Novel approach for determining the optimal axial preload of a simulating rotary table spindle system

This paper presents a new theoretical model to determine the optimal axial preload of a spindle system, for challenging the traditional method which relies heavily on experience of engineers. The axial preloading stiffness was treated as the sum of the spindle modal stiffness and the framework elastic stiffness, based on a novel concept that magnitude of preloads can be controlled by measuring the resonant frequency of a spindle system. By employing an example of a certain type of aircraft simulating rotary table, the modal stiffness was measured on the Agilent 35670A Dynamic Signal Analyzer by experimental modal analysis. The equivalent elastic stiffness was simulated by both finite element analysis in ANSYS? and a curve fitting in MATLAB?. Results showed that the static preloading stiffness of the spindle was 7.2125×107 N/m, and that the optimal preloading force was 120.0848 N. Practical application proved the feasibility of our method.

Design, Development and Geometric Error Analysis of an Aerostatic Rotary Table

Rotary tables are equipments in precision machinery applied in five-axis Machine Tools and CMM （Coordinate Measuring Machines）, offering rotational （C-axis） and tilting motion （A-axis）, allowing the obtaining of several configurations for manufacturing or inspection of parts with complex geometries. The demand for high accuracy, high efficiency and fewer errors in the positioning of the part in precision machines increases every day, thus ensuring their high confidence and the use of aerostatic bearings enable constructive innovations to the equipment. In this context, this work presents the mechanical design, the development and error analysis of a prototype of an aerostatic rotary table. This study emphasizes the analysis of a prototype that uses the air as a working principle for reducing friction between moving parts, increasing the mechanical efficiency, and its influence of motion error is also discussed based on the experimental results. For the geometrical errors analysis, experimental tests were realized in laboratory using a DBB （Double Ballbar）. The tests are performed with only one axis moving, observing the behavior of the system for different feedrate at the C-axis.

Stroke optimization of a novel multi-station rotary polishing robot based on workspace analysis

In order to meet the polishing requirement of faucets and other products,a novel multi-station rotary polishing robot is designed,which is a PPPR + RR type of degree of freedom( DOF) distribution structure,and is similar to dual-arm robot. Forward and inverse kinematic analysis is carried out by robot modeling. In order to make this robot structure more compact,first of all,X,Y and Z three moving degrees of freedom( DOF) limit stroke polishing need is calculated by using an artificial fish swarm algorithm,which analyzes dexterous workspace of this robot. Then,on the basis of the above analysis,the three DOF stroke is optimized. Simulation and polishing experimental results verify that this polishing robot with optimized stroke parameters can meet the polishing needs of faucets and other bathroom pieces.

Rotary axis calculation for five-axis FDM printer using a point-fitting optimization method

This paper presents an optimization method to compute the rotary axes of a 5-axis FDM printer whose A-and C-axes have large deviations relative to the x-and z-directions.The optimization model is designed according to the kinematic model in which a point rotates around a spatial line in the machine coordinate system of the printer.The model considers the A-and C-axes as two spatial lines.It is a two-object optimization model including two aspects.One is that the sum of deviations between the measured and computed points should be small;the other is that the deviations should be uniformly distributed for every measured point.A comparison of the new optimization method with conventional error-compensation methods reveals that the former has higher location accuracy.Using the optimized AC axes,5-axis 3D printing paths are planned for some complex workpieces.Data analysis and printing samples show that the optimized AC axes satisfy 5-axes FDM printing requirements for nozzles with a diameter of 1.0 mm.

