摘要:文(wen)章概述傳(chuan)感器研究現狀與發(fa)展,探(tan)討(tao)傳(chuan)感器在機(ji)電一體化系統中的(de)應用,并分析我國傳(chuan)感器技術發(fa)展的(de)若干問(wen)題及(ji)發(fa)展方向。
關鍵詞:傳感(gan)器(qi)技術;機電一體化;應(ying)用
在機電一體化(hua)系統中,傳(chuan)感器(qi)處系統之首,其作用(yong)相當于系統感受器(qi)官,能快(kuai)速、精確(que)(que)地獲取信(xin)息(xi)(xi)并能經受嚴酷環境考驗(yan),是(shi)機電一體化(hua)系統達到高(gao)水平(ping)的(de)保證。如缺少這些(xie)傳(chuan)感器(qi)對系統狀態和(he)對信(xin)息(xi)(xi)精確(que)(que)而可靠的(de)自動檢測,系統的(de)信(xin)息(xi)(xi)處理(li)、控制決策(ce)等功能就(jiu)無法談及和(he)實現(xian)。
一、傳感(gan)器(qi)的研究現(xian)狀與發展
傳(chuan)感(gan)(gan)器(qi)是能感(gan)(gan)受規(gui)定的被測(ce)量并按一(yi)定規(gui)律(lv)轉(zhuan)換成可(ke)用輸(shu)出(chu)信(xin)(xin)(xin)號的器(qi)件或裝置,主要用于(yu)檢(jian)測(ce)機(ji)電(dian)(dian)一(yi)體化系統自身與操作對象、作業環(huan)境狀態,為(wei)有(you)效控制機(ji)電(dian)(dian)一(yi) 體化系統的運(yun)作提供(gong)必(bi)須的相關信(xin)(xin)(xin)息(xi)(xi)(xi)。隨(sui)著人(ren)類探知領域(yu)和空間的拓(tuo)展,電(dian)(dian)子信(xin)(xin)(xin)息(xi)(xi)(xi)種類日益繁多(duo),信(xin)(xin)(xin)息(xi)(xi)(xi)傳(chuan)遞(di)速度日益加快(kuai),信(xin)(xin)(xin)息(xi)(xi)(xi)處理能力日益增強,相應的信(xin)(xin)(xin)息(xi)(xi)(xi)采集 ——傳(chuan)感(gan)(gan)技術也(ye)將日益發展,傳(chuan)感(gan)(gan)器(qi)也(ye)將無所(suo)不在(zai)。
從20世紀80年代(dai)起(qi),逐步在世界(jie)范(fan)圍內(nei)掀起(qi)一股“傳感(gan)器(qi)熱(re)”,各先進(jin)工業國都極為重視傳感(gan)技(ji)術(shu)和傳感(gan)器(qi)研究、開(kai)發和生產(chan)(chan)。傳感(gan)技(ji)術(shu)已成(cheng)為重要的(de)現代(dai)科技(ji)領(ling)域,傳感(gan)器(qi)及(ji)其系統生產(chan)(chan)已成(cheng)為重要的(de)新興行(xing)業。
二、傳(chuan)感器(qi)在機電一體化系統中的應用
傳感器(qi)是(shi)左右機電(dian)一體(ti)化系(xi)統(或(huo)產品(pin))發展的重要技術之(zhi)一,廣泛(fan)應用于各種(zhong)自動(dong)化產品(pin)之(zhi)中:
1.機器(qi)人用傳感器(qi)。
工業機(ji)器(qi)人之所(suo)以能夠準確操(cao)作,是因為(wei)它能夠通(tong)過各(ge)種傳(chuan)感(gan)器(qi)來(lai)準確感(gan)知自身、操(cao)作對象及作業環境的狀態(tai),包括(kuo):其自身狀態(tai)信息的獲取通(tong)過內部(bu)傳(chuan)感(gan)器(qi)(位 置、位移(yi)、速度、加速度等)來(lai)完成,操(cao)作對象與外(wai)部(bu)環境的感(gan)知通(tong)過外(wai)部(bu)傳(chuan)感(gan)器(qi)來(lai)實現(xian),這(zhe)個過程非常重要,足以為(wei)機(ji)器(qi)人控制提供反饋信息。
2.機械加工過程的傳感檢測技(ji)術。
(1)切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)和機(ji)(ji)(ji)床運(yun)行過(guo)(guo)程(cheng)(cheng)的(de)(de)(de)傳(chuan)(chuan)感技術。切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)傳(chuan)(chuan)感檢(jian)測的(de)(de)(de)目(mu)的(de)(de)(de)在于(yu)優化切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)的(de)(de)(de)生(sheng)產率、制造成本或(huo)(金屬)材料(liao)的(de)(de)(de)切(qie)(qie)(qie)除率等(deng)(deng)。