CN111665878A - Constant force loading simulation device and force loading method based on closed-loop control - Google Patents
Constant force loading simulation device and force loading method based on closed-loop control Download PDFInfo
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Abstract
The invention relates to the technical field of equipment fatigue tests, in particular to a constant force loading simulation device and a force loading method based on closed-loop control, which comprise a torque display instrument and an industrial personal computer; the control signal output end of the industrial personal computer is electrically connected with a voltage-controlled constant current source and a hysteresis brake in sequence, a torque sensor is coaxially arranged on the hysteresis brake, the torque sensor is electrically connected with a torque display instrument, and the output end of the torque display instrument is electrically connected into the feedback signal input end of the industrial personal computer to form a closed-loop control loop. This technical scheme adopts closed-loop control's mode to provide required moment of torsion loading to the measured object, and the advantage lies in can constantly providing feedback signal at the self-monitoring of experimentation to this adjustment loading torque's size improves loading torque precision to 0.5%, further provides continuous, stable loading torque for the measured object, and the effectual moment of torsion of avoiding is applyed too big, exceeds the measured object and bears the scope, and then leads to the condition emergence of measured object damage.
Description
Technical Field
The invention relates to the technical field of equipment fatigue tests, in particular to a constant force loading simulation device and a force loading method based on closed-loop control.
Background
In the fields of precision machine tool, engine design, precision test instrument research and large-scale manufacturing of airplanes, ships, automobiles and the like, on-load tests such as torsion, rotating speed and the like are involved, and specific moment loads need to be set in the test process, so that the driving capability and the stability of a tested object are verified.
At present, torque loading is mainly realized by adopting an open-loop control mode, the quality of a measured object is affected due to unstable torque application in the test process, and even the torque application is too large and exceeds the bearing range of the measured object, so that the measured object is damaged. In order to avoid the condition that a tested object is damaged, a torque detection device is added on testing equipment by part of manufacturers to monitor the torque, when the torque exceeds the range, the controller stops the brake driving device, the test is stopped, and then the test is carried out again after manual fault removal. Although the method can avoid the damage of the measured object, the applied loading force can not be accurately controlled, and the retest is time-wasting after the problem occurs, thereby slowing down the working efficiency.
Disclosure of Invention
The invention aims to provide a simulation device and a method for applying constant load to a small-torque product and verifying the driving capability of a measured object, aiming at the defects of the prior art, so as to realize accurate and constant force loading.
The method is realized by the following technical scheme:
a constant force loading simulation device based on closed-loop control comprises a torque display instrument and an industrial personal computer provided with a control signal output end and a feedback signal input end; the industrial personal computer comprises a central processing unit, a communication module and a digital-to-analog conversion module, wherein the communication module is a communication peripheral interface of the industrial personal computer, the digital-to-analog conversion module is mainly used for converting a digital signal output by the central processing unit into an analog signal and transmitting the analog signal to the voltage-controlled constant current source, and the analog signal is a voltage signal. The communication module is used as a feedback signal input end of the industrial personal computer and is electrically connected with the central processing unit, and the digital-to-analog conversion module is used as a control signal output end of the industrial personal computer and is electrically connected with the central processing unit; the control signal output of industrial computer has voltage-controlled constant current source, hysteresis brake in proper order electric connection, and the hysteresis brake is gone up the coaxial torque sensor that is provided with, torque sensor with torque display instrument electric connection, torque display instrument's output electric access the feedback signal input of industrial computer constitutes a closed-loop control circuit. The industrial personal computer is a tool general name which adopts a bus structure and detects and controls a production process, electromechanical equipment and process equipment; the industrial personal computer has important computer attributes and characteristics, such as a computer mainboard, a CPU, a hard disk, a memory, peripherals and interfaces, an operating system, a control network and protocol, computing capability and a friendly human-computer interface, and is used for realizing torque target value setting, actual torque value computing, control signal output and torque signal acquisition. The hysteresis brake utilizes a hysteresis principle to generate a certain torque by controlling the input exciting current, wherein the control current and the output torque have a better linear relation; the hysteresis brake can provide smooth, stepless and adjustable torque control irrelevant to the rotating speed, has no other friction in a hysteresis brake system except for a bearing, and has the advantages of stability, reliability, high using rotating speed, low noise, long service life, low maintenance cost and the like. The voltage-controlled constant current source is used for receiving a control signal of the industrial personal computer and outputting a current signal for controlling the hysteresis brake to output corresponding torque. Torque sensors are the detection of the perception of torsional moments on various rotating or non-rotating mechanical components. The torque display instrument is used for converting the electric signal into digital quantity for display and forming a corresponding digital signal for a loading controller to collect.
