MECHANICAL-ELECTRIC COUPLING DYNAMICAL CHARACTERISTICS OF AN ULTRA-HIGH SPEED GRINDING MOTORIZED SPINDLE SYSTEM

On the basis of the traditional mechanical model of a grinding wheel rotor and the mechanical-electric coupling model with ideal sinusoidal supply, taking high-frequency converting current of inverter power switches into further consideration, a modified mechanical-electric coupling model is created. The created model consists of an inverter, a motorized spindle, a grinding wheel and grinding loads. Some typical non-stationary processes of the grinding system with two different supplies, including the starting, the speed rising and the break in grinding loads, are compared by making use of the created model. One supply is an ideal sinusoidal voltage source, the other is an inverter. The theoretical analysis of the high-order harmonic is also compared with the experimental result. The material strategy of suppressing high-order harmonic mechanical-electric coupling vibration by optimizing inverter operating parameters is proposed.

Optimization of Bearing Locations for Maximizing First Mode Natural Frequency of Motorized Spindle-Bearing Systems Using a Genetic Algorithm

This paper has developed a genetic algorithm (GA) optimization approach to search for the optimal locations to install bearings on the motorized spindle shaft to maximize its first-mode natural frequency (FMNF). First, a finite element method (FEM) dynamic model of the spindle-bearing system is formulated, and by solving the eigenvalue problem derived from the equations of motion, the natural frequencies of the spindle system can be acquired. Next, the mathematical model is built, which includes the objective function to maximize FMNF and the constraints to limit the locations of the bearings with respect to the geometrical boundaries of the segments they located and the spacings between adjacent bearings. Then, the Sequential Decoding Process (SDP) GA is designed to accommodate the dependent characteristics of the constraints in the mathematical model. To verify the proposed SDP-GA optimization approach, a four-bearing installation optimazation problem of an illustrative spindle system is investigated. The results show that the SDP-GA provides well convergence for the optimization searching process. By applying design of experiments and analysis of variance, the optimal values of GA parameters are determined under a certain number restriction in executing the eigenvalue calculation subroutine. A linear regression equation is derived also to estimate necessary calculation efforts with respect to the specific quality of the optimization solution. From the results of this illustrative example, we can conclude that the proposed SDP-GA optimization approach is effective and efficient.

Temperature prediction model for a high-speed motorized spindle based on back-propagation neural network optimized by adaptive particle swarm optimization

To predict the temperature of a motorized spindle more accurately,a novel temperature prediction model based on the back-propagation neural network optimized by adaptive particle swarm optimization(APSO-BPNN)is proposed.First,on the basis of the PSO-BPNN algorithm,the adaptive inertia weight is introduced to make the weight change with the fitness of the particle,the adaptive learning factor is used to obtain different search abilities in the early and later stages of the algorithm,the mutation operator is incorporated to increase the diversity of the population and avoid premature convergence,and the APSO-BPNN model is constructed.Then,the temperature of different measurement points of the motorized spindle is forecasted by the BPNN,PSO-BPNN,and APSO-BPNN models.The experimental results demonstrate that the APSO-BPNN model has a significant advantage over the other two methods regarding prediction precision and robustness.The presented algorithm can provide a theoretical basis for intelligently controlling temperature and developing an early warning system for high-speed motorized spindles and machine tools.

Research Progress of Key Technology of High-Speed and High Precision Motorized Spindles

High speed machining and high precision machining are two tendencies of themanufacturing technology worldwide. The motorized spindle is the core component of the machine toolsfor achieving the high speed and high precise machining, which affects the general developmentlevel of the machine tools to a great extent. Progress of the key techniques is reviewed in thispaper, in which the high speed and high precision spindle bearings, the dynamical and thermalcharacteristics of spindles, the design technique of the high frequency motors and the drivers, theanti-electromagnetic damage technique of the motors, and the machining and assembling technique areinvolved. Finally, tha development tendencies of the motorized spindles are presented.

Dynamic Response Analysis of Motorized Spindle System

As to motorized spindle system, this paper builds a simplified 3D model of spindle and bearing, performs structure modal analysis, reveals its dynamic characteristics under the free model; furthermore, modifies bearing radial stiffness and number of model and studies the change of modal parameters. On this basis, through the harmonic response analysis of the finite element model, dy- namic response characteristic caused by imbalance of monitored spindle system and law of vibration response to different amount of unbalance is analyzed.

