【作者】 张伟；

【导师】 王连东； 马雷；

【作者基本信息】 燕山大学 ， 车辆工程， 2007， 硕士

【摘要】 液压胀形技术是一种制造空心轻体构件的先进制造技术。用液压胀形工艺生产出的汽车桥壳，可以满足车辆制造轻量化的要求，而且制件壁厚分布合理、强度刚度高。液压胀形桥壳在国外汽车制造业中逐渐获得应用，通过大量的生产试验，已基本掌握了关键工艺参数的优化选取方法。在合理选取关键工艺参数及预定加载路径的前提下，胀形压力的控制是成形出质量良好制件的关键。但是，目前胀形压力的控制方法落后，且控制精度低，利用该工艺制备汽车桥壳类制件的成功与否受操作者对该工艺的了解及其对设备的操作熟练程度等不确定因素影响很大。本文就以上存在的问题，研究了现有条件下液压胀形压力的自动控制问题，并设计了一整套计算机控制系统，取0.75 t载重车桥壳的1／2缩小比例试件进行液压胀形试验，从而检验设计的超高压液压胀形集成装置压力控制系统的可靠性。本文首先根据系统的控制要求，完善了独立于主机系统，具有快速充液、产生变高压、乳化液循环功能的超高压液压胀形集成装置的设计，再采用电液比例控制技术对设备进行控制，并设计了数据采集与加载控制系统的外部控制电路。最后，利用模块化设计方法完成了控制系统硬件的选型与设计，并编制了交互性良好的过程控制软件，从而使该控制系统得以初步实现。文中重点探讨了超高压液压胀形压力控制的控制策略问题，利用系统辨识方法建立了胀形过程的数学模型，在此基础上完成了相应的控制器设计，给出了控制算法，并对所设计的控制系统进行了仿真。最后通过实验验证该控制系统是稳定的，系统性能可满足工艺要求。上述工作的完成，初步解决了超高压液压胀形集成装置的压力自动控制问题，为国内液压胀形工艺的实际应用奠定了基础。更多还原

【Abstract】 Hydro-bugling is a kind of forerunner manufacturing technique in making hollow light body. The axle housing manufactured by hydro-bugling can meet the requirement of light weight in automotive making. The products are of reasonable thickness distribution, high strength and rigidity. Hydro-bugling axle housing is gradually used in foreign automotive manufacturing industry and an optimized selection method of key craft parameter has been mastered after a great deal of productive experiment. Under the premise of reasonably selecting craft parameter and prefixing the loading path, the key that taking shape of the part with high quality is to control hydro-bugling pressure. But, the control method of hydro-bugling pressure is un-advanced and the control accuracy is low, whether making auto axle housing parts by using this craft parameter can be success or not is greatly influenced by the operators’ experience and proficiency in the craft parameter and equipment. Given the above problems, this paper explores auto control of hydro-bugling pressure under the present condition, and designs a whole set of computer-controlling system. Taking 1:2 scale samples of a 0.75 t truck axle housing to hydro-forming test and research so as to test the reliability of auto control system for ultrahigh pressure hydro-forming integrated equipment.Firstly, according to the control requirement of the system, this thesis designs ultrahigh pressure hydro-bugling integrated equipment perfectly, which is independent at the main machine system and has the function of filling the liquid, producing the changed ultrahigh pressure and circulatory function of the emulsion. Secondly, the equipment has been controlled by using control technique of electro-hydraulic proportion, which is designed data acquisition and loading the outer control circuit of the control system. At last, selecting type and design of hardware for the control system has been completed by using modular design method, the process control software with good interactivity has been established, and consequently this control system can be true.The key point in this thesis has studied control strategy problems in ultrahigh pressure hydro-bugling control, making use of the system recognition method to establish a mathematical model in the bulging process. On this foundation we have completed the controller design and given the way of control calculation, together with the control system which has been designed to simulate. At last, the experiment result indicates that the control system is stable and can satisfy the craft request, to prove its feasibility and availability.The completion of the above mentioned work can solve this pressure auto control problem of ultrahigh pressure hydro-bugling integrated equipment, which laid a foundation for the actual application of domestic hydro-bugling craft parameter.更多还原