The torque sensor is a strain gauge torque sensor comprising a strain gauge, the strain gauge is a resistance-type metal foil strain gauge sensor, torque measurement is carried out by adopting a strain electric measurement technology, the strain gauge is adhered to an elastic shaft to form a measurement bridge, when the elastic shaft is subjected to small deformation caused by torque, the resistance value of the bridge is changed, and the change of the resistance of the strain bridge is converted into the change of an electric signal, so that the torque measurement is realized.
And the output end of the torque display instrument is connected to the feedback signal input end of the industrial personal computer through an RS485 communication bus. The RS485 communication bus is an RS485 bus (RS-485), the RS-485 adopts balanced transmission and differential reception, so the RS-485 bus has the capability of inhibiting common mode interference, and the bus transceiver has high sensitivity and can detect the voltage as low as 200mv, so the transmission signal can be recovered beyond kilometers. Therefore, the torque display instrument is connected to the feedback signal input end of the industrial personal computer through the RS485 communication bus, so that the feedback signal is not affected by the outside, the feedback signal can smoothly reach the industrial personal computer, and the reliability of signal transmission is improved.
A constant force loading method based on closed-loop control is characterized in that: the method comprises the steps of preparing in the early stage of a test, primarily applying torque, forming a feedback signal, adjusting the applied torque and keeping the torque;
preparing at the early stage of the test: presetting a target torque value a according to the actually required loading torque of the measured object;
the preliminary applied torque: inputting the target torque value a into an industrial personal computer, outputting a control signal corresponding to the target torque value a by using the industrial personal computer, accessing the control signal into a voltage-controlled constant current source, outputting a current signal corresponding to the control signal by using the voltage-controlled constant current source, introducing the current signal into a hysteresis brake, and controlling the hysteresis brake to apply corresponding torque to the shafting rotation of a measured object according to the current signal;
the forming of the feedback signal: the torque sensor is coaxially arranged with the hysteresis brake to realize real-time monitoring of the loading torque, the torque sensor converts the measured torque into an electric signal which is linearly proportional to the torque, the electric signal is connected into the torque display instrument, the torque display instrument converts the electric signal into a digital quantity to be displayed, meanwhile, a digital signal corresponding to the digital quantity is formed in the torque display instrument, and the digital signal is used as a feedback signal and is sent to the industrial personal computer through an RS485 communication bus;
the adjustment applies a torque: after the industrial personal computer receives the feedback signal, the internal central processing unit is utilized to calculate the actual measured load torque value NrAnd the industrial personal computer adjusts the control signal output by the digital-to-analog conversion module according to the difference q, further adjusts the magnitude of the current signal output by the voltage-controlled constant current source, and finally changes the actual output torque of the hysteresis brake.
Preferably, the process of adjusting the applied torque further comprises judging whether the difference q is equal to 0 in an industrial personal computer; if q =0, the output control signal is unchanged, and the actual output torque of the hysteresis brake is continuously maintained; if q is not equal to 0, judging that q is greater than 0, if q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the output current signal of the voltage-controlled constant current source, and further reducing the actual output torque of the hysteresis brake, if q is not greater than 0, increasing the output current signal of the voltage-controlled constant current source by increasing the control signal output by the digital-to-analog conversion module, and further increasing the actual output torque of the hysteresis brake until the industrial personal computer judges that q =0, and then keeping the actual output torque of the hysteresis brake.