Analysis of Thermal Characteristics for a High Speed Motorized Spindle Based on the ANSYS Workbench

The high-speed motorized spindle, as the key component of machining centers and other high-end CNC machine tools, has performance directly affecting machining accuracy. According to the internal motor character- istics of the high speed motorized spindle in the paper, two major heat sources are analyzed and quantity of heat is calculated. The finite element analysis model of motorized spindle thermal characteristics is built through ap- plying the ANSYS Workbench. The thermal steady state, heat-structure coupling characteristics is carried out based on the cooling coefficient of thermal boundary conditions, and taking heating value of the bearing and mo- tor as thermal load, the temperature field distribution and thermal deformation of the spindle system are obtained, which prepare fox＂ the next thermal error modeling

Design of Rotor Magnetic Barrier Structure of Built-in Permanent Magnet Motor Based on Taguchi Method

In this paper,a 20kW vehicle built-in permanent magnet synchronous motor is taken as an example,and a magnetic barrier structure is added to the rotor of the motor to solve the uneven saturation problem of the rotor side magnetic bridge.This structure improves the air-gap flux density waveform of the motor by influencing the internal magnetic flux path of the motor rotor,thus improving the sine of the no-load back EMF waveform of the motor and reducing the torque ripple of the motor.At the same time,Taguchi method is used to optimize the structural parameters of the added magnetic barrier.In order to facilitate the analysis of its uneven saturation phenomenon and improve the optimization effect,a simple equivalent magnetic network(EMN)model considering the uneven saturation of rotor magnetic bridge is established in this paper,and the initial values of optimization factors are selected based on this model.Finally,the no-load back EMF waveform distortion rate,torque ripple and output torque of the optimized motor are compared and analyzed,and the influence of magnetic barrier structure parameters on the electromagnetic performance of the motor is also analyzed.The results show that the optimized motor can not change the output torque of the motor as much as possible on the basis of reducing the waveform distortion rate of no-load back EMF and torque ripple.

Dynamic Analysis of Axial Magnetic Forces for DVD Spindle Motors

The axial magnetic force, induced by the complicated flux linkage distribution from rotor magnet and stator slotted, is constructed by different relative heights and calculated by 3D finite element method (FEM) to analyze the dynamic characteristics for a DVD spindle motor. The axial magnetic force is designed to provide an axial stiffness, and govern the natural frequency of the dynamic performance. According to the simulation results and experimental measurements, the dynamic behaviors are significantly improved with a variation of relative height of rotor magnet and stator slotted on a DVD spindle motor.

Identification Method of Dynamic Coefficients of Fluid Film Bearings for HDD Spindle Motors

Fluid film bearings are widely used as support elements of rotating shaft for HDD （hard disk drive） spindle motors. Recently, the opportunity for the HDD spindle motors exposed to external vibration has been increasing because the HDDs are used for various information related equipments such as mobile PCs, car navigation systems. Hence, the rotating shaft has a possibility to come in contact with the bearing and it causes wear or seizure to the bearing surface. In order to avoid the problems, it is extremely important to enhance the dynamic characteristics of the fluid film bearings for spindles. However, verification from both theory and experiment of dynamic characteristics such as spring coefficients and damping coefficients is rare and few. In this paper, the bearing vibration characteristics when the HDD spindle is oscillated are investigated theoretically and experimentally. And then the identification method ofoil film coefficients of fluid film bearing spindles is described.

Vibration Response Characteristics against the Radial and Axial Shocks on Small Size Hard Disk Drive Spindle Supported by Oil Film Bearings

This paper describes the experimental study on shock response of FDB （fluid dynamic bearing） spindle for HDDs （hard disk drives）. The FDBs are widely used as rotating shaft support elements for HDD spindle motors. Recently, the opportunity for the HDD spindle motors exposed to external vibration has been increasing because the HDDs are used for various information related equipment such as mobile PCs （personal computers）, video cameras, car navigation systems and so on. Hence, the rotating shaft has a possibility to come in contact with the bearing by external shocks and it causes wear or seizure to the bearing surface. To avoid the problem, it is extremely important to know how the spindle moves against the large shock on HDDs experimentally. However, as far as the authors know, there are few experimental studies treating the shock response of HDD spindles. In this paper, firstly, we propose a new test rig and experimental method for shock response of FDB spindles. Then the shock tests against the radial and axial disturbance on FDB spindle for 2.5＂ HDD are conducted. Finally, the experimental results of shock response waveforms and maximum displacement of disk are shown.

