可控磁电混合悬浮带式输送机运行机理及实验研究

Conventional belt conveyor using rollers to support belt and shipment leads to serious mechanical wear and huge energy consumption. In this project, a new type of controllable magnetoelectric hybrid suspension belt conveyor is proposed by changing the belt supporting mode by non contact no-roller supporting. On this basis, the related operation mechanism is studied, and the mathematical model of the single-point magnetoelectric hybrid suspension system is established by using the equivalent magnetic circuit method, to get the quantitative relationship between the balance influence factors and the levitation force. The nonlinear deformation field is used to study the modeling problem of large deformation and wide range flexible belt. Then the one-order approximate dynamic model of the conveyor belt with terminal added mass is built, and the stable suspension condition under the hybrid magnetic field is calculated. Based on the electromagnetic equations and mechanical models, the hybrid suspension system model is derived to study the dynamic characteristics of equivalent suspension stiffness, system damping and the dynamic response curves under external system excitation. The belt’s air gap and attitude control are studied to design the control system based on state feedback, and the control strategy of hybrid suspension system is proposed accordingly. At length, the small prototype is trial-manufactured for the relevant principle experiments which could corrected the prototype and provide theoretical reference and technical support for the design and development of new belt conveyor with non-roller and low running resistance.

普通带式输送机采用托辊支撑输送带和物料，机械磨损严重，能耗大。本项目改变输送带支撑方式，提出了一种新型可控磁电混合悬浮带式输送机结构，实现无托辊式非接触支撑。在此基础上，开展相关运行机理研究，利用等效磁路法建立单点磁电混合悬浮系统的数学模型，获取平衡影响因素与悬浮力的量化关系；采用非线性变形场研究大范围大变形柔性输送带建模问题，建立带有末端附加质量的输送带一次近似动力学模型，提出混合磁力场下柔性输送带的稳定悬浮条件；联立电磁学方程与力学模型，研究等效悬浮刚度和系统阻尼等系统动态特性，获取外部激励下磁电混合悬浮系统的动态响应曲线；开展悬浮气隙及柔性输送带姿态控制研究，设计基于状态反馈的控制系统，并提出与之相协调混合悬浮系统控制策略；进而试制小型样机，开展相关原理性实验研究并修正样机，为设计开发新型无辊式低运行阻力带式输送机提供理论参考和技术支持。

本项目以磁电混合悬浮技术和带式输送机设计理论为基础，对一种新型无辊式低运行阻力带式输送机—可控磁电混合悬浮磁垫带式输送机的运行机理、永磁体—电磁铁—导磁体混合悬浮系统的悬浮力及平衡影响因素、系统稳定性及控制策略等相关基础问题进行理论与实验研究，获取相关基础理论信息，优化系统设计参数，为设计开发新型无辊式低运行阻力带式输送机，实现绿色节能连续输送提供理论参考和技术支持。. 对磁电混合系统的悬浮力及悬浮扰动因素进行分析，建立系统悬浮力模型，分别提出T型、敛磁体式、Halbach式的电磁结构对系统悬浮力及稳定性进行增强；研究电磁特性、输送带变形、物料冲击对输送机稳定性的影响规律；采用反馈控制、PID控制、改进的滑模控制、自适应控制、反演控制、交叉耦合控制等一系列控制策略实现悬浮稳定。. 理论部分主要基于分子环流假说和毕奥—萨伐尔定律，磁路原理和基于数据驱动的机器学习方法，建立不同电磁结构对应的悬浮系统模型；利用智能优化算法为核心的优化设计方法对模型相关影响参数进行优化调整；通过有限元仿真以及建模仿真软件对系统模型进行验证，分析磁场分布和系统动态响应；搭建实验平台验证不同悬浮控制策略的有效性。. 此外，在项目执行过程中还进行了相关扩展研究，设计了一种新型的磁电混合悬挂液压阻尼器；研究了带式输送机丁苯橡胶（SBR）输送带的老化和摩擦磨损行为；提出了一种高效的MobileNetv3 及YOLOv4 集成网络输送带纵向撕裂多维度实时检测方法；相关成果对磁电混合悬浮带式输送机的推广及其应用研究具有理论和实践意义。