Preferably, the preliminary test preparation process further includes setting a maximum allowable error value Q; the process of adjusting the applied torque further comprises judging whether the absolute value of the difference value Q is less than or equal to the maximum allowable error value Q; if Q |. is not more than Q, the output control signal is unchanged, and the actual output torque of the hysteresis brake is kept continuously; if the absolute value of the difference Q is not less than or equal to the maximum allowable error value Q, judging that Q is greater than 0, if Q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the current signal output by the voltage-controlled constant current source, further reducing the actual output torque of the hysteresis brake, if Q is not greater than 0, increasing the current signal output by the voltage-controlled constant current source and further increasing the actual output torque of the hysteresis brake by increasing the control signal output by the digital-to-analog conversion module until the industrial personal computer judges that Q is less than or equal to Q, and keeping the actual output torque of the hysteresis brake.
Preferably, the maximum allowable error value Q is set to 1N · m.
The beneficial effect that this technical scheme brought:
this technical scheme adopts closed-loop control's mode to provide required moment of torsion loading to the measured object, the advantage lies in can be at the self-monitoring of testing process, constantly provide feedback signal, with this size of adjustment loading moment of torsion, improve loading moment of torsion precision to 0.5%, further provide continuous, stable loading moment of torsion for the measured object, the effectual moment of torsion of avoiding is applyed oversize, exceed the measured object and bear the scope, and then the condition that leads to the measured object to damage takes place, and this technical scheme adopts automatic control, with loading moment of torsion control in the scope of bearing of measured object, need not take the measure of torque detection device control, the process of troubleshooting has also been saved, and work efficiency is improved.
Drawings
The foregoing and following detailed description of the invention will be apparent when read in conjunction with the following drawings, in which:
FIG. 1 is a schematic flow diagram of the closed loop control signal of the present invention;
FIG. 2 is a torque loading flow diagram of a basic aspect of the present invention;
FIG. 3 is a torque loading flow diagram of a preferred embodiment of the present invention.
Detailed Description
The technical solutions for achieving the objects of the present invention are further illustrated by the following specific examples, and it should be noted that the technical solutions claimed in the present invention include, but are not limited to, the following examples.
Example 1
The embodiment discloses a constant force loading simulation device based on closed-loop control, which is used as a basic implementation scheme of the invention and comprises a torque display instrument and an industrial personal computer provided with a control signal output end and a feedback signal input end; the industrial personal computer internally comprises a central processing unit, a communication module and a digital-to-analog conversion module, wherein the communication module is used as a feedback signal input end of the industrial personal computer and is electrically connected with the central processing unit, and the digital-to-analog conversion module is used as a control signal output end of the industrial personal computer and is electrically connected with the central processing unit; the control signal output end of the industrial personal computer is electrically connected with a voltage-controlled constant current source and a hysteresis brake in sequence, a torque sensor is coaxially arranged on the hysteresis brake, the torque sensor is electrically connected with a torque display instrument, and the output end of the torque display instrument is electrically connected with the feedback signal input end of the industrial personal computer to form a closed-loop control loop.
In the technical scheme, the industrial personal computer has important computer attributes and characteristics and is used for realizing torque target value setting, actual torque value calculation, driving signal output and torque signal acquisition, wherein the torque signal acquisition is to acquire a feedback signal output by a torque display instrument; the voltage-controlled constant current source receives a control signal output by the loading controller, and outputs a corresponding current signal according to the control signal to control the hysteresis brake to generate torque. The hysteresis brake comprises a rotor and a stator magnetic pole; the rotor is made of special magnetic hysteresis material, and the stator magnetic poles have certain gaps in which the rotor rotates. When the coil is electrified, a magnetic field is generated in the gap, so that the rotor generates a hysteresis effect; when the hysteresis rotor is rotated against the hysteresis force by an external force, a rated torque is generated. The torque is only related to the magnitude of the exciting current and is not related to the rotating speed, and non-contact torque transmission is realized. The torque sensor converts the measured torque into an electrical signal with a frequency linearly proportional to the torque; the torque display instrument converts an electric signal output by the torque sensor into a digital quantity to be displayed and forms a corresponding digital signal for an industrial personal computer to collect, the industrial personal computer brings the collected digital signal into the central processing unit to carry out data operation, and selects to keep or adjust the control signal according to an operation result, if the collected digital signal meets the actual requirement on the applied torque, the digital signal is kept continuously, if the collected digital signal does not meet the actual requirement on the applied torque, the digital signal is adjusted until the digital signal collected by the loading controller meets the actual requirement on the applied torque, and then the digital signal is kept, so that the torque loading of closed-loop control is formed.
