Modeling, Analysis and Control of Hydraulic Actuator for Forging

228 Pages·2018·6.97 MB·English

by  Xinjiang Lu

Xinjiang Lu
Minghui Huang
Modeling, Analysis
and Control of
Hydraulic Actuator
for Forging
Modeling, Analysis and Control of Hydraulic
Actuator for Forging
Xinjiang Lu Minghui Huang
(cid:129)
Modeling, Analysis
and Control of Hydraulic
Actuator for Forging
123
Xinjiang Lu Minghui Huang
State Key Laboratoryof High Performance State Key Laboratoryof High Performance
ComplexManufacturing, ComplexManufacturing,
Schoolof MechanicalandElectrical Schoolof MechanicalandElectrical
Engineering Engineering
Central SouthUniversity Central SouthUniversity
Changsha Changsha
China China
ISBN978-981-10-5582-9 ISBN978-981-10-5583-6 (eBook)
https://doi.org/10.1007/978-981-10-5583-6
LibraryofCongressControlNumber:2017958722
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Preface
Theforgingiswidelyappliedformanufacturingpartsfromaviation,aerospaceand
transportation, etc. For example, most of the components in aircraft parts that bear
alternating and concentrated loads are formed via forging including the fuselage,
rotarypartsinengines,theundercarriage,etc.Developmentsinforgingtechnology
have increased the range of shapes, sizes, material, and properties of formed
products, enabling them to meet various design and performance requirements.
Forged parts are required specifically to have high mechanical strength, high reli-
ability, resistance to shock and fatigue, abrasion, as well as economy. Forging is a
process that must accommodate all of these specifications.
In order to satisfy the requirements offorged parts, a strict process and minute
control for hydraulic actuator for forging are necessary. Achieving this high-
accuracy and high-performance control is a great challenge due to (1) complex
forgingprocessofirregulargeometricshapesduetocomplexrheologicalbehavior;
(2)complexhydraulicdriveprocess,suchasmulti-cylinderparalleldrive,andhuge
inertia of the motion part of hydraulic actuator; (3) friction, leakage, and other
uncertaintiesareinevitable;and(4)Itoftenrequirestousingahugedrivingforceto
control an extremely low or variable forging velocity within a large distance. As a
result, accuratecontrolofhydraulic actuator isoneofthemostimportant concerns
in forging industry and other hydraulic manufacturing industries.
The studies of modeling, analysis, and control of hydraulic actuator for forging
become more and more active and important. In the last few decades, much pro-
gress has been achieved in this field. However, there are still many unsolved
problems in this field as the range of shapes, sizes, and properties of formed
products have been increased and the forging machinery becomes huger and more
complex, as well higher accuracy and higher performance control is further
required.Thepurposeofthebookistoprovideabriefviewofthepreviousworkon
modeling,analysis, andcontrolofhydraulic actuatorforforging,anddevelopnew
methods to tackle some of these unsolved problems.
In the book, a systematic overview and classification is first presented on
modeling, analysis, and control of hydraulic actuator for forging. Limitations and
advantagesofvariousapproachesarealsodiscussed.Next,severalnovelmodeling
v
vi Preface
approaches are proposed for modeling of the load and forging processes: a
process/shape-decomposition modeling method to help estimate the deformation
force, an online probabilistic extreme learning machine for the modeling of batch
forging processes, and several data-driven identification and modeling approaches
for unknown forging processes under different work conditions. Then, the
model-based dynamic analysis methods are developed to derive the conditions of
stability,vibration,andcreepnotonlyforopen-loopforgingprocessesbutalsofor
closed-loop forging processes. Finally, two novel intelligent control methods are
proposed for complex forging processes. One method is for complex forging
processes working in a large operation domain. Since the system complexity and
controltask areshared by a group ofsimplesub-controllers, this proposedmethod
can be effective to control the complex system through the cooperation of a group
of sub-controllers. Another method is for time-varying forging processes with big
uncertaintiesandsuddenchanges.Throughtheintelligentintegrationcontrolforthe
smooth operation region and the sudden change region, the continuity and
smoothness between the multiple localized nonlinear dynamics can be guaranteed
even if the forging processes have big uncertainties and sudden changes. All these
methods presented in this book have been successfully applied to the practical
forging processes and should be applicable to a wide range of systems in manu-
facturing industry.
