Article(id=1154065256071553504, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1148011752937218501, articleNumber=null, orderNo=null, doi=10.7654/j.issn.2097-1974.20250210, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1706976000000, receivedDateStr=2024-02-04, revisedDate=1715702400000, revisedDateStr=2024-05-15, acceptedDate=null, acceptedDateStr=null, onlineDate=1753080198542, onlineDateStr=2025-07-21, pubDate=1745510400000, pubDateStr=2025-04-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1753080198542, onlineIssueDateStr=2025-07-21, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1753080198542, creator=13701087609, updateTime=1753080198542, updator=13701087609, issue=Issue{id=1148011752937218501, tenantId=1146029695717560320, journalId=1146119989267898375, year='2025', volume='48', issue='2', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1751636930927, creator=13701087609, updateTime=1754905338909, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1161720449667785615, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1148011752937218501, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1161720449667785616, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1148011752937218501, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=77, endPage=84, ext={EN=ArticleExt(id=1154065256583258593, articleId=1154065256071553504, tenantId=1146029695717560320, journalId=1146119989267898375, language=EN, title=Anti-overload Structure Design and Characteristic Analysis of Brushless DC Motor on Projectile, columnId=1154057567442559335, journalTitle=Missiles and Space Vehicles, columnName=Material and Manufacturing, runingTitle=null, highlight=null, articleAbstract=

In order to solve the problem of vulnerability of the missile-loaded motor shaft and bearing in the high overload environment of 23 000g guided artillery projectile, the anti-high overload brushless DC motor using a combination of disc spring and special steel ball for buffering and vibration damping is designed. Firstly, the acceleration load curve of the missile-borne motor is obtained by calculation. The bearing and shaft of the brushless DC motor are analyzed to be the failure prone parts. Secondly, according to the energy absorption characteristics of dish spring and steel ball, a composite damping structure of brushless DC motor combining dish spring and special steel ball is designed in the case of limited structural space. And based on this structure, a high speed and fast response anti-high overload motor is designed. Finally, the simulation and experimental analysis of the designed motor show that the design of the composite buffer structure can effectively reduce the stress and deformation of the motor shafting parts under the high overload environment. The structure of the anti-high overload motor has no obvious damage after the Marshall's drop hammer test, and the working performance meets the requirements of precision guidance control.

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针对制导炮弹23 000g 高过载环境下弹载电机转轴与轴承易损问题,设计了一种采用碟簧与特制钢球组合缓冲减振的抗高过载无刷直流电机。首先通过计算得到弹载电机加速度载荷曲线,分析了无刷直流电机轴承与转轴为易失效部件。其次根据碟形弹簧与钢球吸能特性,在结构空间有限的情况下设计了一种碟形弹簧与特制钢球结合的无刷直流电机复合缓冲减振结构,并基于该结构设计一种高转速快响应的抗高过载电机。最后对设计的电机进行仿真与试验分析,结果表明冲击过载环境下所设计复合缓冲结构能够有效降低电机轴系零部件所受应力与变形。抗高过载电机经锤击试验后结构无明显损伤,工作性能满足精确制导控制要求。

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肖磊(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

冯治国(1978—),男,博士,教授,主要研究方向为机器人技术及其应用、运动控制技术、材料加工等。

赵磊(1985—),男,工程师,主要研究方向为无刷直流电机及齿轮油泵。

张宇(1989—),男,工程师,主要研究研究方向为无刷直流电机。

旷华聪(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

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肖磊(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

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肖磊(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

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冯治国(1978—),男,博士,教授,主要研究方向为机器人技术及其应用、运动控制技术、材料加工等。

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冯治国(1978—),男,博士,教授,主要研究方向为机器人技术及其应用、运动控制技术、材料加工等。