Example 2
The embodiment discloses a constant force loading simulation device based on closed-loop control, which is a preferred embodiment of the invention, namely, the torque sensor in the embodiment 1 is a strain gauge torque sensor comprising a strain gauge, and the strain gauge is a resistance-type metal foil; the output end of the torque display instrument is connected to the feedback signal input end of the industrial personal computer through the RS485 communication bus.
In the technical scheme, a strain gauge sensor adopts a strain gauge electrical measurement technology for measuring the torque, the strain gauge is a resistance-type metal foil, the strain gauge is adhered to an elastic shaft to form a measuring bridge, when the elastic shaft is slightly deformed by the torque, the strain gauge also changes correspondingly to further cause the resistance value of the bridge to change, and the change of the resistance of the strain bridge is converted into the change of an electrical signal so as to realize the torque measurement; when the strain gauge is unchanged, the output voltage of the resistance bridge is zero; after the strain gauge appears the condition of deformation, the bridge resistance value changes, and the bridge is unbalanced, outputs corresponding voltage value, and this voltage value is converted into the signal of telecommunication for moment of torsion display instrument to rethread pressure frequency interface, can not receive external cable influence to change. The stable transmission of the feedback signal is ensured through the RS485 communication bus, and the received feedback signal is further more accurate and reliable.
Example 3
The embodiment discloses a constant force loading method based on closed-loop control, which is used as a basic implementation scheme of the invention and comprises the steps of preliminary test preparation, preliminary torque application, feedback signal formation, applied torque adjustment and torque maintenance;
preparation in the early stage of the test: presetting a target torque value a according to the actually required loading torque of the measured object;
preliminary applied torque: selectively inputting a target torque value a into an industrial personal computer through a mouse, outputting a control signal corresponding to the target torque value a by using the industrial personal computer, accessing the control signal into a voltage-controlled constant current source, outputting a current signal corresponding to the control signal by using the voltage-controlled constant current source, introducing the current signal into a hysteresis brake, and controlling the hysteresis brake to apply corresponding torque to the shafting rotation of a measured object according to the current signal;
forming a feedback signal: the torque sensor is coaxially arranged with the hysteresis brake to realize real-time monitoring of the loading torque, the torque sensor converts the measured torque into an electric signal which is linearly proportional to the torque, the electric signal is connected into the torque display instrument, the torque display instrument converts the electric signal into a digital quantity to be displayed, meanwhile, a digital signal corresponding to the digital quantity is formed in the torque display instrument, and the digital signal is used as a feedback signal and is sent to the industrial personal computer through an RS485 communication bus;
adjusting the applied torque: after the industrial personal computer receives the feedback signal, the internal central processing unit is utilized to calculate the actual measured load torque value NrAnd the industrial personal computer adjusts the control signal output by the digital-to-analog conversion module according to the difference q between the target torque value a and the target torque value a, namely: judging whether the difference q is equal to 0 in the industrial personal computer; if q =0, the output control signal is unchanged, and the actual output torque of the hysteresis brake is continuously maintained; if q is not equal to 0, judging that q is greater than 0, if q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the output current signal of the voltage-controlled constant current source, and further reducing the actual output torque of the hysteresis brake, if q is not greater than 0, increasing the output current signal of the voltage-controlled constant current source by increasing the control signal output by the digital-to-analog conversion module, and further increasing the actual output torque of the hysteresis brake until the industrial personal computer judges that q =0, and then keeping the actual output torque of the hysteresis brake.
According to the technical scheme, the loading controller is continuously provided with the feedback signal, the loading torque is adjusted until the actual required torque, so that continuous and stable loading torque is provided for the measured object, and the situation that the torque is applied too much and exceeds the bearing range of the measured object, so that the measured object is damaged is avoided.