The bookwill be ofgreat benefittoundergraduate andpostgraduate students in
many disciplines including manufacturing engineering, mechanical engineering,
electrical engineering, computer engineering, and control engineering. It is also
intended for researchers, research students, and application engineers interested in
modeling, dynamic process analysis, and control.
Authors are grateful to colleagues and students in our research group for their
supportandcontributions,andalsowouldliketothanktheNationalBasicResearch
Program (973) of China (2011CB706802), the National Natural Science
Foundation of China (51205420, 51675539), the Program for New Century
Excellent Talents in University (NCET-13-0593), the Project of Innovation-driven
Plan in Central South University (2015CX002, 2016CX009), Hunan Province
Science and Technology Plan (2016RS2015), Hunan Provincial Natural Science
Foundation of China (14JJ3011),the Fund from the State Key Laboratory of High
Performance Complex Manufacturing for their financial support to our research.
Last, but not least, we would like to express our deepest gratitude to our parents,
wives, and children for their love, understanding, and support.
Changsha, China Xinjiang Lu
Minghui Huang
Contents
Part I Background and Fundamental
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Background and Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Classification of Forging Forming . . . . . . . . . . . . . . . . 4
1.1.2 Characteristics of Forging System . . . . . . . . . . . . . . . . 5
1.1.3 Complexity of Forging Process and Unsolved
Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Objectives of the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Contribution and Organization of the Book . . . . . . . . . . . . . . . 17
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Part II Modeling of Forging Loads and Processes
2 Process/Shape-Decomposition Modeling for Deformation
Force Estimation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Process/Shape-Decomposition Modeling Method . . . . . . . . . . . 31
2.2.1 Process/Shape-Decomposition and Sub-process
Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2.2 Global Deformation Force Model and Modeling
Performance Analysis. . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Model Analysis and Verification . . . . . . . . . . . . . . . . . . . . . . . 41
2.3.1 Simulation Verification. . . . . . . . . . . . . . . . . . . . . . . . 41
2.3.2 Experiment Verification . . . . . . . . . . . . . . . . . . . . . . . 45
2.4 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Distribution Modeling of Batch Forging Processes . . . . . . . . . . . . . 51
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2 Problem Description and Review of Extreme
Learning Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
vii
viii Contents
3.2.1 Problem Description. . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2.2 Review of Extreme Learning Machine. . . . . . . . . . . . . 54
3.3 Online Probabilistic ELM for Distribution Modeling. . . . . . . . . 56
3.3.1 Probabilistic ELM . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3.2 Model Update Strategy. . . . . . . . . . . . . . . . . . . . . . . . 61
3.3.3 Reliability Measure . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.3.4 Modeling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.4 Model Analysis and Verification . . . . . . . . . . . . . . . . . . . . . . . 63
3.4.1 Model Verification Using Free Forging . . . . . . . . . . . . 63
3.4.2 Model Verification Using Open Die Forging . . . . . . . . 66
3.4.3 Performance Comparison . . . . . . . . . . . . . . . . . . . . . . 70
3.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4 Multi-level Parameter Identification Approach . . . . . . . . . . . . . . . . 75
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.2 Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.3 Multi-level Modeling and Parameter Identification Method . . . . 77
4.3.1 Model of the Deformation Process . . . . . . . . . . . . . . . 79
4.3.2 Parameter Identification . . . . . . . . . . . . . . . . . . . . . . . 82
4.4 Verification of Both Simulation and Experiment. . . . . . . . . . . . 85
4.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5 Novel LS-SVM Modeling Method for Forging Processes
with Multiple Localized Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2 Process Description and Modeling Problem . . . . . . . . . . . . . . . 96
5.3 Novel LS-SVM Modeling Method. . . . . . . . . . . . . . . . . . . . . . 98
5.3.1 Region Decomposition and Local LS-SVM Model. . . . 100
5.3.2 Global Regularization and Model Optimization . . . . . . 100
