大型伺服压力机主传动系统能耗机理解析及高能效机构设计

Equipment manufacturing is one of the core parts of the manufacturing industry. It is of great importance to reducing energy demands and improving energy efficiency for the realization of low carbon economy development. This project aims at proposing design methodologies for highly energy efficient main transmission system of large scale servo press. The research is to be carried out in the following aspects: based on the characteristic analysis and energy dissipation modeling of impacts between joint elements induced by clearance, the influences of the structure and dynamic features of linkage mechanism on joint impacts are to be studied. Then, the relations between forming performance, energy efficiency and mechanism and joint design parameters are to be modeled, and based on which, the topological structure design method of mechanism and joints for energy efficiency optimization will be studied. The relations between stress distribution, surface topography, wearing, lubrication and frictional energy dissipation of major friction pairs of the main transmission system under conditions of large scale and discontinued heavy load will be studied. The complex influences of friction on mechanism energy dissipation are to be revealed. The simulation model of friction energy dissipation of the rolling guide of the slide block with considerations of impacts from multi-source motion error and eccentric load conditions is to be developed, and based on which the influences of rolling guide structure design, frame structure design and assembly design on the rolling guide friction energy dissipation will be analyzed. Then, the method for low energy dissipation friction pair design of the main transmission system will be studied. The coupling model of servo motor efficiency, mechanism structure and load spectrum is to be developed, and based on which the influences of mechanism features on servo motor load are to be studied for energy efficient coupling design of the mechanism and the servo unit. Based on the above research, this project is expected to provide theoretical basis and methodologies for development of highly energy efficient large scale servo press.

装备制造是制造业的核心组成部分，承担着提质增效和促进“低碳经济”发展的重任。本项目以大型伺服压力机为对象开展高能效传动系统设计研究。分析运动副间隙冲击特性及能耗机理，研究传动机构运动和结构特征对间隙冲击能耗特征的影响，建立成型性能、能效与传动机构和运动副参数之间的关系模型，研究高能效传动系统及运动副的拓扑结构综合方法。研究大尺度、重载、非连续工况下关键摩擦副界面应力分布、表面形貌、摩擦副损伤和能耗之间的本质关系，解析摩擦对传动机构能耗的综合影响规律，建立不同工况下考虑多源运动误差影响的冲压滑块导轨摩擦能耗仿真模型，研究滑动副结构、机架结构和装配方式等对摩擦能耗影响，提出低能耗摩擦副表面及相关结构的优化方法。建立伺服驱动效率、机构构型与载荷谱的耦合模型，研究主传动特征对电机负载特性的影响，实现驱动单元、传动机构与载荷高效匹配。通过本研究为高能效大型伺服压力机研发提供理论基础和设计方法。

装备制造是制造业的核心组成部分，承担着提质增效和促进“低碳经济”发展的重任。本项目以大型伺服压力机为典型对象开展高能效设计研究。针对多连杆机械式伺服压力机，建立了动力-传动-执行-控制-承支系统耦合能耗模型，揭示了该类伺服压力机的能耗机理，着重探究了传动系统的典型运动副间隙（连杆转动副和导轨-滑块移动副）引起的冲击、摩擦能耗对整机能效的影响规律。针对该类压力机的伺服电机匹配问题和储能提出了改进方案。在以上典型产品设计问题研究基础上，面向先进制造的低碳化高效率制造装备需求，进一步开展了面向近净成形的高精度压力机设计方法，提出了成形“精度”目标驱动、自顶向下的机械系统设计方法；开展了能效导向的装备产品设计理论与方法，对机电产品设计方法的能效导向性、系统性和通用性进行了深入探索，建立了适用于制造装备的能效设计方法框架，提出了能效设计关键任务的实现方法；开展了基于CAX-LCA集成的绿色装备设计方法研究，针对产品、过程设计与环境评价不同知识领域之间工程语义复杂相关关系所造成的绿色设计难题，构建了CAX与LCA系统的信息集成环境，提出了基于CAX-LCA集成的绿色设计创新方法并开发了相应的计算机应用工具。以上研究成果不仅为低碳绿色压力机产品设计提供了理论、方法和计算机应用工具支持，也可为同类型的大能耗制造装备设计开发提供支持。