切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)傳(chuan)(chuan)感檢(jian)測的(de)(de)(de)目(mu) 標(biao)有(you)(you)切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)的(de)(de)(de)切(qie)(qie)(qie)削(xue)(xue)力及其變(bian)化、切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)顫震(zhen)、刀具(ju)與(yu)工(gong)(gong)件(jian)的(de)(de)(de)接觸和切(qie)(qie)(qie)削(xue)(xue)時(shi)切(qie)(qie)(qie)屑的(de)(de)(de)狀(zhuang)態(tai)及切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)辨(bian)識等(deng)(deng),而(er)最重要的(de)(de)(de)傳(chuan)(chuan)感參(can)數(shu)有(you)(you)切(qie)(qie)(qie)削(xue)(xue)力、切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)振動、切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo) 程(cheng)(cheng)聲(sheng)發射、切(qie)(qie)(qie)削(xue)(xue)過(guo)(guo)程(cheng)(cheng)電機(ji)(ji)(ji)的(de)(de)(de)功(gong)率等(deng)(deng)。對于(yu)機(ji)(ji)(ji)床的(de)(de)(de)運(yun)行來講(jiang),主要的(de)(de)(de)傳(chuan)(chuan)感檢(jian)測目(mu)標(biao)有(you)(you)驅動系(xi)統、軸承與(yu)回轉系(xi)統、溫度的(de)(de)(de)監測與(yu)控(kong)制及安全(quan)性等(deng)(deng),其傳(chuan)(chuan)感參(can)數(shu)有(you)(you)機(ji)(ji)(ji)床的(de)(de)(de) 故障停機(ji)(ji)(ji)時(shi)間、被加工(gong)(gong)件(jian)的(de)(de)(de)表面粗糙度和加工(gong)(gong)精度、功(gong)率、機(ji)(ji)(ji)床狀(zhuang)態(tai)與(yu)冷卻潤滑液的(de)(de)(de)流量等(deng)(deng)。
(2)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)的(de)(de)(de)(de)過(guo)程(cheng)(cheng)傳感(gan)(gan)(gan)。與刀(dao)具和(he)(he)機床的(de)(de)(de)(de)過(guo)程(cheng)(cheng)監(jian)視(shi)技術相(xiang)比,工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)的(de)(de)(de)(de)過(guo)程(cheng)(cheng)監(jian)視(shi)是(shi)(shi)研(yan)究和(he)(he)應(ying)用(yong)最早、最多的(de)(de)(de)(de)。它們多數以(yi)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)質量控(kong)制為目標。20世紀80年代以(yi)來(lai),工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)識(shi)(shi)(shi)別(bie)(bie)(bie)和(he)(he)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)安(an)裝(zhuang)(zhuang)位(wei)姿(zi)監(jian)視(shi)要(yao)求(qiu)也提到(dao)日程(cheng)(cheng)上 來(lai)。粗(cu)略地講,工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)序識(shi)(shi)(shi)別(bie)(bie)(bie)是(shi)(shi)為辨(bian)識(shi)(shi)(shi)所執行的(de)(de)(de)(de)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)序是(shi)(shi)否(fou)是(shi)(shi)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)(零)件(jian)(jian)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)要(yao)求(qiu)的(de)(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)序;工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)識(shi)(shi)(shi)別(bie)(bie)(bie)是(shi)(shi)辨(bian)識(shi)(shi)(shi)送入機床待(dai)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)或(huo)者毛(mao)坯(pi)(pi)是(shi)(shi)否(fou)是(shi)(shi)要(yao)求(qiu)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)或(huo)毛(mao) 