Jiaotong Univ ,shanghai 200030,China ) Abstract:The application is a control movement of two hydraulic cylinder for a synchronize movement. The main purpose of this paper is to show a short programming code in LabVIEW to control the movement of two cylinders with an automatic control program using only analog inputs from the sensor of pressure and linear displacement sensor and the digital output from the hydraulic valvesThis is designed for one of the test of this synthetic rubber spring testing machineKey words:rubber elasticity; multi layer rubber spring;stacked sequence structureDocument code:AIntroduction The synthetic rubber test machine is to test the rubber spring of the subway wagonThe practical use of this machine is to make a preventing maintenance so we can know with accuracy the spending life of the rubber springEvery rubber spring is a subject of a cycle or working hours, after this period the testing of this spring rubber must do it according to specification of the manufacturer,the testing machine is designed to test 4 kinds of rubber springs;the one that is used for this test is called multi layer rubber springThe main characteristic of this test,compared with the other rubber springs,is that this is the only one which combines the force of two cylinders:one vertical and one horizontal. 1. Structure Assembly The structure assembly for the testing machine is very simple The testing platform has an upper frame,mobile frame,lower frame,test piece vertical column of a chucking frame,chucking frame support upper of the working platform,hydraulic system is installed down to the working platformThe platform highest hydraulic pressure is 150 KN ,and a simple mechanical structure only uses two vertical columns to hold itAt the same time the design is under the consideration of the rigid transversal measurement of the multilayer rubber spring elementsMoreover,there are different test pieces and the measurements are not the Same The horizontal hydraulic cylinder is fixed into the frame structureThe altitude of the base can be modified according to the testing piece just changing the base support according to the test. The vertical pressure sensor is fixed at the head of the vertical cylinderThe movement of the vertical cylinder is always pushing down applying a compression force into the testing pieceThe vertical sensor is installed at the bottom frame structure in a fixed position just parallel to the vertical columnsThe vertical force sensor is installed at the base of the head of the vertical cylinder and also the horizontal displacement sensor is installed at the back of the horizontal cylinder right at the bottom of this ( View Fig.1 ) During the elasticity test of a multi layer rubber spring,a horizontal force must be apply to 65 KN and then the horizontal cylinder must displace 土30 mm,during this process we acquire the analog signal from the force sensor of the horizontal cylinder,then we have to measure the constant K of the rubber spring for this reason using this formula K=(F1+F2)60(Nmm) Fig.1 General view of the testing machine 1-Upper frame;2-Vertical cylinder;3-Mobile frame;4-Vertical force sensor;5-Force column; 6-Verticl displacement sensor; 7-Test piece; 8-Tool plate;9-Lower frame; 10-Assembly frame;11- Horizontal force sensor;12-Horizontal cylinder ; 13-Horizontal displacement sensor 2. Pressure System The pressure system principles can be seen as in the Fig .2 The system uses two hydraulic pump connected with an electrical motor,the hydraulic pumps never exceed the working pressure of 16 MPa,a flow of 6 ml/r and 16 ml/r The pump station is designed with a pressure gauge meter,filter etcThe pumps working pressure(horizontal and vertical cylinder)is divided through four electromagnetic valvesThe pump 1 is designed for three different working pressure(150,100,50 KN).Therefore for the high frequency of measurement test the speed of both hydraulic pumps can be adjusted using a valveDuring the loading test the speed is about 1mms,this is also during the unloading processThe speed can be adjusting around 2mms;the system has two close valves these are for protecting the hydraulic pumps. The schematic of the hydraulic system can be appreciated in the Fig.2 and the control and change of the electromagnetic valves can be seen in Tab.1 Fig.2 Hydraulic pressure diagram1,2,3,4一Pressure relief valve;5,6一Electromagnetic commute valves;7,8一One way re strictor;9一Flow control one way valve; 10, II, I2一Electromagnetic commute valves;I3一One way valve; 14-Gate valve;15 - Filter;16-Pressure gauge;17 一Air filter Tab 1 Action chart of the hydraulicsystem Standard state Main cylinder fast advanced Main cylinder slow advanced Main cylinder slow return Main cylinder fast return Horizontal cylinder left advanced Horizontal cylinder right advanced Main cylinder hydraulic pressure I Main cylinder hydraulic pressure2Main cylinder hydraulic pressure3 3. Acquisition Card and Control Drivers For the control and acquisition of data we use two different cards: one analog card to collect the signal from the sensors and the other digital card to control the onoff valves. Both cards are advantech cards,these cards are made in Taiwan and they are also controllable using LabVIEW, the drivers for LabVIEW must be downloading from the Website of Advantechl Company. The analog card is the PCL 818L 16 singleended or 8 differential analog inputs,40 kHz,12-bit A/D converter (conversion time 25 s)Programmable gain for each input channel(up to 8 )Automatic channel/gain scanning with DMAThe Digital I/O card is PCL-730 which has 32 isolated DIO channels(16 inputs and 16 outputs),the hardware structure you can appreciate in Fig.3 Fig.3 The hardware system structure 4. Programming of the Control Program Once we install the drivers for the advantech cards the program can start. The configuration of the program is a basic control using LabVIEW as it shows in Fig.4At the beginning stage the vertical cylinder compresses the rubber spring until it senses a force of 65 KN then horizontal cylinder must start moving + 30 mm to the right and then return to the left-60mm and then move to the right+ 30 mm and stop,and the vertical cylinder returns to its original point(view Fig.4)During this combination process one of the difficulties is the control movement because this