Modular flywheel set type inertia moment adjusting mechanism

Abstract

This invention provides a modular inertia disk-type inertia torque adjustment mechanism. Through standard module units with calibrated inertia values ​​and a conical sleeve-type quick-locking mechanism, it achieves precise quantification and rapid assembly / disassembly of inertia, solving the problems of cumbersome operation, low accuracy, and poor repeatability associated with existing manual steel plate addition / reduction methods. By utilizing the target torque-angular acceleration conversion algorithm and greedy combination optimization algorithm built into the inertia matching controller, it can automatically output the optimal module configuration scheme without manual calculation, improving testing efficiency and accuracy. Furthermore, through the safety verification function of dynamic torque and motion range prediction, it can provide early warning of risks exceeding mechanical limits, avoiding equipment damage and safety hazards. This invention, while retaining the compact structure and high reliability of the original inertia disk assembly, significantly improves the intelligence level and ease of operation of inertia torque adjustment, meeting the engineering requirements of dynamic load simulation for high-precision servo mechanisms.

Description

Technical Field

[0001] This invention relates to the field of load simulation loading experiments, and in particular to a modular inertia disk-type inertia torque adjustment mechanism. Background Technology

[0002] The electric servo system simulation load table is a key testing device for servo mechanisms to verify control algorithms, simulate dynamic characteristics, and facilitate production delivery. One of its core functions is to provide an adjustable inertial torque load to the tested servo mechanism to simulate the rotational inertia effect under real-world operating conditions. The inertial torque adjustment mechanism typically takes the form of an inertial disk assembly or an inertial pendulum, changing the rotational inertia by altering the mass distribution or lever arm of the rotating mass, thereby generating the required inertial torque. In existing technologies, common inertial torque adjustment mechanisms, such as the scheme disclosed in the project proposal, use several steel plates to form an inertial disk assembly. When the inertia needs to be changed, the number of steel plates is manually added or removed to meet the testing requirements of different inertial torques. This scheme is simple in structure and low in cost, and has already been applied to some servo mechanism load tables.

[0003] However, the existing structures described above have significant shortcomings in practical use. First, the manual addition and removal of steel plates lacks quantitative guidance. Operators typically rely on experience or rough calculations to select the number of steel plates, resulting in low accuracy and poor repeatability of inertia adjustment, making it difficult to meet the requirements of dynamic performance testing for high-precision servo mechanisms. Second, the use of ordinary bolts to fasten the steel plates to the rotating shaft is cumbersome, and repeated disassembly and assembly can easily lead to positioning loosening and concentricity deviations, affecting the stability of rotational inertia and the reliability of test data. Furthermore, the existing solutions do not provide an automatic matching algorithm between inertial torque, angular acceleration, and rotational inertia. Experimenters must calculate the required inertia value themselves and then manually assemble the steel plate combination, which is inefficient and prone to errors. In addition, there is a lack of dynamic safety verification mechanism. When the lever arm is long or the inertia configuration is too large, the rocker arm may exceed the mechanical limit during acceleration and deceleration, causing equipment damage or personal injury. Therefore, how to provide a modular inertial torque adjustment mechanism that can achieve rapid disassembly and assembly, quantitative matching, and automatic verification is a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to provide a modular inertia disk assembly inertial torque adjustment mechanism to solve the problems existing in the prior art.

[0005] To achieve the above objectives, the present invention provides the following solution: This invention provides a modular inertia disk-type inertia torque adjustment mechanism, comprising: The basic inertia unit is fixedly mounted on the rotating rocker arm and is used to provide a reference moment of inertia. The standard inertia module group consists of multiple independent standard inertia module units with calibrated rotational inertia values. Each standard inertia module unit is coaxially stacked on the basic inertia unit to provide the required additional rotational inertia. The quick-locking mechanism passes through the center hole of each standard inertia module unit and mates with the base inertia unit to achieve axial positioning, radial tightening, and quick assembly / disassembly of each module unit. An angle encoder, installed at the end of the rotating shaft, is used to monitor the rotation angle of the rocker arm in real time; The inertia matching controller communicates with both the angle encoder and the host computer to receive the target inertial torque and angular acceleration parameters, calculate the required total rotational inertia, and output the combination scheme of the standard inertia modules.