坯(pi)(pi),同時還要(yao)求(qiu)辨(bian)識(shi)(shi)(shi)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)安(an)裝(zhuang)(zhuang)的(de)(de)(de)(de)位(wei)姿(zi)是(shi)(shi)否(fou)是(shi)(shi)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)藝規程(cheng)(cheng)要(yao)求(qiu)的(de)(de)(de)(de)位(wei)姿(zi)。此外,還可以(yi)利用(yong)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)識(shi)(shi)(shi)別(bie)(bie)(bie)和(he)(he)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)安(an)裝(zhuang)(zhuang)監(jian)視(shi)傳感(gan)(gan)(gan)待(dai)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)毛(mao)坯(pi)(pi)或(huo)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)的(de)(de)(de)(de)加(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)(gong)裕量和(he)(he)表(biao)面缺陷。完成這 些識(shi)(shi)(shi)別(bie)(bie)(bie)與監(jian)視(shi)將采(cai)用(yong)或(huo)開發許多傳感(gan)(gan)(gan)器,如基于TV或(huo)CCD的(de)(de)(de)(de)機器視(shi)覺(jue)傳感(gan)(gan)(gan)器、激光表(biao)面粗(cu)糙(cao)度傳感(gan)(gan)(gan)系統等。
(3)刀(dao)(dao)具(砂(sha)(sha)輪(lun)的(de)檢測傳感。切削(xue)與(yu) 磨削(xue)過程是(shi)重要的(de)材料切除過程。刀(dao)(dao)具與(yu)砂(sha)(sha)輪(lun)磨損(sun)到一定(ding)限度(按(an)磨鈍標(biao)準判定(ding))或(huo)出現(xian)破損(sun)(破損(sun)、崩刃、燒傷、塑變或(huo)卷刀(dao)(dao)的(de)總(zong)稱),使它們失(shi)去(qu)切(磨削(xue)能(neng)力 或(huo)無法保證加工精(jing)度和(he)加工表(biao)面完整性時(shi),稱為刀(dao)(dao)具/砂(sha)(sha)輪(lun)失(shi)效。工業(ye)統(tong)計證明,刀(dao)(dao)具失(shi)效是(shi)引起(qi)機(ji)(ji)床故障(zhang)停(ting)機(ji)(ji)的(de)首要因素,由(you)其引起(qi)的(de)停(ting)機(ji)(ji)時(shi)間占(zhan)NC類機(ji)(ji)床的(de)總(zong) 停(ting)機(ji)(ji)時(shi)間的(de)1/5-1/3.此外,它還可能(neng)引發設(she)備或(huo)人身安(an)全事故,甚至是(shi)重大事故。
3.汽車自(zi)動(dong)控制系統中的傳(chuan)感技術。
隨(sui)著傳(chuan)(chuan)感器(qi)技(ji)術(shu)和其它新(xin)技(ji)術(shu)的應用,現代(dai)化汽車工業(ye)進入了全新(xin)時(shi)期。汽車的機(ji)電一體化要求用自(zi)動控(kong)(kong)制(zhi)系統(tong)取(qu)代(dai)純(chun)機(ji)械式控(kong)(kong)制(zhi)部件(jian),這不(bu)僅體現在發動機(ji)上,為更全面地(di)改善 汽車性(xing)(xing)(xing)(xing)能(neng),增加人性(xing)(xing)(xing)(xing)化服務功能(neng),降低油耗,減少(shao)排氣污(wu)染,提高行駛(shi)安全性(xing)(xing)(xing)(xing)、可靠性(xing)(xing)(xing)(xing)、操作方便和舒適性(xing)(xing)(xing)(xing),先進的檢測和控(kong)(kong)制(zhi)技(ji)術(shu)已擴大到汽車全身。在其所有重 點控(kong)(kong)制(zhi)系統(tong)中,必不(bu)可少(shao)地(di)使用曲(qu)軸(zhou)位置(zhi)傳(chuan)(chuan)感器(qi)、吸(xi)氣及冷卻水溫(wen)度(du)傳(chuan)(chuan)感器(qi)、壓力傳(chuan)(chuan)感器(qi)、氣敏傳(chuan)(chuan)感器(qi)等各(ge)種傳(chuan)(chuan)感器(qi)。