基于扰动补偿的磁悬浮转台分数阶滑模控制

针对存在非线性、耦合性和不确定性的磁悬浮转台的高精度运动控制问题,提出一种基于非线性干扰观测器的分数阶滑模控制方法以提高跟踪精度.首先,基于系统电磁力模型和动态解耦方法,构建六自由度磁悬浮转台系统动力学模型;其次,设计非线性干扰观测器,对包含系统误差、六自由度间耦合项和外界干扰的集总扰动进行估计,证明了估计误差有界且可调节到任意小;然后,在离散域提出了一种分数阶滑模面,采用分数幂函数替代传统符号函数来抑制抖振,引入分数阶微积分来减小跟踪误差;最后,设计有限时间收敛的分数阶滑模控制策略,并利用李雅普诺夫稳定性理论证明闭环系统稳定性.实验结果表明:与整数阶滑模控制方法相比,采用所提方法,2个水平自由度和绕竖直方向旋转自由度对三角波的跟踪误差均方根分别减小了12.8%、16.8%和23.7%,最大跟踪误差分别减小9.26%、13.00%和33.20%;跟踪圆形轨迹时,2个水平自由度的跟踪误差均方值分别减小6.39%和12.40%,最大跟踪误差分别减小9.90%和12.10%.

基于主动激励的掘进机回转台振动抑制研究

悬臂式掘进机截割过程由于煤岩形状、硬度分布的随机性,当截割到硬岩时截割头会产生无规则的剧烈振动,瞬时高强度的冲击对掘进机关键受力部件回转台影响最大,其动态可靠性和寿命影响着截割效率和截割稳定性,为减弱截割过程回转台的振动,首先,基于截割现场回转台易失效损坏现象,建立截割过程回转台力学模型,推导回转台力学方程,研究回转台受力随截割参数变化规律;通过搭建截割试验台,测试截割过程回转台振动响应,结合有限元进行回转台振动模态分析,求解回转台前6阶固有频率及振型,分析回转台剧烈振动的原因。其次,基于工况路径分析理论,建立截割过程回转台工况传递路径分析模型,模拟回转台合成振动,分析各激励点对回转台振动贡献量及贡献程度,准确找到回转台主要激振源。最后,通过施加外部主动激励的方式,分析不同激励频率加载下回转台振动情况,探寻能够降低截割过程回转台振动的激励频段。试验结果表明:外部激振频率处于20~60 Hz,回转台振动幅值降低明显,此频段激励频率对回转台振动控制效果良好,有益于提高回转台寿命,且激振频率为40 Hz时回转台振动最小,回转台振动抑制效果最佳。研究结果有益于丰富回转台振动相关研究理论,实现在不改变机械结构基础上,降低回转台受力与结构变形,可为掘进机回转台的振动问题提供理论参考。

钢包回转台三排滚子回转轴承强度分析及结构尺寸优化研究

钢包回转台是炼钢车间中低速重载工况下工作的重要设备。某企业的钢包回转台在运行过程中出现了回转支承强度不足的问题。为了探究回转支承的破坏原因,采用理论计算和数值仿真的方法开展研究。采用赫兹接触理论对两种工况下的回转支承进行相应的研究。经过仿真验证发现,在偏载工况下,回转支承中部分滚动体的应力超过了滚动体材料的屈服应力,导致了破坏。为改善受力状态,对回转支承结构的尺寸进行了优化选择,以降低应力。

一种专用平旋盘数控传动装置结构设计

针对组合机床通用部件镗孔车端面动力头镗刀杆径向移动不能数控控制的不足,设计了一种采用伺服电机驱动的镗刀杆径向运动的结构方案。将平旋盘镗刀杆径向往复运动由液压缸驱动转换成伺服电机驱动,实现对平旋盘镗刀杆径向运动的伺服控制。使得平旋盘具备自动粗精镗内孔、台阶孔、锥孔、端面,通过合理布置多刀实现内孔、外圆、端面的多工序加工。拓宽了机床加工工艺,提高了生产效率。在数控组合镗床上实现柔性化加工,得到广泛应用。

卧式加工中心转台回转夹具定位销连线的数学建模及实例应用研究分析

卧式加工中心转台回转夹具的典型结构是通过在卧式加工中心工作台上配置转台、尾座和夹具体,进而构成摇篮式转台,该种方式可以使加工工序集中化,进一步提高零件的加工质量和加工效率。在基于摇篮式转台回转夹具构成型式分析的基础上,以定位销连线为研究对象,通过讨论定位销连线与转台回转轴线及机床坐标系三者之间平行关系的几种情况,进而建立数学模型,并通过实例的方式解决生产过程中遇到的实际问题。