[0006] Preferably, the quick-locking mechanism includes a tapered mandrel and a radial locking nut; the tapered mandrel passes through each standard inertia module unit and engages with the central tapered hole of the basic inertia unit; when the radial locking nut is tightened, it drives the mandrel to move axially, causing the tapered surface to tighten all module units.

[0007] Preferably, each standard inertia module unit in the standard inertia module group is a circular or fan-shaped disk structure. Each module unit is calibrated with a unique moment of inertia value at the factory, and the module units use the same center aperture and positioning end face.

[0008] Preferably, the inertia matching controller includes: The parameter input module is used to receive the target inertial torque set by the experimenter. and maximum angular acceleration ; The total inertia calculation module, based on the formula Calculate the required total moment of inertia; The basic inertia deduction module stores the inherent rotational inertia of the basic inertia unit, rocker arm, and shaft. inertia of other fixed components And calculate the inertia that needs to be provided by the standard inertia module group. ; The module combination optimization module selects module units from the standard inertia module library based on a greedy algorithm, such that the total inertia is closest to and does not exceed the specified value. and output a list of module numbers; Security verification module, according to and Calculate the dynamic torque and predict the range of rocker arm movement angle based on the current lever arm length, determine whether it exceeds the mechanical limit, and issue a warning if it does.

[0009] Preferably, the specific execution steps of the module combination optimization module are as follows: sort the available standard inertia modules in descending order of inertia value; initialize the selected total to zero; traverse each module sequentially, and if the sum of the inertia value of the current module and the selected total does not exceed... If the selected module is selected, the total number of selected modules will be updated; after the traversal is complete, the numbers of all selected modules will be output.

[0010] Preferably, the angle encoder is a high-precision absolute encoder or an incremental encoder, and its signal output terminal is connected to an inertia matching controller for real-time feedback of the actual rotation angle during experimental operation. When the measured angular acceleration deviates from the set value by more than a preset threshold, the inertia matching controller issues an inertia configuration deviation prompt.

[0011] Preferably, it also includes a limiting guard rod, which is set below the rotation position of the inertia component. The limiting guard rod is made of Q235 round steel, and its installation position and the minimum distance between it and the rocker arm's motion trajectory are dynamically calculated and determined based on the current total moment of inertia and the maximum angular acceleration.

[0012] Preferably, the basic inertia unit is rigidly connected to the rotating rocker arm via a flange and bolts, and the basic inertia unit has a tapered positioning hole at its center for engaging with the tapered mandrel of the quick-locking mechanism.

[0013] Preferably, each standard inertia module unit of the standard inertia module group is provided with an anti-rotation positioning structure, which is a positioning pin distributed along the axial direction that engages with a positioning hole, or a toothed end face engagement.

[0014] Preferably, the inertia matching controller is also connected to a human-machine interface for displaying recommended module combination schemes, module installation order, locking torque requirements, and safety verification results; the human-machine interface also receives manual correction commands, allowing experimenters to manually adjust the module combination.

[0015] The present invention achieves the following beneficial technical effects compared to the prior art: This invention provides a modular inertia disk-type inertia torque adjustment mechanism, featuring modular assembly, rapid locking, intelligent matching, and dynamic safety verification. By setting standard module units with calibrated inertia values ​​and a conical sleeve-type rapid locking mechanism, it achieves precise quantification and rapid assembly / disassembly of inertia, solving the problems of cumbersome operation, low accuracy, and poor repeatability of existing manual steel plate addition / reduction methods. Through the target torque-angular acceleration conversion algorithm and greedy combination optimization algorithm built into the inertia matching controller, it can automatically output the optimal module configuration scheme without manual calculation, improving testing efficiency and accuracy. Furthermore, through the safety verification function of dynamic torque and motion range prediction, it can provide early warning of risks exceeding mechanical limits, avoiding equipment damage and safety hazards. This invention, while retaining the compact structure and high reliability of the original inertia disk assembly, significantly improves the intelligence level and ease of operation of inertia torque adjustment, meeting the engineering requirements of dynamic load simulation for high-precision servo mechanisms. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 The modular inertia disk assembly inertia torque adjustment mechanism provided by this invention; Figure 2 A schematic diagram of the operation of the modular inertia disk-type inertia torque adjustment mechanism provided by the present invention; Figure 3 A schematic diagram of the communication relationship of the modular inertia disk group inertia torque adjustment mechanism provided by the present invention. Detailed Implementation