喷嘴位置对轴承腔内油气润滑两相流的影响

基于气液两相流理论,采用多重坐标系法构建角接触球轴承数值计算模型,分析不同喷嘴位置和转速下轴承腔内油相体积分数、保持架表面及轴承内外圈的油气分布特性。结果表明:在轴承低转速下,正面供油时轴承腔内油相体积分数及其周向分布的波动大于背面供油;正面供油时保持架下表面会产生润滑油的积聚,造成润滑油无法及时通过出口排出,而背面供油时润滑油在保持架表面的油相分布更均匀;正面供油时内圈左面油相体积分数较高,外圈油相分布变化较大,而背面供油时内圈右面、中间面及外圈中间面油相体积分数较高。不同转速下喷嘴位置对腔内油相分布的影响也不同,低转速下正面供油时腔内油相体积分数更高,高转速下喷嘴位置对轴承腔内油相分布的影响较小,润滑油在轴承腔内分布较为均匀,保持架下侧未见明显的润滑油积聚。

考虑热误差的电主轴建模与可靠性全局灵敏度分析

以数控机床电主轴为研究对象,旨在分析其轴向热伸长量对电主轴可靠性的影响.采用Svenska Kullager-Fabriken(SKF)摩擦力矩模型对轴承生热量进行分析,设定对流换热系数为边界散热条件,建立了热分析有限元耦合模型,求解电主轴的温度以及轴向热伸长分布.将有限元模型与实验结果进行对比,验证了建立的有限元模型的准确性.考虑随机因素的影响,建立电主轴热变形可靠性分析模型,并采用Kriging模型进行可靠性求解.对电主轴热误差可靠性全局灵敏度进行分析,结果表明,转速和冷却水流量对可靠度影响较大,轴向力和径向力对可靠度影响较小.

电主轴热补偿及轴承故障检测在热辐射测温方面的研究

针对电主轴轴体的热变形以及重要零部件轴承在加工中心上的常见故障,提出基于收集电主轴温度变化的热误差实时补偿计算方法与轴承常见故障的诊断方法。热误差补偿方法可以通过对轴体上测温点数据的处理对电主轴单元进行实时的热误差补偿提高加工精度。故障诊断方法是对不同的温度节点设置不同的阈值,阈值对应着电主轴单元内部某些重要零件的故障特征,当节点温度变化超出阈值即进行报警以诊断具体零件的故障。促进了电主轴的智能化进程,为接下来的研究打下基础。

Study of the thermal influence on the dynamic characteristics of the motorized spindle system

The severe internal heat generation of the motorized spindle system causes uneven temperature dis- tribution, and will affect the vibration characteristics of the system. Based on the thermal analysis about the motorized spindle by finite element method （FEM）, the thermal deformations of the spindle system are calculated by the thermal structure coupling simulation, and the thermal deformations of the rotor and the bearing units are extracted to analyze the bearing stiffness changes so that the modal characteristics of the rotor can be simulated in different thermal state conditions. And then the rotor thermal deformation experiment and the modal experiment of spindle by exciting with hammer are performed. The result shows that the thermal state of the motorized spindle system has a significant influence on the natural frequency of the rotor, which can be carefully treated when a spindle system is designed.

Improved thermal resistance network model of motorized spindle system considering temperature variation of cooling system

In the motorized spindle system of a computer numerical control (CNC) machine tool, internal heat sources are formed during high-speed rotation;these cause thermal errors and affect the machining accuracy. To address this problem, in this study, a thermal resistance network model of the motorized spindle system is established based on the heat transfer theory. The heat balance equations of the critical thermal nodes are established according to this model with Kirchhoffs law. Then, they are solved using the Newmark-β method to obtain the temperature of each main component, and steady thermal analysis and transient thermal analysis of the motorized spindle system are performed. In order to obtain accurate thermal characteristics of the spindle system, the thermal conduction resistance of each component and the thermalconvection resistance between the cooling system and the components of the spindle system are accurately obtained considering the effect of the heat exchanger on the temperature of the coolant in the cooling system. Simultaneously, high-precision magnetic temperature sensors are used to detect the temperature variation of the spindle in the CNC machining center at different rotational speeds. The experimental results demonstrate that the thermal resistance network model can predict the temperature field distribution in the spindle system with reasonable accuracy. In addition, the influences of the rotational speed and cooling conditions on the temperature increase of the main components of the spindle system are analyzed. Finally, a few recommendations are provided to improve the thermal performance of the spindle system under different operational conditions.

