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Hui Li
Tianjin University of Technology and Education,Tianjin,China
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(Manuscript Received April 6, 2009; Revised April 16, 2010; Accepted April 16, 2010)
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Abstract
Modeling and dynamic analysis of the electromechanical coupling system of a hybrid-driven mechanical press were undertaken.
A dynamic model of a two-degrees-of-freedom seven-bar linkage was developed using Lagrange’s equation. According to the
equivalent circuit of a DC motor and a brushless servomotor, a dynamic model and negative feed-back model were separately
developed. The fourth-order Runge-Kutta method, an explicit method, was employed as the integration technique in a computer
simulation, and the time history of the hybrid-driven press was obtained.
L S4
Md4 S L 4
4
L S3 φ2 S2
2 2
S3
φ4 D C
φ3
L3 where J11 ´, J12 ´, J 22 are the equivalent moments of inertia
of the two-DOF seven-bar mechanism. These relationships are
S0
L S6
S6 further elucidated in the Appendix.
L6 The potential energy of the mechanism can be expressed as
F
G
φ6
V = −m1gxS1 − m2 gxS 2 − m3 gxS 3 − m4 gxS 4 − m6 gxS 6 − m7 g (S0 − S )
(6)
S
e Q
where φi is the angular velocity of link i , and x Si and y Si ⎧⎪ q1 = A0 + A11q12 + A12 q1q 2 + A22 q 22
⎨ (9)
are the x and y velocity components of its center of mass. 2
⎪⎩q2 = B0 + B11q1 + B12 q1q 2 + B22 q 2
2
Rk L mk where ktk is the motor torque constant and kek is the motor
+ Bk
voltage constant. Observing that
ik TLk Tmk
ωak = nk ωbk = nk q k , (16)
Uk ek J hk ak
Tmk substituting Eqs. (14), (15) and (16) into Eqs. (12) and (13),
-
we find
bk
Tbk
dik U k − Rk ik − nk kek q k
= (17)
dt Lmk
Fig. 2. Schematic representation of DC motor. Tbk = nk ktk ik − nk TLk − nk2 Bk q k − nk2 J hk qk , (18)
Tbk ωak Eqs. (17) and (18) being the mathematical models of the mo-
nk = = ( k = 1 ,2) (10)
Tak ωbk tor dynamics.
PID controllers are commonly used in many industrial proc-
where ωak is the angular velocity of the input shaft ak , and esses. Their popularity is attributed partly to their performance
ωbk is the angular velocity of output shaft bk . In Fig. 2, the in a wide range of operational conditions, and partly to their
input to the motor-gear system is voltage U k , and the output functional simplicity. Indeed, they can be operated by engi-
of the system is the torque Tbk , which, as defined in Eq. (7), is neers in a simple and straight-forward manner. PID controllers
equal to M dk . Rk , Lk , and ik are the armature resistance, utilize a control signal involving positional, velocity error and
inductance and current, respectively. The shaft bk is con- integral of position error functions. Here, the objective was to
nected so as to drive the crank L1 and crank L4 of the establish a PID control algorithm in order to determine how it
mechanism, respectively. Bk is a damping coefficient due to can improve the transient and steady-state responses of the
a possible viscous bearing friction, TLk is a constant mechani- electromechanical system.
cal load, due to either brush friction, gear friction or dry bear- When the motor is controlled by the PID position closed
ing friction. J hk is the combined moment of inertia of the loop, the voltage U i can be given as
motor rotor , the speed reducer, and the flywheel. Since two
different DC motor types were studied, the same motor equa- t
tions were used, and different motor data were utilized. Here,
U k = k pk (qkic − qk ) + kdk (q kic − q k ) + k Ik
∫ 0
(qKc − qk )dt (19)
k is equal to 1 for a DC motor and 2 for a brushless servomo-
tor, respectively, throughout the work. J hk can be given as where k pk is the proportional gain constant, kdk is the de-
rivative gain constant, and k Ik is the integral gain constant.
J hk = J mk + J Rk + J fk (11) qkc and q kc are the ideal angular displacement and ideal
angular velocity of the crank Lk , respectively, and qk and
where J mk is the moment of inertia of the motor rotor, J Rk q k are the actual angular displacement and actual angular
is the equivalent moment of inertia of the speed reducer, and velocity of the crank Lk , respectively.
J fk is the moment of inertia of the flywheel. Substituting Eq. (19) into Eq. (17) ,
From Kirchhoff’s voltage law,
⎛ t ⎞
U k = Rk ik + Lmk
dii
dt
+ ek (12) dik ⎝
=
∫
⎜⎜ k pk (qkc − qk ) + kdk (qkc − qk ) + kIk (qkic − qk )dt ⎟⎟ − Rkik − nk kek qk
0 ⎠
dt Lmk
(k = 1, 2) .
where ek is the generated electromotive force of the motor.
Using a Newtonian equation for the mechanical load, we have (20)
dωak Eq. (20) is the PID control model of the servo motor dynamics.
