Research On Fast Calculation Model And Application Of Balance Force Relay

Balance force relay has the problem of product inconsistency between batches, which effects its performance and reliability deeply. The problem can be solved by quality characteristic analysis and tolerance design. Quality characteristic analysis and tolerance design need to calculate a large amount of data and the common method is FEM, which may cost a long time. Aiming to get a high efficiency and accuracy, this paper studies on the fast calculation model built by MEC. After finding the limit of MEC, a method combining self-defined interpolating function and Kriging method is used to establish a new fast calculation method, which is adapt to the calculation of multi-loop magnetic circuit.The accuracy and basic data are based on the results of FEM, which needs to build the simulation platform of dynamic characteristic. Firstly, the model of balance force relay is built by UG. Then FLUX is used to analyze electromagnetic system and static data table of electromagnetic characteristic is achieved. Next, the model of spring system is built by ADAMS and spring characteristic on different positions is computed. Finally, the simulation platform of dynamic characteristic is established based on Matlab/Simulink and differential equations of dynamic characteristic is solved through the fourth order Ronge-Kutta method.Then basing on FEM results, the fast calculation method of MEC is studied. The electromagnetic system of balance force relay is multi-loop magnetic circuit containing permanent magnet. Firstly, it needs to determine the type of air-gap reluctance and computational methods. Then reverse problem could be solved through fitting the B-H curve of soft magnetic materials and the equivalent model of permanent magnet should be determined. Next, non-linear equation of magnetic circuit is solved by QPSO and static characteristic of electromagnetic system is computed roughly. Finally space mapped method is used to improve the accuracy of the model and the limit of the method is found.Basing on the upper results, approximate function is used to build the fast calculation model of balance force relay. Basic model is determined by Tylor formulation and self-defined interpolating function. Then Kriging model is put forward to compensate the error and improve accuracy. Finally, spring force characteristic is analyzed by strain energy method and solve differential equations of dynamic characteristic to achieve the establishment of fast calculation model.At last, based on fast calculation model key design parameters is optimized and quality characteristic analysis and tolerance design method are used to improve product consistency between batches. Firstly, virtual samples are built based on Monte Carlo method and key design parameters are determined through quality characteristic analysis. Besides, it needs to design orthogonal test and compute contribution rate of design parameters. Finally, a new method of tolerance optimization is put forward and the tolerance range of key design parameters is improved, which is verified by quality characteristic analysis.