基于界面摩擦与涡流耦合效应的机-电-液复合制动原理研究

As a fundamental braking method of mechanical systems, the friction braking which depends on interfacial sliding friction has the risk of friction failure under extreme conditions. What is more, once the loading of braking pressure which originates from a single source is failed, it will lead to braking failure directly. Therefore, aiming at extreme braking conditions of mechanical systems such as high speed, heavy load and repeated braking, it must be an effective way to improve the braking efficiency and reliability by exploring various kinds of new combined braking with multiple force redundant loading and different principle collaborative braking. Firstly, based on interface friction and eddy current coupling effect, a new mechanical-electromagnetic-hydraulic combined braking principle is proposed in this project, which is loaded redundantly by magnetic-hydraulic force and braked collaboratively by friction-eddy-current braking. Secondly, the friction and magnetic coupling effect on friction interface of magnetic conductive brake pair under magnetic field will be investigated by tribological tests and interfacial microanalysis. Thirdly, by carrying out braking tests with different loading mode of brake pressure, the dynamic response characteristics and reliability distribution method of braking pressure will be studied, and a multimode redundant loading model of braking pressure will then be built. Fourthly, the superposition principle of eddy current effect in brake disc and the mechanism of friction-eddy-current collaborative braking which is loaded redundantly by magnetic force will be investigated based on simulated braking tests with different braking method. Finally, based on all of these experimental and theoretical results, the mechanical-electromagnetic-hydraulic coupling structure of the brake will be optimized, and a new mechanical-electromagnetic-hydraulic combined brake prototype as well as its dynamic model will be established. It is believed that the research results of this project will possess both important theoretical value and practical significance for improving the braking efficiency and reliability of mechanical systems under extreme conditions.

摩擦制动作为基础制动方式，一方面依赖于界面摩擦在极端工况下有摩擦失效风险，另一方面制动压力源自单一动力容易加载失败而制动失灵。因此，面向机械系统高速重载、重复制动等极端工况，探索多种动力冗余加载、不同原理协同制动的新型复合制动将是提高制动效能与可靠性的有效途径。基于界面摩擦与涡流耦合效应提出一种磁力-液压冗余加载、摩擦-涡流协同制动的新型机-电-液复合制动原理；开展磁场摩擦学试验和界面微观分析，揭示导磁制动副摩擦界面摩-磁耦合效应；开展不同模式加载试验，研究制动压力动态响应特性及可靠性分配方法，构建制动压力多模式冗余加载模型；开展不同方式制动试验，研究制动盘涡流效应叠加原理，揭示基于磁力的冗余加载式摩擦-涡流协同制动机理；优化制动器机械-电磁-液压耦合结构，创成新型机-电-液复合制动器原理样机并建立其动力学模型。研究结果对于提高极端工况下机械系统制动效能与可靠性具有重要理论意义和实用价值。

摩擦制动作为机械系统基础制动方式，一方面完全依赖于界面摩擦作用，在极端工况下有摩擦失效的风险，另一方面制动压力源自液压等单一动力，容易因加载失败而导致制动失灵。因此，探索多种动力冗余加载、不同原理协同制动的新型复合制动应是提高制动效能与可靠性的有效途径。本项目基于界面摩擦与涡流耦合效应，构建了一种“磁力-液压冗余加载、摩擦-涡流协同制动”的新型机-电-液复合制动方式，并通过建模仿真与样机试验进行了分析与验证。首先，开展导磁制动副摩擦磨损与界面分析试验，掌握了制动工况对其摩擦磁化行为的影响规律，揭示了制动界面摩-磁耦合效应及其作用机理。其次，设计新型复合制动器的机械-电磁-液压耦合结构，开展在不同加载模式下的模拟制动试验，掌握了液压、磁力、磁力-液压冗余加载时制动性能变化规律；基于旁联模型构建复合制动器可靠性模型，并对制动系统可靠度进行了估算和分配。再次，基于不同加载模式下的涡流制动试验结果，掌握了励磁电流对摩擦-涡流协同制动性能的影响规律，揭示了制动盘内涡流效应叠加机理；综合考虑磁力-液压冗余加载的制动压力和摩擦-涡流协同产生的制动力矩，揭示了基于磁力的制动压力冗余加载式摩擦-涡流协同制动机理。最后，基于理论分析和试验结果对制动器结构及摩擦材料配方进行优化，研制了改进后的复合制动器原理样机，掌握了复合制动器用导磁摩擦材料配方与制备工艺；构建新型机-电-液复合制动器动力学模型，并开展仿真试验对其动力学性能进行了验证；基于人工智能和模糊PID控制技术，建立了基于磁场的摩-磁复合制动性能智能调控模型。本项目提出并构建了一种新型机-电-液复合制动方式，研究结果对于提高极端工况下机械系统制动效能与可靠性具有较高的理论意义和实用价值。在项目执行期内，共发表标注本项目资助的学术论文11篇，授权与本项目相关的发明专利4件，获得与本项目相关的省级科技奖励1项，培养青年教师和研究生10人。