双盘式磁力耦合器振动噪声分析与实验研究

为了在双盘式磁力耦合器设计阶段分析振动噪声特性,优化双盘式磁力耦合器设计,提出了一种利用模态叠加原理来分析其振动噪声的方法。双盘式磁力耦合器具有高转矩密度与高效率等优势,因此逐渐发展成为煤矿机械柔性传动装置。由于双盘式磁力耦合内部的转子磁场非正弦分布以及涡电流谐波等因素影响,双盘式磁力耦合器输出转矩中不可避免的存在波动。若根据计算得出的双盘式磁力耦合器的电磁振动噪声特点,在设计时选取振动噪声小的参数进行优化组合,可在实际中降低其电磁振动及噪声,有利于减少制造成本。本文结合双盘式磁力耦合器的结构特征,提出了一种模态叠加响应法计算电磁振动噪声,建立了其电磁径向力的解析模型,并在多物理场耦合作用下分析主要电磁径向力波在工作频率内的谐波响应,最后在额定功率为55 kW双盘式磁力耦合器实验台上进行试验验证。基于麦克斯韦张量法,建立了双盘式磁力耦合器的径向电磁力解析模型,并得出0阶与10阶电磁径向力波是产生振动噪声的最主要原因;利用多物理场耦合分析法进行谐波响应NVH特性分析,结果显示0阶力波的振动加速度与形变量均大于10阶力波的振动加速度与形变量,因此双盘式磁力耦合器的电磁振动主要来源于0阶力波;在额定功率为55 kW,最高转速为1 500 r/min的双盘式磁力耦合器实验台进行振动测试,试验结果显示在1 500 r/min时,试验得出的最大振动峰值及频率约为35 m/s^2和4 950 Hz,与有限元仿真结果的误差对应为6.3%和1.1%;而当变频电机的输入转速依次增大时,振动加速度的理论值、仿真值与试验值的曲线形态较为接近,误差较小;噪声估计值与实测值的最大误差仅为8.9%,基本验证了本文所提出模态叠加法的正确性。

Analysis and experimental study of vibration and noise of double disk magnetic coupler

In order to analyze and optimize the characteristics of vibration and noise in the process of double disk magnetic coupler design,the method to analyze the vibration and noise with modal superposition is proposed.The double-disk magnetic coupler has the advantages of high torque density and high efficiency,hence,it has gradually become a flexible transmission device in coal mine machinery.Due to the non-sinusoidal distribution of the rotor magnetic field and eddy current harmonics in the double-disk magnetic coupling system,there are inevitable fluctuations in the output torque of the double-disk magnetic coupler.According to these characteristics of the coupler,the optimal combination of the parameters of low vibration and noise can reduce the electromagnetic vibration and noise in practice,which is helpful in reducing the manufacturing cost.Therefore,it is very important to predict and calculate the characteristics of electromagnetic vibration and noise accurately at the design stage of the double-disk magnetic coupler for reducing cost and improving its operation stability.The modal superposition response method was proposed to calculate electromagnetic vibration noise based on the structural characteristics of the double-disk magnetic coupler in this paper.The analytical model of the electromagnetic radial force was established,and the harmonic response of the main electromagnetic radial force wave in the working frequency was analyzed under the coupling action of multiple physical fields.Also,an experimental verification was conducted on a double-disk magnetic coupler test bench with a rated power of 55 kW.Based on the Maxwell tensor method,an analytical model of the radial electromagnetic force of the double-disk magnetic coupler was established.It was concluded that the main cause of vibration and noise is the electromagnetic radial force wave of orders 0 and 10.The NVH characteristic of harmonic response was analyzed by means of multi-physical field-coupling analysis.The results show that the vibration acceleration and deformation of the 0-order force wave are greater than that of the 10-order force wave.Thus,the electromagnetic vibration of the double-disk magnetic coupler is primarily attributed to the 0-order force wave.Vibration tests were conducted on a double-disk magnetic coupler test bench with a rated power of 55 kW and maximum speed of 1 500 r/min.The experimental results show that the maximum vibration peaks and frequencies are about 35 m/s^2 and 4 950 Hz at 1 500 r/min,and the errors corresponding to the finite element simulation results are 6.3% and 1.1%.When the input speed of the variable frequency motor increases in turn,the theoretical value and simulation value of the vibration acceleration are close to the curve shape of the test value,and the error is small.The maximum error between the noise estimation and the measured value is only 8.9%,which basically verifies the correctness of the modal superposition method proposed in this paper.