模糊自整定PID的液压马达驱动机床主轴速度控制研究

液压马达驱动机床主轴系统具有参数时变和高度非线性,传统PID控制器控制精度不高。针对液压马达驱动机床主轴系统速度控制问题,采用模糊自整定PID控制器实现液压马达驱动机床主轴系统的有效控制,并对控制效果进行仿真验证。构造了液压马达驱动机床主轴系统模型简图,建立了液压马达驱动机床主轴系统数学模型。对传统PID控制器参数,用模糊控制器进行实时整定,开发了模糊自整定PID控制器。最后,采用MATLAB对液压马达驱动机床主轴系统进行仿真。同时,与传统PID控制器的计算结果进行对比和分析。仿真结果显示:采用模糊自整定PID控制器的液压马达驱动机床主轴转速超调量小,具有更快的响应时间,跟踪精度高,同时系统能耗减少20%左右;即使受到较大随机干扰,模糊自整定PID控制器也能快速消除干扰,使机床主轴转速处于受控状态。采用模糊自整定PID控制器可以有效提高液压马达驱动机床主轴系统的动态稳定性以及抗干扰能力。

面向电主轴热误差预测建模分析的改进IGWO-LSTM算法

针对电主轴复杂运行工况下的热误差建模问题,提出一种基于改进灰狼优化算法(IGWO)的LSTM神经网络参数预测模型IGWO-LSTM。通过对灰狼算法收敛因子a计算方法进行优化来提高算法寻优性能;通过IGWO算法的适应度函数与LSTM隐含层节点数组成的IGWO-LSTM闭环系统对电主轴热误差预测模型进行训练和预测,避免陷入局部最优,同时提升模型预测精度。为了验证该算法性能,将它与改进前的算法进行对比,通过求取平均绝对误差、平均绝对百分比误差以及均方根误差对这两种神经网络进行评价,结果显示:文中算法的3种指标均优于改进前的LSTM模型,具有更好的热误差预测准确性和全局搜索能力。

基于主轴电机电流信号的表面粗糙度检测

针对表面粗糙度不能及时检测造成的工件浪费问题,首次提出根据主轴电机电流信号进行表面粗糙度检测分类。通过实验采集不同表面粗糙度加工时的主轴电机电流信号,采用小波包分解将电流信号分解成不同频段,借助能量特征和裕度因子对不同频段电流信号进行评估,过滤低相关性频段,再通过随机森林筛选特征,降低特征的冗余性。总谐波失真特征实现了积屑瘤检测,仅依赖构建的电流信号特征工程表面粗糙度检测准确率高达95%以上,并且检测时间在2 s以内,基本实现了工件表面粗糙度的快速准确检测。

基于ANSYS Workbench的磨削用电主轴转子动力学特性研究

电主轴是将电机与主轴融为一体的新技术,相比传统主轴它具有更高的精度、转速与功率。为了开发性能更加优良的电主轴,在设计环节需要通过转子动力学方法验算出极限转速,从而提高其寿命和加工性能。目前行业上广泛采用的是刚性梁假设的转子动力学方程组,来求解轴系的动态特性,该方法未能充分考虑到模型的所有自由度导致不能充分测算出主轴的性能。针对于此,本文提出了一种采用仿真软件结合轴承理论的方法,在ANSYS Workbench软件中搭建主轴的网格模型,分析了主轴的刚度、极限转速与模态频率,并与试验结果进行验证。结果表明,仿真结果误差较小,该方法具有有效性与实用性。

集成式电机主轴的力感知及微进给特性研究

为满足精密加工过程中对电机主轴的转速、进给距离和切削力精确控制的需求,将永磁同步电机和超磁致伸缩驱动器结合,提出一种具有转动、微进给及力感知功能的集成式电机主轴。为验证集成式电机主轴力感知部分的结构合理性,基于磁路法和有限元分析法,得出集成式电机主轴的微进给距离、外线圈感应电压与外部载荷的关系。最后,为验证仿真的准确性,搭建集成式电机主轴力感知及微进给试验平台。结果显示,在此磁路模型设计中,集成式电机主轴的磁通密度可达0.551 9 T,磁通密度均匀度大于77.85%,集成式电机主轴的微进给距离可达26.5μm,外线圈感应电压与外部载荷成反比且内线圈的最佳外加电流为5 A。研究结果表明,集成式电机主轴力感知及微进给功能的设计是合理可行的,为深入研究和精确控制集成式电机主轴奠定了基础。