Tbk = nk (Tmk − TLk − Bk ωak − J hk ) (13)
dt The proportional gain constant k pk , the derivative gain con-
stant kdk and the integral gain constant k Ik were optimized by
where Tmk is the magnetic motor torque, and nk is the gear running the simulation software with real mechanism parame-
ratio defined by Eq. (10). The magnetic torque and the gener- ters and motor data [17].
ated electromotive force are given as
2.3 Mathematical model for electromechanical press system
Tmk = ktk ik (14)
ek = kek ωak (15) Combining Eqs. (9) and (20) gives
2164 H. Li and Y. Zhang / Journal of Mechanical Science and Technology 24 (11) (2010) 2161~2167
(22)
where ⎡1 ∂J ∂J 1 ∂J ⎤ 1
A22 = ⎢ J12 22 − J 22 12 + J 22 22 ⎥
⎣2 ∂q2 ∂q2 2 ∂q1 ⎦ C1
⎧ ⎡⎛ ∂x ⎞ 2 ⎛ ∂y ⎞ 2 ⎤
7
⎛ ∂φ j ⎞ ⎫⎪
2
J11 = ∑
⎪ ⎢
⎨m j ⎜
j =1 ⎪
Sj
⎟ +⎜
Sj
⎥
⎟ + Jj⎜
⎢⎝ ∂q1 ⎠ ⎝ ∂q1 ⎠ ⎥
⎣ ⎦
⎟ ⎬
⎝ ∂q1 ⎠ ⎪⎭
⎡ 1 ∂J ∂J 1 ∂J ⎤ 1
B22 = ⎢ − J12 22 + J12 12 − J11 22 ⎥ .
2 ∂q ∂q 2 ∂q2 ⎦ C1
j ≠5
⎩ ⎣ 1 2
7
⎧ ⎡⎛ ∂xSj ∂xSj ∂ySj ∂ySj ⎞ ⎤ ⎛ ∂φ j ∂φ j ⎞ ⎪⎫
J12 = ∑ ⎪⎨⎩⎪m ⎢⎣⎢⎜⎝ ∂q
j =1
j
1 ∂q2
+ ⎟⎥ + J j ⎜
∂q1 ∂q2 ⎠ ⎦⎥
⎟⎬
⎝ ∂q1 ∂q2 ⎠ ⎭⎪
j ≠5
Hui Li received his B.S. in Mechanical
7 ⎧ ⎡⎛ ∂x ⎞ 2 ⎛ ∂y ⎞ 2 ⎤ ⎛ ∂φi ⎞ ⎫⎪
2
Engineering from the Hebei Polytechnic
J 22 = ∑ ⎪ ⎢
⎨m j ⎜
⎢ ∂q
Sj
⎟ +⎜
∂q
Sj
⎟ ⎥+ Jj⎜
⎥
⎟ ⎬.
⎝ ∂q2 ⎠ ⎭⎪
University, Hebei, China, in 1991. He
j =1
j ≠5
⎩⎪ ⎣⎝ 2 ⎠ ⎝ 2 ⎠ ⎦ received his M.S. in Mechanical
Engineering from the Harbin University
Explicit forms of A0 , B0 , A11 , B11 , A12 , B12 , A22 , B22 are of Science and Technology, Hei-
given as longjiang, China, in 1994. He received
his PhD from the School of Mechanical
A0 = (Q1 J 22 − Q2 J12 ) / C1 Engineering of Tianjin University, Tianjin, China, in 2003. He
B0 = (Q2 J11 − Q1J12 ) / C1 was a postdoctoral researcher at Shijiazhuang Mechanical
Engineering College from August 2003 to September 2005,
C1 = J11 J 22 − J12 2
and at Beijing Jiaotong University from March 2006 to De-
⎡ ∂J 1 ∂J 1 ∂J ⎤ 1 cember 2008. He is currently a professor in Mechanical Engi-
A11 = ⎢ J12 12 − J12 11 − J 22 11 ⎥
⎣ ∂q1 2 ∂q2 2 ∂q1 ⎦ C1 neering at Shijiazhuang Institute of Railway Technology,
⎡ ∂J 1 ∂J 1 ∂J ⎤ 1 China. His research and teaching interests include hybrid-
B11 = ⎢ − J11 12 + J12 11 + J11 11 ⎥ driven mechanisms, kinematics and dynamics of machinery,
⎣ ∂q 1 2 ∂q 1 2 ∂q2 ⎦ C1
mechatronics, CAD/CAPP, signal processing for machine
⎡ ∂J ∂J ⎤ 1 health monitoring, diagnosis and prognosis. He is currently a
A12 = ⎢ J12 22 − J 22 11 ⎥
⎣ ∂q1 ∂q2 ⎦ C1 senior member of the Chinese Society of Mechanical Engi-
⎡ ∂J ∂J ⎤ 1 neering.
B12 = ⎢ J12 11 − J11 22 ⎥
⎣ ∂q 2 ∂q1 ⎦ C1