[0018] Unless otherwise specified, the terms "connection" and "linkage" used in this application include both direct and indirect connections (linkages). In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0019] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] The purpose of this invention is to provide a modular inertia disk assembly inertial torque adjustment mechanism to solve the problems existing in the prior art.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] Example 1: Please see Figures 1 to 3 This invention provides a modular inertia disk-type inertia torque adjustment mechanism for use in an electric servo system simulation load table to simulate the inertia torque experienced by the servo mechanism under different operating conditions. The mechanism mainly includes a basic inertia unit 1, a standard inertia module group 2, a quick-locking mechanism, an angle encoder 3, and an inertia matching controller. The basic inertia unit is fixedly installed on the rotating rocker arm 4 to provide a known and constant reference moment of inertia. The standard inertia module group 2 consists of multiple independent standard inertia module units with calibrated moment of inertia values. These module units are coaxially stacked in the middle of the basic inertia unit. By selecting different numbers and models of module units, various additional moments of inertia can be combined to meet different testing requirements. The quick-locking mechanism passes through the center hole of each standard inertia module unit and cooperates with the basic inertia unit. Its function is to quickly position, tighten and lock each module unit in the axial and radial directions, while allowing for quick assembly and disassembly. The angle encoder 3 is installed at the end of the rotating shaft to monitor the rotation angle of the rocker arm in real time and transmit the signal to the control system. The inertia matching controller is connected to the angle encoder and the host computer. Its core function is to receive the target inertial torque and angular acceleration parameters input by the experimenter, automatically calculate the required total moment of inertia, and output the optimal standard inertia module combination scheme.

[0024] Specifically, the basic inertia unit 1 and the rotating rocker arm 4 are rigidly connected via a flange and high-strength bolts to ensure reliable power transmission. The basic inertia unit 1 has a conical positioning hole at its center, which mates with the conical sleeve mandrel of the quick-locking mechanism. The quick-locking mechanism preferably employs a structure of a conical sleeve mandrel and a radial locking nut: the conical sleeve mandrel passes sequentially through the central holes of each standard inertia module unit, and its conical end fits tightly against the central conical hole of the basic inertia unit; when the operator tightens the radial locking nut, the mandrel moves axially, and the conical surface radially expands the inner holes of each module unit, achieving gapless, highly concentric fixation. This locking method not only allows for rapid assembly and disassembly but also enables repeated use without reducing positioning accuracy. Each standard inertia module unit is preferably designed as a circular or fan-shaped disc structure. Each module unit undergoes a calibration test before leaving the factory to determine its unique moment of inertia value, which is marked on the module surface. All module units use the same central hole diameter and positioning end face to ensure that any module can be interchangeably stacked. In addition, an anti-rotation positioning structure is provided between each module unit. This anti-rotation positioning structure can be a positioning pin distributed along the axial direction that cooperates with the positioning hole, or it can be a toothed fit on the end face, to prevent relative rotation of the module during high-speed rotation or acceleration and deceleration.

[0025] In this invention, the inertia matching controller is the core component for achieving intelligent matching. This controller integrates multiple functional modules, specifically including a parameter input module, a total inertia calculation module, a basic inertia deduction module, a module combination optimization module, and a safety verification module. Researchers set two key parameters to the parameter input module through a human-computer interaction interface (e.g., a touchscreen or host computer software): the target inertial torque. (Unit: N·m) and maximum angular acceleration (Unit: rad / s) 2 The total inertia calculation module automatically calculates the required total moment of inertia based on the fundamental formulas of rigid body dynamics. : ; in, This represents the total moment of inertia required for the test, expressed in kg·m. 2 ; For the target inertial torque; This represents the maximum angular acceleration. The formula means that, at a given angular acceleration, the moment of inertia necessary to generate the target inertial torque.

[0026] The basic inertia deduction module pre-stores the fixed rotational inertia values ​​of the mechanism, including the inherent rotational inertia of components such as the basic inertia unit, the rotating rocker arm, and the rotating shaft. And the moment of inertia of other fixed components (such as couplings, sensor rotors, etc.) These values ​​can be precisely calculated using a 3D model or calibrated through a torsional pendulum experiment. Therefore, the actual moment of inertia required from the standard inertia module group is: ; If calculated If ≤0, it means no additional module is needed, and the controller will directly provide a prompt; if If the value is greater than 0, then proceed to the module combination optimization stage.

