热轧环过程在线精确测量与智能控制技术基础研究

The ring products have been widely used in industry fields such as machinery, automobile, railway, aerospace, energy, weapons, etc. However, hot ring rolling process which has been widely adopted in our country still depends on manual experience control. This project takes the hot ring rolling process as the research object, aims at establishing the theories and methods of on-line measurement of the ring's geometry and shape precision and process intellegent control. Through theoretical analysis, mathematical modeling, virtual simulation and experimental test, combining with the practical ring rolling production, the comprehensive research will be conducted on the change laws of the ring's geometry and shape during the ring rolling process and its mathematical model, the on-line measurement models of the ring's geometry and shape and the weight ramdon errors of the ring blanks, the methods of ring rolling process planning and tolerance intelligent allocation. The theories and technical methods of on-line measurement of the ring's geometry and shape precision and process intellegent control will be established. This project can provide the scientific fundament for the digital and intellegent control of hot rolled ring's precise forming process. The research results of this project have the important academic value and practical significance for building the theories of accurate measurement and intelligent control of the hot ring rolling process and developing the accurate hot ring rolling technology.

环类零件广泛用于机械、汽车、火车、能源、国防等众多工业领域，热轧环工艺是环类零件的主要成形技术。然而，我国广泛应用的热轧环技术仍然处于人工经验控制的落后状态。本课题以热轧环工艺过程为研究对象，以热轧环件几何形状精确在线测量与轧环过程智能控制理论和方法为目标，通过理论分析、数学建模、虚拟仿真和实验测试，研究热轧环过程中环件几何形状变化规律和数学模型，研究环件几何形状在线精确测量模型和测量方法，研究环件毛坯重量随机误差在线测量模型和方法，研究热轧环过程工艺规划方法和公差智能分配方法，建立热轧环件几何精度在线精确测量和智能控制理论与技术设计方法，为热轧环精确成形过程数字化与智能化控制提供科学依据。本项目研究对于建立热轧环过程精确智能测量控制理论，发展精确热轧环技术具有重要学术价值和实际意义。

环类零件（简称环件）是机械装备承载与传动的关键基础件，广泛应用于国民经济和国防工业领域，其制造技术和产业体现着国家基础制造能力与水平。环件轧制技术通过连续局部回转塑性变形，可高效成形精密尺寸和致密组织无缝环件，是国际公认的高性能环件不可替代的先进制造技术。环件轧制技术历经了一百多年的发展历程，却一直没有摆脱人工手工操作的粗放式生产模式。本项目开展了热轧环装备及其测量控制理论的相关基础研究，研究了轧环过程环件与轧辊运动规律，提出了环件尺寸公差控制模型和方法，建立了热轧环过程在线测量和控制数学模型，开发了热轧环机专用数控系统，建设了国内首条数控径向热轧环自动生产线并进行了工业化生产应用，生产效率最高可达1000件/小时，尺寸误差可达200±0.25mm，圆度误差≤0.5mm。研究成果对于建立热轧环过程精确智能测量控制理论，发展精确热轧环技术具有重要学术价值和实际意义。