三(san)、我國傳(chuan)感(gan)器技(ji)術發展的若干問題及發展方向
傳感(gan)器技術是實現自(zi)動(dong)控制、自(zi)動(dong)調節(jie)的(de)(de)關(guan)鍵(jian)環節(jie),也是機(ji)電一(yi)(yi)體化(hua)系(xi)統(tong)(tong)不可缺少的(de)(de)關(guan)鍵(jian)技術之一(yi)(yi),其水平高(gao)(gao)低在很大程度(du)上影響和(he)決定(ding)著系(xi)統(tong)(tong)的(de)(de)功能(neng);其水平越 高(gao)(gao),系(xi)統(tong)(tong)的(de)(de)自(zi)動(dong)化(hua)程度(du)就(jiu)越高(gao)(gao)。在一(yi)(yi)套完整(zheng)的(de)(de)機(ji)電一(yi)(yi)體化(hua)系(xi)統(tong)(tong)中(zhong),如果不能(neng)利用傳感(gan)檢(jian)測技術對被控對象的(de)(de)各(ge)項(xiang)參數進行(xing)及時準確地檢(jian)測出并轉換成易(yi)于傳送和(he)處(chu)理 的(de)(de)信(xin)號(hao),我們所需要的(de)(de)用于系(xi)統(tong)(tong)控制的(de)(de)信(xin)息就(jiu)無法獲得,進而使(shi)整(zheng)個系(xi)統(tong)(tong)就(jiu)無法正常有效的(de)(de)工作。
我國傳感器(qi)的(de)研(yan)(yan)究主要(yao)集(ji)中在(zai)專(zhuan)業(ye)研(yan)(yan)究所和(he)大學,始(shi) 于20世紀80年代(dai),與國外先(xian)進(jin)(jin)技(ji)術(shu)相比,我們還有(you)較大差距,主要(yao)表(biao)現在(zai):(1)先(xian)進(jin)(jin)的(de)計算、模擬和(he)設(she)計方法;(2)先(xian)進(jin)(jin)的(de)微(wei)機械加(jia)工技(ji)術(shu)與設(she)備(bei);(3) 先(xian)進(jin)(jin)的(de)封裝技(ji)術(shu)與設(she)備(bei);(4)可靠性(xing)技(ji)術(shu)研(yan)(yan)究等方面(mian)(mian)。因此,必須加(jia)強技(ji)術(shu)研(yan)(yan)究和(he)引進(jin)(jin)先(xian)進(jin)(jin)設(she)備(bei),以(yi)提高整體(ti)水平(ping)。傳感器(qi)技(ji)術(shu)今后(hou)的(de)發展(zhan)方向(xiang)可有(you)幾方面(mian)(mian):
1.加速開發(fa)新(xin)型(xing)敏感材(cai)料:通過微電子、光(guang)電子、生物(wu)化(hua)學、信息處(chu)理等各種學科,各種新(xin)技術的(de)互(hu)相(xiang)滲透和(he)綜合(he)利用,可望(wang)研制出(chu)一批(pi)基于(yu)新(xin)型(xing)敏感材(cai)料的(de)先(xian)進傳感器。
2.向高精度(du)發展:研(yan)制出靈敏度(du)高、精確度(du)高、響(xiang)應速度(du)快(kuai)、互換性(xing)好的新型傳感器以確保(bao)生產自動化的可靠性(xing)。
3.向微(wei)型(xing)化發展:通過發展新的(de)(de)材料及加工(gong)技術實現傳感器微(wei)型(xing)化將(jiang)是近(jin)十年研究的(de)(de)熱點。
4.向(xiang)微功耗及無源(yuan)化(hua)發(fa)展:傳感(gan)器(qi)一般都是(shi)(shi)非電(dian)(dian)量向(xiang)電(dian)(dian)量的轉化(hua),工作時離不(bu)開(kai)電(dian)(dian)源(yuan),開(kai)發(fa)微功耗的傳感(gan)器(qi)及無源(yuan)傳感(gan)器(qi)是(shi)(shi)必(bi)然(ran)的發(fa)展方向(xiang)。
5.向智(zhi)能(neng)(neng)化(hua)數字(zi)化(hua)發展:隨著現代化(hua)的發展,傳感器(qi)的功能(neng)(neng)已突破傳統(tong)的功能(neng)(neng),其輸出不(bu)再(zai)是一個單一的模(mo)擬信(xin)號(如(ru)0-10mV),而是經過(guo)微電(dian)腦處理好后的數字(zi)信(xin)號,有點甚至帶(dai)有控制功能(neng)(neng),即智(zhi)能(neng)(neng)傳感器(qi)。
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