转台负载工况下角位置误差补偿方法研究

负载会影响转台回转轴的运动状态,进一步影响转台角位置误差的大小。通过分析负载工况下转台角位置误差傅里叶阶次的变化情况,提出一种基于谐波补偿的误差补偿方法。首先,分析负载对转台回转轴的影响,建立回转轴误差运动与角位置误差之间的数学模型,并进行数值仿真;其次,通过负载变化影响回转轴误差运动的大小,获取转台不同负载下的自校准曲线,采用傅里叶法分析对负载变化敏感的傅里叶阶次;最后,选取对负载变化敏感的傅里叶阶次拟合谐波补偿函数对转台角位置误差进行补偿。误差补偿后转台在不同负载工况下的角位置误差最大为±0.25″,与补偿后空载工况下角位置误差相差±0.03″,有效减小了负载对转台角位置误差的影响。

融合GRU单元的CNN网络在石油旋转机械故障诊断中的应用

针对现有石油旋转机械故障诊断算法存在的问题,提出一种融合GRU单元优化改进的CNN网络算法模型。先利用小波包算法保留高频区间的弱故障信号特征,选择ReLU函数作为CNN网络卷积层的激活函数,提升算法的运行速率并抑制模型梯度值的过快衰减;基于GRU单元整合输入门和遗忘门,抑制CNN网络存在的梯度弥散问题,改善了CNN网络模型的故障数据训练性能和分类检测性能。实验结果显示:融合GRU单元的CNN网络对训练集和测试集的故障诊断精度和故障分类能力均优于现有故障诊断算法,而且MAE函数的预测值和真实值更接近。

基于运动形式转化利用转动惯量虚拟平动惯性质量的TMD控制系统

针对调谐质量阻尼器(Tuned Mass Damper,TMD)通常需要较大的附加质量,安装空间受限以及质量块运动时需要较大的行程等问题,基于平动‐转动运动形式相互转化和能量守恒原理,本文提出了利用转动惯量虚拟平动惯性质量的TMD控制系统(Rotary inertia virtualizing translational mass based Tuned Mass Damper,简称RTMD),进行RTMD控制系统的设计概念,以单自由度结构对象为例建立了附加RTMD控制系统的运动方程,分析了RTMD控制系统参数对结构振动控制效果的影响规律。结果表明控制效果与系统的质量比、惯质比、阻尼比等参数密切相关,相关规律也可以推广到一般多自由度结构体系一阶振动的调谐吸振减振控制。进行了模型振动台试验研究,时域分析和频域分析结果均表明,试验结果与基于理论模型的数值分析结果一致性良好,验证了RTMD控制系统理论模型的正确性、设计参数的合理性以及控制系统应用于实际问题的可行性。

金属旋转挤压液压机的旋转系统及挤压成形方法

在金属旋转挤压液压机基础上增加一套能通过电液控制速度和扭矩的旋转系统,并通过控制各个机械部件完成旋转挤压成形。应用于金属旋转热挤压成形领域,特别是铝镁合金在军工产品的热旋转挤压一次成形领域。整个旋转系统主要包括压机系统和旋转台系统,主要用于镁合金杯型零件的成形。该设备可以由内向外旋转挤压成形。

RH精炼三钢包车双工位布局型式的研究

针对现有RH工艺布局存在热损失较高的现状,提出了一种连续高效生产的三钢包车双处理工位的RH布局型式。三套钢包车平行并列布置,三列钢包车的运行轨道相互平行。两侧钢包车(1#和2#)分别对应处理工位,中间钢包车(0#共享)对应处理位中间的回转台装置。0#共享钢包车运行至回转台上后,回转台装置旋转90°后可直达两个处理工位之一。三台钢包车两两组合可单工位交叉生产,可双工位交替生产,实现多种组合生产模式。使用该布局型式,可实现钢水连续冶炼过程的"无缝对接"且灵活多变,故障小效率高,可以适应不同钢种的冶炼要求。

Study of the influences of rotary table speed on stick-slip vibration of the drilling system