[0027] The module combination optimization module employs a greedy algorithm to select suitable module units from the available standard inertia module library, such that the total inertia of the selected modules is as close as possible to and does not exceed the limit. The specific execution steps are as follows: First, sort all currently available standard inertia modules according to their calibrated inertia values ​​from largest to smallest; then, initialize the total number of selected inertia modules. =0, the selected module list is empty; then, iterate through each sorted module in turn, and for the current module's inertia value ,like + ≤ If so, select that module and... Add the selected modules to the total sum and add the module number to the selected list; after traversal, output the list of selected module numbers. This algorithm can provide a near-optimal combination in polynomial time and is simple and reliable to implement. For example, suppose... =650kg·m 2 The module library contains inertia values ​​of 200, 200, 100, 50, and 50 (all in kg·m). 2 If the algorithm selects the first 200, the second 200, 100, and the first 50 in sequence, the total is 550. It will not select the second 50 to avoid exceeding the requirements, and finally output the numbers of these four modules.

[0028] After completing the module combination recommendation, the safety verification module is based on the final determined total moment of inertia. and maximum angular acceleration The maximum dynamic torque that the calculation system may generate during dynamic operation is: ; The dynamic torque, together with the current lever arm length (in meters, input by the experimenter based on the actual installation, typically ranging from 0.55m to 0.7m), determines the maximum linear acceleration at the end of the rocker arm. Furthermore, based on rotational kinematics formulas, the angle required to accelerate from rest to maximum angular velocity at a given angular acceleration can be estimated, or the maximum permissible angular acceleration can be calculated back from the maximum permissible mechanical limit angle. If the predicted rocker arm motion angle exceeds the mechanical limit (e.g., ±10°), the safety verification module will issue a warning through the human-machine interface, prompting the experimenter to reduce the angular acceleration or readjust the inertia configuration. In addition, this invention also includes a limit protection rod 5 located below the rotation position of the inertia component. This limit protection rod 5 is made of Q235 round steel, preferably with a diameter of 45mm. The minimum distance between its installation position and the rocker arm's motion trajectory is not a fixed value, but is dynamically calculated and determined based on the current total moment of inertia and maximum angular acceleration, ensuring that in extreme cases, the protection rod withstands impact and undergoes plastic deformation before other components, thereby absorbing impact energy and protecting the main equipment and personnel.

[0029] The angle encoder uses a high-precision absolute encoder or incremental encoder, and its signal output is connected to an inertia matching controller. During the experiment, the angle encoder provides real-time feedback on the actual rotation angle of the rocker arm, and the controller calculates the measured angular acceleration based on the change of angle over time. When the measured angular acceleration matches the value set by the experimenter... When the deviation exceeds a preset threshold (e.g., 5%), the controller will issue an inertia configuration deviation warning, suggesting that the experimenter check whether the module combination is correct or recalibrate the basic inertia value. The inertia matching controller is also connected to a human-machine interface, which not only displays the recommended module combination scheme (including module number, installation order, locking torque requirements, etc.), but also displays the safety verification results in real time. At the same time, the interface allows the experimenter to make manual corrections according to specific needs, such as manually adding or removing a module, and the system will recalculate the verification results and provide feedback.

[0030] The following is combined Figure 2 and Figure 3 Briefly describe the working process of this invention. Before the experiment begins, the operator sets the target inertial torque... and maximum angular acceleration Input inertia matching controller. The controller automatically calculates and outputs a recommended standard inertia module combination scheme. The operator follows the prompts to retrieve the corresponding modules from the module library, sequentially inserts them onto the tapered mandrel of the quick-locking mechanism, and tightens the radial lock nut to complete the installation. Subsequently, the system performs a safety check; if there are no warnings, the experiment can begin. During the experiment, the angle encoder monitors the rotation angle in real time, and the controller compares the measured angular acceleration with the set value; if the deviation is too large, an alarm is triggered. When it is necessary to change the load conditions, simply loosen the lock nut and replace or add modules to quickly complete the adjustment. The entire operation process requires no manual calculation, is convenient to install and disassemble, and is safe and reliable.

