基于新型装置的碳刷高质量适形研磨机制研究

Research on mechanism of high-quality conformal grinding of carbon brushes based on a new device

为解决调相机所用碳刷的适形研磨效果不佳问题,以提高碳刷研磨质量为标准,首先基于新型碳刷研磨装置,分析碳刷适形研磨过程、摩擦接触面的摩擦机制;其次建立该结构的运动学模型并运用Adams仿真,进行误差分析;然后在系统偏差影响下,从宏观与微观角度分析摩擦机制;最后通过理论关系式计算,分析在该影响下粗糙度对摩擦力的影响,探究粗糙度及摩擦力之间的影响关系。结果表明:该设备可靠性高,但仍存在微量系统偏差,偏差值在0.002~0.017范围内;通过公式推导分析出宏观层面磨损率呈指数级降低,微观层面形成三体摩擦;碳刷与砂轮研磨块的摩擦力与两者接触表面的轮廓高度标准差呈正相关关系。

To solve the problem of poor conformal grinding effect of carbon brushes used in phase-shifting cameras and improve the grinding quality of carbon brushes,a new type of carbon brush grinding device was first adopted to analyze the process of conformal grinding of carbon brushes and the friction mechanism of the friction contact surface.Secondly,a kinematic model of the structure was established,and Adams simulation was used to analyze errors.Then,under the influence of system bias,the friction mechanism was analyzed from both macro and micro perspectives.Finally,through theoretical relationship calculation,the influence of roughness on friction under this system bias was analyzed,and the relationship between roughness and friction was explored.The results show that the device has high reliability,but there are still trace system deviations,with deviation values ranging from 0.002 to 0.017.Through formula deduction and analysis,it is found that the wear rate at the macro level decreases exponentially,while at the micro level,a three-body friction is formed.There is a positive correlation between the friction force between the carbon brush and the grinding wheel block and the standard deviation of the contour height of the contact surface between them.