Example 4
The embodiment discloses a constant force loading method based on closed-loop control, which is a preferred embodiment of the invention and comprises the steps of preliminary test preparation, preliminary torque application, feedback signal formation, applied torque adjustment and torque maintenance;
preparation in the early stage of the test: presetting a target torque value a according to the actually required loading torque of the measured object, and simultaneously inputting a maximum error value Q (namely the actually measured load torque value N) into the industrial personal computer through a keyboardrThe absolute value of the maximum allowable difference from the target torque value a), and the maximum allowable error value Q is set to 1N · m;
preliminary applied torque: inputting a target torque value a into an industrial personal computer through a keyboard, outputting a control signal corresponding to the target torque value a by using the industrial personal computer, accessing the control signal into a voltage-controlled constant current source, outputting a current signal corresponding to the control signal by using the voltage-controlled constant current source, introducing the current signal into a hysteresis brake, and controlling the hysteresis brake to apply corresponding torque to the shafting rotation of a measured object according to the current signal;
forming a feedback signal: the torque sensor is coaxially arranged with the hysteresis brake to realize real-time monitoring of the loading torque, the torque sensor converts the measured torque into an electric signal which is linearly proportional to the torque, the electric signal is connected into the torque display instrument, the torque display instrument converts the electric signal into a digital quantity to be displayed, meanwhile, a digital signal corresponding to the digital quantity is formed in the torque display instrument, and the digital signal is used as a feedback signal and is sent to the industrial personal computer through an RS485 communication bus;
adjusting the applied torque: after the industrial personal computer receives the feedback signal, the internal central processing unit is utilized to calculate the actual measured load torque value NrAnd the industrial personal computer adjusts the control signal output by the digital-to-analog conversion module according to the difference q between the target torque value a and the target torque value a, namely: judging whether the absolute value of the difference value Q is less than or equal to the maximum allowable error value Q; if Q |. is not greater than Q, the output control signal is not changed, and the actual output of hysteresis brake is not changedThe output torque is continuously maintained; if the absolute value of the difference Q is not less than or equal to the maximum allowable error value Q, judging that Q is greater than 0, if Q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the current signal output by the voltage-controlled constant current source, further reducing the actual output torque of the hysteresis brake, if Q is not greater than 0, increasing the current signal output by the voltage-controlled constant current source and further increasing the actual output torque of the hysteresis brake by increasing the control signal output by the digital-to-analog conversion module until the industrial personal computer judges that Q is less than or equal to Q, and keeping the actual output torque of the hysteresis brake.
The technical scheme sets the maximum allowable error value Q, namely a buffer space is provided for the device, the working order of the device is reduced, the service life of the device is further prolonged, the maximum allowable error value Q is set to be 1 N.m, the performance definition according to the resolution of a hysteresis brake and a torque sensor is met with the existing front wheel system test, and the maximum measuring range of the torque sensor is 200 N.m, so that the actual precision of the required torque generated by a shafting can be controlled within the range of 1 N.m/200 N.m = 0.5%.
Claims (7)
1. A constant force loading simulation device based on closed-loop control is characterized in that: the torque control device comprises a torque display instrument and an industrial personal computer provided with a control signal output end and a feedback signal input end; the industrial personal computer internally comprises a central processing unit, a communication module and a digital-to-analog conversion module, wherein the communication module is used as a feedback signal input end of the industrial personal computer and is electrically connected with the central processing unit, and the digital-to-analog conversion module is used as a control signal output end of the industrial personal computer and is electrically connected with the central processing unit; the control signal output of industrial computer has voltage-controlled constant current source, hysteresis brake in proper order electric connection, and the hysteresis brake is gone up the coaxial torque sensor that is provided with, torque sensor with torque display instrument electric connection, torque display instrument's output electric access the feedback signal input of industrial computer constitutes a closed-loop control circuit.
2. A closed-loop-control-based constant force loading simulation apparatus as claimed in claim 1, wherein: the torque sensor is a strain gauge torque sensor comprising a strain gauge, and the strain gauge is a resistance-type metal foil.