[0031] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0032] It should be noted that the components mentioned in the above embodiments are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0033] This invention has illustrated its principles and implementation methods using specific examples. The descriptions of these embodiments are merely illustrative of the method and its core ideas; furthermore, those skilled in the art will recognize that modifications may be made to the specific implementation methods and application scope based on the principles of this invention. Therefore, the content of this specification should not be construed as limiting the invention.

Claims

1. A modular inertia disk-type inertia torque adjustment mechanism, characterized in that, include: The basic inertia unit is fixedly mounted on the rotating rocker arm and is used to provide a reference moment of inertia. The standard inertia module group consists of multiple independent standard inertia module units with calibrated rotational inertia values. Each standard inertia module unit is coaxially stacked on the basic inertia unit to provide the required additional rotational inertia. The quick-locking mechanism passes through the center hole of each standard inertia module unit and mates with the base inertia unit to achieve axial positioning, radial tightening, and quick assembly / disassembly of each module unit. An angle encoder, installed at the end of the rotating shaft, is used to monitor the rotation angle of the rocker arm in real time; The inertia matching controller communicates with both the angle encoder and the host computer to receive the target inertial torque and angular acceleration parameters, calculate the required total rotational inertia, and output the combination scheme of the standard inertia modules.

2. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The quick-locking mechanism includes a tapered mandrel and a radial locking nut. The tapered mandrel passes through each standard inertia module unit and engages with the central tapered hole of the basic inertia unit. When the radial locking nut is tightened, it drives the mandrel to move axially, causing the tapered surface to tighten all module units.

3. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, Each standard inertia module unit in the standard inertia module group is a circular or sector-shaped disk structure. Each module unit is calibrated with a unique rotational inertia value at the factory, and the module units use the same center aperture and positioning end face.

4. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The inertia matching controller includes: The parameter input module is used to receive the target inertial torque set by the experimenter. and maximum angular acceleration ; The total inertia calculation module, based on the formula Calculate the required total moment of inertia; The basic inertia deduction module stores the inherent rotational inertia of the basic inertia unit, rocker arm, and shaft. inertia of other fixed components And calculate the inertia that needs to be provided by the standard inertia module group. ; The module combination optimization module selects module units from the standard inertia module library based on a greedy algorithm, such that the total inertia is closest to and does not exceed the specified value. and output a list of module numbers; Security verification module, according to and Calculate the dynamic torque and predict the range of rocker arm movement angle based on the current lever arm length, determine whether it exceeds the mechanical limit, and issue a warning if it does.

5. The modular inertia disk-type inertia torque adjustment mechanism according to claim 4, characterized in that, The specific execution steps of the module combination optimization module are as follows: sort the available standard inertia modules in descending order of inertia value; initialize the sum of the selected modules to zero; iterate through each module sequentially, and if the sum of the inertia value of the current module and the sum of the selected modules does not exceed the specified value... If the selected module is selected, the total number of selected modules will be updated; after the traversal is complete, the numbers of all selected modules will be output.

6. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The angle encoder is a high-precision absolute encoder or incremental encoder. Its signal output terminal is connected to an inertia matching controller to provide real-time feedback of the actual rotation angle during experimental operation. When the measured angular acceleration deviates from the set value by more than a preset threshold, the inertia matching controller issues an inertia configuration deviation prompt.

7. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, It also includes a limit guard rod, which is set on the side below the rotation position of the inertia component. The limit guard rod is made of Q235 round steel, and its installation position and the minimum distance between it and the rocker arm's motion trajectory are dynamically calculated and determined based on the current total moment of inertia and the maximum angular acceleration.

8. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The basic inertia unit is rigidly connected to the rotating rocker arm via a flange and bolts. The center of the basic inertia unit is provided with a tapered positioning hole for engaging with the tapered mandrel of the quick-locking mechanism.

9. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The standard inertia module group is provided with an anti-rotation positioning structure between each standard inertia module unit. The anti-rotation positioning structure is a positioning pin distributed along the axial direction that fits with a positioning hole, or a toothed end face fit.

10. The modular inertia disk-type inertia torque adjustment mechanism according to claim 1, characterized in that, The inertia matching controller is also connected to a human-machine interface, which displays recommended module combination schemes, module installation order, locking torque requirements, and safety verification results; the human-machine interface also receives manual correction commands, allowing experimenters to manually adjust the module combination.

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