Stick-slip vibration presents one of the major causes of drilling problems,such as premature tool failures,low drilling efficiency and poor wellbore quality.The objective of this work is to investigate the influences of rotary table speed(RTS)on stick-slip phenomenon of the drilling system.In this study,the drilling system is treated as a lumped torsional pendulum model of which the bit/rock interaction is regarded as Coulomb friction.By analyzing cases with different RTS,two types of vibrations on the bit are found:stick-slip vibration and uniform motion.With an increase in the RTS,the stick-slip vibration on the drill bit disappears once the RTS arrives at its critical value.For the cases that stick-slip vibrations occur,the phase trajectories converge toward a limit cycle.For the cases that stick-slip vibration does not appear,the drill bit tends to stabilize at a uniform motion and the phase trajectories correspond to contracting spirals observed in the phase plane.

转台运动误差分离与角度优化技术研究

为了解决测量转台运动误差时存在的多种误差耦合问题,提出了一种基于多点法的运动误差分离方法。首先,通过分析转台在回转过程中多自由度误差的运动特性,提出了一种端面四点误差分离方法,在分离出测量盘下表面的平面度误差的同时,可完成倾斜误差和轴向误差的解耦。然后,建立了该方法的误差传递函数,采用麻雀算法(SSA)进行优化,寻找不同阶次下受谐波抑制影响最小的最优布置角,提高了误差解耦精度。最后,通过仿真与实验的方式对该方法进行验证。仿真结果表明,端面四点误差分离方法对轴向、倾斜误差的分离精度(相对误差)分别为1.934%和9.177%。实验结果表明,分离的运动误差与转台标定误差相符合,验证了该方法能够精确获得转台运动误差。

薄膜反馈式节流器的结构设计

薄膜反馈式节流器因反馈精度高,常被用于液体静压转台中。目前,国内液体静压转台高精度缺乏、需求激增,为了提高转台精度,设计了一种新型薄膜反馈式节流器,以获得稳定的高刚度油膜,并采用Ansys进行双向流固耦合分析,获得液压油的流速和压力分布;然后,对比PM流量控制器,结果表明随着入口压力的增加,两者的薄膜最大变形量均呈近似线性关系递增,其递增率仅相差0.11,因此证明所设计的节流器是合理可行的;最后,对基于薄膜反馈式节流的液体静压转台进行性能测试,结果表明转台的各项性能指标均能达到要求:承载力大于1000 kg、刚度大于2077 N/μm、轴向跳动小于1μm,表明设计的节流器是合理可行的。

五轴转台的摇篮机体结构优化

由于摇篮五轴转台其自身精度直接决定了整个数控机床的最终加工精度,而摇篮机体的精度是决定摇篮五轴转台回转精度主要因素之一,因此针对五轴转台的摇篮机体进行了优化设计,提出了分体式摇篮机体结构,该结构可降低机体的加工难度,提高机体的装配精度,以期对五轴摇篮式转台的实际应用提供设计参考。

Modeling and analysis of steady-state vibration induced by backlash in servo rotary table

Backlash cannot be always avoided in mechanical systems because of wear or looseness. Steady-state vibration may be induced by backlash in closed loop feed drive systems. This paper presents a mathematical model ofa servo rotary table, considering the effect of backlash. The accuracy of this model is verified by an experiment. The influences of the parameters, such as position controller gain, velocity controller gain, load and the magnitude of backlash, on steady-state vibration are discussed. The steady-state vibration amplitude increases with the position controller gain, load and the magnitude of backlash. The steady-state vibration fre- quency increases with the position controller gain and the velocity controller gain, while an increase in load leads to a decrease in the frequency.

基于OpenMV的电动转台位置调整设计

介绍一种电动圆转台位置调整控制系统,实现将转台中放置物体转到指定方向。该系统主要由Arduino UNO微处理器和OpenMV视觉模块以及步进电机驱动组成,使用Python作为编程语言和JSON数据格式,实现转台上图像识别和驱动信号输出。测试表明:电动转台系统可以实现较好的定位。