3. A closed-loop-control-based constant force loading simulation apparatus as claimed in claim 1, wherein: and the output end of the torque display instrument is connected to the feedback signal input end of the industrial personal computer through an RS485 communication bus.
4. A constant force loading method based on closed-loop control is characterized in that: the method comprises the steps of preparing in the early stage of a test, primarily applying torque, forming a feedback signal, adjusting the applied torque and keeping the torque;
preparing at the early stage of the test: presetting a target torque value a according to the actually required loading torque of the measured object;
the preliminary applied torque: inputting the target torque value a into an industrial personal computer, outputting a control signal corresponding to the target torque value a by using the industrial personal computer, accessing the control signal into a voltage-controlled constant current source, outputting a current signal corresponding to the control signal by using the voltage-controlled constant current source, introducing the current signal into a hysteresis brake, and controlling the hysteresis brake to apply corresponding torque to the shafting rotation of a measured object according to the current signal;
the forming of the feedback signal: the torque sensor is coaxially arranged with the hysteresis brake to realize real-time monitoring of the loading torque, the torque sensor converts the measured torque into an electric signal which is linearly proportional to the torque, the electric signal is connected into the torque display instrument, the torque display instrument converts the electric signal into a digital quantity to be displayed, meanwhile, a digital signal corresponding to the digital quantity is formed in the torque display instrument, and the digital signal is used as a feedback signal and is sent to the industrial personal computer through an RS485 communication bus;
the adjustment applies a torque: after the industrial personal computer receives the feedback signal, the internal central processing unit is utilized to calculate the actual measured load torque value NrThe difference q between the target torque value a and the target torque value a, and the industrial personal computer controls the output of the digital-to-analog conversion module according to the magnitude of the difference qThe signal is adjusted, the magnitude of the current signal output by the voltage-controlled constant current source is further adjusted, the actual output torque of the hysteresis brake is finally changed, during the period, the torque display instrument continuously feeds back signals to the industrial personal computer until the digital quantity meets the actual requirement, the industrial personal computer stops adjusting the output control signal, and the actual output torque of the hysteresis brake is kept.
5. The constant force loading method based on closed-loop control as claimed in claim 4, wherein: the process of adjusting the applied torque further comprises the step of judging whether the difference q is equal to 0 in an industrial personal computer; if q =0, the output control signal is unchanged, and the actual output torque of the hysteresis brake is continuously maintained; if q is not equal to 0, judging that q is greater than 0, if q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the output current signal of the voltage-controlled constant current source, and further reducing the actual output torque of the hysteresis brake, if q is not greater than 0, increasing the output current signal of the voltage-controlled constant current source by increasing the control signal output by the digital-to-analog conversion module, and further increasing the actual output torque of the hysteresis brake until the industrial personal computer judges that q =0, and then keeping the actual output torque of the hysteresis brake.
6. The constant force loading method based on closed-loop control as claimed in claim 4, wherein: the preliminary preparation process of the test also comprises setting a maximum allowable error value Q; the process of adjusting the applied torque further comprises judging whether the absolute value of the difference value Q is less than or equal to the maximum allowable error value Q; if Q |. is not more than Q, the output control signal is unchanged, and the actual output torque of the hysteresis brake is kept continuously; if the absolute value of the difference Q is not less than or equal to the maximum allowable error value Q, judging that Q is greater than 0, if Q is greater than 0, reducing the control signal output by the digital-to-analog conversion module, reducing the current signal output by the voltage-controlled constant current source, further reducing the actual output torque of the hysteresis brake, if Q is not greater than 0, increasing the current signal output by the voltage-controlled constant current source and further increasing the actual output torque of the hysteresis brake by increasing the control signal output by the digital-to-analog conversion module until the industrial personal computer judges that Q is less than or equal to Q, and keeping the actual output torque of the hysteresis brake.
7. The constant force loading method based on closed-loop control as claimed in claim 6, wherein: the maximum allowable error value Q is set to 1N · m.
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| WO2023173373A1 (en) * | 2022-03-17 | 2023-09-21 | Apex Brands, Inc. | Torque measurement with increased accuracy at lower torque values |
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| Publication number | Priority date | Publication date | Assignee | Title |
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