高温环境下弹簧功能-传感共形位移测量装置及方法

doi:10.12382/bgxb.2022.0672

摘要/Abstract

摘要：

机械装备的位移测量是状态检测和运动控制的关键,基于激光、电涡流、电感和电阻等原理的常规位移测量方法无法应对高端装备紧凑测试空间和高温、油污等恶劣环境条件下的位移测量挑战。基于材料力学与弹簧结构,构建一种新的弹簧功能-传感共形的位移测量模型,对弹簧整体受力及位移进行分析,确定位移-应变映射关系;基于有限元方法建立弹簧的应变-位移模型,分析弹簧位移测量的敏感点、不同组桥形式、位移激励频率等因素影响;通过搭建电液伺服高频冲击试验台,在扫频和加热工况下进行弹簧位移测量装置及方法的有效性和动态性能测试。试验结果表明:加载频率在100Hz及以下时测试精度可达0.06mm,高温适应性不低于275℃;经车用干片式制动器高温制动试验应用验证,在工作温度160℃以上仍能实时稳定获取机构的动态位移信号,为高温制动器状态检测及其故障诊断提供了嵌入式测试技术支撑;该共形位移测量方法在高温条件下具有良好的线性度和精度,为紧凑空间及高温等恶劣环境下位移测量提供了一种有效方法,尤其是在具有弹簧等弹性元件的情况下能够实现对原系统无影响的嵌入式测试。

关键词: 弹簧, 位移测量, 应变, 高温, 制动

Abstract:

The displacement measurement of mechanical equipment is the key to state detection and motion control. Conventional displacement measurement methods based on the principles of laser, eddy current, electric resistance and inductance cannot cope with the challenges of displacement measurement in the compact test space of high-end equipment and harsh environmental conditions such as high temperature and oil contamination. A spring function-sensing conformal displacement measurement model is constructed based on material mechanics and spring structure. the overall spring force and displacement are analyzed, and the displacement-strain mapping relationship is determined. A strain-displacement model of the spring is established on the basis of the finite element method, and the effects of the sensitive point of spring displacement measurement, different group bridge forms, displacement excitation frequency and other factors are analyzed. The effectiveness and dynamic performance of spring function-sensing conformal displacement measuring devices is tested under frequency sweeping and heating conditions on an electro-hydraulic servo high-frequency impact test rig. The test results show that the test error is within 0.06mm when the loading frequency is 100Hz and below, and the high temperature adaptability is not below 275℃. Finally, it is verified by the application of high temperature brake test for automotive dry pad brakes. The dynamic displacement signal of the mechanism can still be obtained stably in real time above the operating temperature of 160℃, which provides embedded test technology support for high-temperature brake condition detection and its fault diagnosis. The conformal sensor has good linearity and accuracy under high temperature conditions, which provides an effective method for displacement measurement in compact space and harsh environments such as high temperature. Especially in the case of elastic elements such as springs, the embedded test without affecting the original system can be realized.

Key words: spring, displacement measurement, strain, high temperature, braking

中图分类号:

TH822

宁克焱, 曾强, 田金山, 赵攀, 兰海, 何家富, 万丽. 高温环境下弹簧功能-传感共形位移测量装置及方法[J]. 兵工学报, 2024, 45(2): 662-670.

NING Keyan, ZENG Qiang, TIAN Jinshan, ZHAO Pan, LAN Hai, HE Jiafu, WAN Li. A Spring Function-sensing Conformal Displacement Measuring Device and Method for High Temperature Application[J]. Acta Armamentarii, 2024, 45(2): 662-670.

图/表 22

图1 弹簧实物

Fig.1 Spring

图2 弹簧受力示意图

Fig.2 Simplified diagram of spring forces

图3 弹簧挂钩简化图

Fig.3 Simplified diagram of spring hanger

图4 弹簧应变云图

Fig.4 Cloud diagram of spring strain

图5 测点仿真应变-位移拟合

Fig.5 Strain-displacement linear fit of measuring point simulation

图6 惠斯通电桥

Fig.6 Wheatstone bridge

图7 弹簧功能-传感一体化位移测量装置

Fig.7 Spring function-sensing integrated measuring device

表1 弹簧约束模态频率

Table 1 Spring constraint modal frequency

阶数	1	2	3	4	5	6	7
频率/Hz	75.0	75.5	143.3	270.5	299.8	310.1	428.9

图8 弹簧约束模态

Fig.8 Spring constrained mode

图9 弹簧功能-传感一体化位移装置验证系统组成

Fig.9 Composition of verification system for spring function-sensing integrated displacement device

图10 实物图

Fig.10 Material object picture

图11 弹簧应变位移拟合直线

Fig.11 Spring strain-displacement fitting line

图12 弹簧高温标定试验结果

Fig.12 Spring high temperature calibration experimental results

图13 加载频率范围为1~80Hz时的应变数据

Fig.13 Strain data with loading frequency range of 1-80Hz

图14 加载频率范围为80~130Hz时的应变数据

Fig.14 Strain data with loading frequency range of 80-130Hz

图15 加载频率范围为130~150Hz时的应变数据

Fig.15 Strain data with loading frequency range of 130-150Hz

图16 动态加载试验验证

Fig.16 Dynamic loading experiment verification

表2 弹簧动载试验误差分析

Table 2 Error analysis of spring dynamic load test

频率/Hz	20	50	100	110
误差/mm	-0.0477	-0.0585	0.0228	0.1265

图17 高温制动试验弹簧功能-位移测量系统

Fig.17 System diagram of spring function-displacement measurement in high temperature braking test

图18 弹簧在弹子加压制动器的安装示意图

Fig.18 Installation diagram of spring

表3 制动器连续制动工况

Table 3 Continuous braking condition of brake

制动惯量/ (kg·m^-2)	制动初转速/ (r·min^-1)	制动末转速/ (r·min^-1)	制动减速度/ (m·s^-2)	制动周期/s
80	1620	694	2	60

图19 制动试验数据曲线

Fig.19 Braking test data curve

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