5.3.3 Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.4 Experiment Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6 Forging Process Modeling via Multi-experiment Data . . . . . . . . . . 111
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.2 Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.3 Modeling Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.3.1 Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.3.2 SVD-Based Separation Method and Model
Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.3.3 Neural Network Modeling . . . . . . . . . . . . . . . . . . . . . 117
6.3.4 Model Reconstruction. . . . . . . . . . . . . . . . . . . . . . . . . 118
Contents ix
6.4 Experiment Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7 Online Modeling Approach for Time-Varying Forging
Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.2 Online Modeling Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.2.1 Construction of Model Set . . . . . . . . . . . . . . . . . . . . . 128
7.2.2 Parameter Identification . . . . . . . . . . . . . . . . . . . . . . . 129
7.2.3 Error Minimization Based Model Match Method . . . . . 129
7.2.4 Update of Model Set . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.2.5 Modeling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.3 Case Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.4 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Part III Dynamic Analysis of Forging Processes
8 Model-Based Estimation and Prediction of System Dynamics. . . . . 143
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Modeling of Forging Process and Its Solving Process. . . . . . . . 145
8.2.1 Modeling of Forging Process . . . . . . . . . . . . . . . . . . . 145
8.2.2 Solving Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
8.3 Dynamic Analysis Under Linear Pressure. . . . . . . . . . . . . . . . . 150
8.3.1 Condition of Stable Run. . . . . . . . . . . . . . . . . . . . . . . 151
8.3.2 Conditions of Velocity Vibration and Creep. . . . . . . . . 152
8.4 Dynamic Analysis Under Nonlinear Pressure . . . . . . . . . . . . . . 153
8.5 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.5.1 Model Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.5.2 Simulation Verification of Run Conditions. . . . . . . . . . 156
8.5.3 Experiment Verification of Run Conditions . . . . . . . . . 162
8.6 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
9 Dynamic Analysis of Closed-Loop Forging System . . . . . . . . . . . . . 167
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
9.2 Modeling of Closed-Loop Forging Process and Its Solving
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
9.2.1 Modeling of Closed-Loop Forging Process . . . . . . . . . 169
9.2.2 Solving Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
9.3 Dynamic Characteristics of Closed-Loop
Forging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
x Contents
9.3.1 Stability Condition and Stability Domain. . . . . . . . . . . 174
9.3.2 Velocity Vibration Condition . . . . . . . . . . . . . . . . . . . 175
9.3.3 Flow Limitation Condition . . . . . . . . . . . . . . . . . . . . . 176
9.4 Feasible Domain of Controller Parameters . . . . . . . . . . . . . . . . 177
9.5 Case Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.5.1 Feasible Domain of Control Parameters. . . . . . . . . . . . 179
9.5.2 Simulation Verification of Control Performance . . . . . . 179
9.5.3 Experiment Verification of Control Performance . . . . . 182
9.6 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Part IV Intelligent Control of Complex Forging Processes
10 System-Decomposition Based Multi-level Control Approach. . . . . . 191
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10.2 Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.3 System Decomposition Based Multi-level Control Method . . . . 196
10.3.1 System Decomposition . . . . . . . . . . . . . . . . . . . . . . . . 198
10.3.2 Design of Level-One Control . . . . . . . . . . . . . . . . . . . 198
10.3.3 Design of Level-Two Control . . . . . . . . . . . . . . . . . . . 201
10.4 Case Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
10.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11 Intelligent Integration Control for Time-Varying Forging
Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
11.2 Problem Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
11.3 Intelligent Integration Control . . . . . . . . . . . . . . . . . . . . . . . . . 213
11.4 Case Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
11.5 Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
12 Conclusion and Challenge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
12.1 Summary and Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
12.2 Challenge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227