movement must be synchronized to avoid both cylinders collidingIn this case we are going to show only the control for the cylinders because the full control of this program is too extended to show it in this report also we are only going to show the back panel program to control this testThis LabVIEW program is mainly designed by using the element called stacked sequence structure which consists of one or more sub diagrams,or frames,that execute sequentiallyUse the stacked sequence structure to ensure a sub diagram executes before or after another sub diagram Fig4 View of the control process of the cylinders 4.1 Beginning Stage As you can see in Fig.5,at the first stage when the vertical cylinder is coming down until the vertical force sensor acquire 65kN of force against the rubber spring then the cylinder stops and stays in this position until the test is completed(See also Fig.4) 4.2 First Stage For the control of the horizontal cylinder, first we have to acquire the initial posit using the horizontal displacement sensor,and then we can mark our initial point and base on this initial point and can make our displacement and control of the cylinder counting + 30 mm (View Fig.6 ) 4.3 Second Stage During the second stage the return of the horizontal cylinder must extend -60mm to the left and then stop ,during this process we must acquire the measurement of the force that the cylinder exerts over the rubber spring(See Fig7) 4 .4 Third Stage In the third stage,the cylinder must return + 30mm to the right and then stop to the original point( first stage )( See Fig8) 4 .5 Final Stage 0nce the horizontal cylinder has returned to the original point(First Stage)and the program has shut off all the valves of the horizontal cylinder and then the vertical cylinder must start workingIn this case,the vertical cylinder uses the vertical displacement sensor to make the cylinder return the original point of work,but at the beginning because we need to control the force applied to the spring rubber we have to use the force sensor to do this(See Fig9) Fig.5 Beginning stage of the vertical cylinder Fig.6 First stage of the horizontal cylinder Fig7 Second s t a g e of t he h or i z ont al c yl i nd e r The stacked sequence structure has many frames in order to make run a sequence we use 10 sequence during this program from 0 to 9;in this report we only show the principal stages, for the intern media stages are mainly to control the off of the valves of the last stageThis is because the valves that we are using are onoff valves and the retain memory of the last process, SO we must careful when we programming by using the stacked sequence structureFor example,you can see Fig.10. this show the last stage 9 which is when the vertical cylinder stops at the initial point. The signals acquired from the horizontal displacement sensor and the horizontal force sensor are used to plot a curve of the elasticity of the rubber spring using,during this test we can measure the K constant of the rubber springThis allow US to know the life cycle and also the condition of this rubber spring,to have a clear idea of this process we can see Fig.11,as you see,Fy is the horizontal force signal(KN)and the Sy horizontal displacement signal(mm),F1 and F2 are the final forces acquired during the end of the measurement of the first and second stageThe final plot in the program can tell us the status of the multi layer rubber spring which you can see in Fig.12 Fig10 Last frame of the vertical cylinder Fig11 Data processing of the rubber spring during the test Fig12 Final plot of the rubber elasticity curve using the program data 5. Conclusion LabVIEW is used to program the control of the cylinderThis is an easy and reliable software and without using coding programming to do thisThe only issue that we must take care is to have the libraries for the acquisition card that we are going to use if these are not NI control cards The development of this machine helps us to make preventing maintenance The elements of control are not difficult to acquire but the software could be a difficult step to do itbut using LabVIEW this step is a simple oneOne of the advantages of LabVIEW is that the undergoing work can be seen in a visual way so this helps us to see and correct any mistake in the program without debugging the main code when we use Visual C+ + or another programming language References 1 Essick JAdvanced Lab VIEW MNY,USA;Prentince Hall, 1999 2 Bitter R,Mohiuddin T,Nawrocki M Lab VIEW: Advanced programming techniques M2nd edBoca Raton:CRS Press,2001 3 Wang Xiongbing, Wang Xuyong, Xie Wenhua. Development of a rubber spring synthetic test bed J Electrical Locomotives Mass Transit Vehicles,2003,26(6):4143 4 Wang Xiongbing,Wang XuyongTest and data analysis on rubber spring J Electrical Locomotives Mass Transit Vehicles,2003,26(4):5659 References 1 Liu C R,Mittal S Singlestep superfinish hard machining :Feasibility and feasible cutting condition J Robotics Compute Integrated Manufacturing,1995,12 (1):1527 2 Tonshoff H K,Arendt C,Amor R BC utting of hardened steel J Annals of the CIRP, 2000,49 (2);547566 3 Liu C R Mittal SSinglestep superfinish using hard machining resulting in superior surface integrity J J Manufacturing Syst ,1995,14(2):124133 4 Rech J ,Moisan ASurface integrity in finish hard turning of casehardened steels J International Journal of Machine ToolsManufacture,2003,43(3):543550 5 Abrao A M ,Aspinwall D KThe surface integrity of turned and ground hardened bearing steel JWear,1996,196(2):279284 6 Chou Y K,Evans C J White layers and thermal modeling of hard turned surfaces JInternational Journal of Machine ToolsManufacture,1999,39(2):18631881 7 Sasahara H,Obikawa T。Shirakashi T. FEM analysis of cutting sequence effect on mechanical characteristics in machined layer J J Materi PrO Tech 199662(4):448453. 8 Jacobson M ,Dahlman P,Gunnberg F Cutting speed influence on surface integrity of hard turned bainite steel J Journal of Materials Technology,2002,128(3):318323 9 Yang W H ,Tarng Y SDesign optimization of cutting parameters for turning operations based on the Taguchi method J Journal of Materials Processing Technology,1998,84 (1 ):122129
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高速数字多功能土槽试验台车的设计
高速
数字
多功能
试验
实验
台车
设计
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