A real-time dynamic feedback control system is developed. An improved PID algorithm, called the integral separated piecewise PID scheme, is used in the control system. This algorithm is able to limit the contribution of the integral component in the PID calculation to avoid integral windup. In addition, it could use different PID parameters to adapt to different segments within one punch motion cycle. Hence, the error of the punch motion, either resulting from the machine assembly or from the machine dynamics, can be compensated by tuning the velocity of the servomotor. This is a unique feature of the new press that ensures its accuracy. / Based on the novel structure, the detailed design is then carried out, which includes the mechanical design, kinematics and inverse kinematics analysis, static force analysis, parametric design and the other related designs. A calibration method based on the experiment and computer simulation is proposed for the new press, which is also useful for the parallel mechanisms. Cooperated with Guangdong Metal Forming Machine Works Co. Ltd., a 250 KN prototype has been built and tested. / In order to ensure the desirable performance, dynamic control is necessary. The thesis uses two dynamic modeling methods to study the dynamics of the press. One is the kineto-static method. It is also called D'Alembert principle which rearranges Newton's second law and transfers a dynamic problem to an equivalent static problem by adding the inertial forces and inertial torques onto the system. The model can then be analyzed easily and exactly as a static system subjected to the inertial forces and torques and the external forces. The other method is the Lagrangian method which derives the dynamic model from the energy perspective. Based on the model, the dynamics of the press is studied by means of computer simulation and is validated experimentally. / In this thesis, a controllable hybrid mechanical metal forming press is developed, which is driven by a CSM with a flywheel and a servomotor. From a mechanism point of view, it is a closed-loop 2-DOF parallel planar five-bar mechanism with four resolute joints and one prismatic joint. Thanks to the usage of the servomotor, the punch motion of the new press can be controlled by tuning the velocity of the servomotor. Accordingly, desired punch motions for different stamping processes can be obtained. In other words, the new press is flexible and controllable like the servo mechanical press and the hydraulic press. Moreover, the CSM with flywheel provides the main power during the stamping operation, and hence, it is energy efficient. In addition, it is not expensive to build, as it uses only a small servomotor. / Metal forming is one of the oldest production processes and yet, is still one of the most commonly used processes today. Everyday, millions of parts are produced by metal forming ranging from battery caps to automobile body panels. Therefore, even a small improvement may add to significant corporative gain. / The thesis also describes the trajectory planning method for the press, which is based on the combination of the inverse kinematics and cubic spline interpolation. The trajectory is optimized under multiple constraints on velocity, acceleration and jerk of the servomotor. It guarantees the new press is controllable and energy efficient. / Two typical stamping processes, drawing and forging, are taken as examples for the operations of the new press. The results of the simulation and the experiment match well. Based on the simulation and experiments, it is found that the CSM provides the main power for the metal forming operations, while the servomotor is mainly responsible for overcoming the inertia forces to realize the desired punch motion. The experiments show that the new press is energy efficient, fast, controllable and inexpensive to build. It combines the advantages of both mechanical press and hydraulic press and has a good performance. It is expected the new press will have a great potential for the metal forming industry. (Abstract shortened by UMI.) / He, Kai. / "February 2008." / Adviser: Ruxu Du. / Source: Dissertation Abstracts International, Volume: 70-03, Section: B, page: 1902. / Thesis (Ph.D.)--Chinese University of Hong Kong, 2008. / Includes bibliographical references (p. 147-149). / Electronic reproduction. Hong Kong : Chinese University of Hong Kong, [2012] System requirements: Adobe Acrobat Reader. Available via World Wide Web. / Electronic reproduction. [Ann Arbor, MI] : ProQuest Information and Learning, [200-] System requirements: Adobe Acrobat Reader. Available via World Wide Web. / Abstracts in English and Chinese. / School code: 1307.
| Identifer | oai:union.ndltd.org:cuhk.edu.hk/oai:cuhk-dr:cuhk_344181 |
| Date | January 2008 |
| Contributors | He, Kai, Chinese University of Hong Kong Graduate School. Division of Automation and Computer-Aided Engineering. |
| Source Sets | The Chinese University of Hong Kong |
| Language | English, Chinese |
| Detected Language | English |
| Type | Text, theses |
| Format | electronic resource, microform, microfiche, 1 online resource (xv, 149 p. : ill.) |
| Rights | Use of this resource is governed by the terms and conditions of the Creative Commons “Attribution-NonCommercial-NoDerivatives 4.0 International” License (http://creativecommons.org/licenses/by-nc-nd/4.0/) |
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