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Journal of Vibration, Measurement & Diagnosis, 2014,34(1): 8-14+185., articleTitle=Impact dynamics simulation and experiment analysis of impact dynamics of traveling wave type rotary ultrasonic motor, refAbstract=null)], funds=[Fund(id=1197261062228718457, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, awardId=黔科合支撑[2021]一般280, language=CN, fundingSource=贵州省科技计划项目(黔科合支撑[2021]一般280), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1197261055048069927, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, xref=1, ext=[AuthorCompanyExt(id=1197261055056458536, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, companyId=1197261055048069927, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=1School of Mechanical Engineering,Guizhou University,Guiyang,550025), AuthorCompanyExt(id=1197261055064847145, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, companyId=1197261055048069927, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=1贵州大学机械工程学院,贵阳,550025)]), AuthorCompany(id=1197261055157121834, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, xref=2, ext=[AuthorCompanyExt(id=1197261055161316139, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, companyId=1197261055157121834, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=2Guizhou Kaiminbo Electromechanical Technology Co., Ltd.,Guiyang,550025), AuthorCompanyExt(id=1197261055169704748, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, companyId=1197261055157121834, language=CN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=2贵州凯敏博机电科技有限公司,贵阳,550025)])], figs=[ArticleFig(id=1197261058428678997, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Fig. 1, caption=Analysis of forces in the chamber stage of projectile, figureFileSmall=X3eA/Lo5KPxn/vuCi2ImJQ==, figureFileBig=eeKv9zkW9xxvLCjL4GsIXQ==, tableContent=null), ArticleFig(id=1197261058487399254, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=图1, caption=炮弹膛内阶段受力分析, figureFileSmall=X3eA/Lo5KPxn/vuCi2ImJQ==, figureFileBig=eeKv9zkW9xxvLCjL4GsIXQ==, tableContent=null), ArticleFig(id=1197261058638394199, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Fig. 2, caption=Motor axial overload acceleration, figureFileSmall=negg9v/FNsHMXg9cKQd81Q==, figureFileBig=X485bl2ZebvjucuYYJ2oAw==, tableContent=null), ArticleFig(id=1197261058705503064, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=图2, caption=电机轴向过载加速度, figureFileSmall=negg9v/FNsHMXg9cKQd81Q==, figureFileBig=X485bl2ZebvjucuYYJ2oAw==, tableContent=null), ArticleFig(id=1197261058768417625, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Fig. 3, caption=Structure of motor steel ball and spring against high overload, figureFileSmall=y0qHiX62Bl3TEGlVNp56hw==, figureFileBig=vEX1/quGcQBpSFCM7LrxZw==, tableContent=null), ArticleFig(id=1197261058831332186, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=图3, caption=电机钢球+弹簧抗高过载结构

1—轴承;2—轴承挡圈;3—弹簧;4—后端盖;5—钢珠。

, figureFileSmall=y0qHiX62Bl3TEGlVNp56hw==, figureFileBig=vEX1/quGcQBpSFCM7LrxZw==, tableContent=null), ArticleFig(id=1197261058894246747, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Fig. 4, caption=Decomposition of faulty motor, figureFileSmall=rT+2rl1fScOY4jMSZD2a0g==, figureFileBig=dU1GZEt8mhSMuTaV97qsPA==, tableContent=null), ArticleFig(id=1197261058990715740, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=图4, caption=故障电机分解情况, figureFileSmall=rT+2rl1fScOY4jMSZD2a0g==, figureFileBig=dU1GZEt8mhSMuTaV97qsPA==, tableContent=null), ArticleFig(id=1197261059053630301, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Fig. 5, caption=Structure of high overload resistant motor, figureFileSmall=7BHCXRRK+mZkAXcG7hAtVw==, figureFileBig=OO00u1fPTJbbvvHwqGRaZw==, tableContent=null), ArticleFig(id=1197261059120739166, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=图5, caption=抗高过载电机结构

1—螺栓;2—深沟球轴承;3—端盖;4—碟簧;5—调整垫圈;6—特制钢球;7-O形橡胶圈;8—挡环;9—橡胶圈;10—转子;11—定子;12—机壳;13—橡胶垫;14—深沟球轴承;15—碟簧。

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mechanical properties of materials, figureFileSmall=null, figureFileBig=null, tableContent=
零件材料密度/(g $\cdot {\mathrm{{cm}}}^{-3}$)弹性模量 /GPa泊松比屈服强度/MPa
端盖2Cr137.752280.29440
机壳
转轴
碟簧60Si2Mn7.852060.291 375
轴承GCr157.802080.30518.42
钢球结构钢7.852050.3250
), ArticleFig(id=1197261061897368438, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=表1, caption=材料力学性能参数, figureFileSmall=null, figureFileBig=null, tableContent=
零件材料密度/(g $\cdot {\mathrm{{cm}}}^{-3}$)弹性模量 /GPa泊松比屈服强度/MPa
端盖2Cr137.752280.29440
机壳
转轴
碟簧60Si2Mn7.852060.291 375
轴承GCr157.802080.30518.42
钢球结构钢7.852050.3250
), ArticleFig(id=1197261061998031735, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=EN, label=Tab. 2, caption=Comparison of running performance before and after hammering test of high overload resistant motor, figureFileSmall=null, figureFileBig=null, tableContent=
项目锤击试验前锤击试验后
结构外观完整无明显变形及裂纹
轴向间隙/mm0.30.33
空载启动电压/V0.840.86
空载转速/$\left({\mathrm{r}\cdot {\mathrm{{min}}}^{-1}}\right)$10 74310 718
空载电流/A0.200.21
额定转速$/\left({\mathrm{r}\cdot {\mathrm{{min}}}^{-1}}\right)$8 9068 882
额定电流/A1.341.36
额定力矩$/\left({\mathrm{N}\cdot \mathrm{m}}\right)$0.0280.028
电阻值/Ω3.0973.096
电感值/mH1.0941.095
绝缘电阻/$\Omega$>500M>500M
), ArticleFig(id=1197261062073529208, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1154065256071553504, language=CN, label=表2, caption=抗高过载电机锤击试验前后运转性能对比, figureFileSmall=null, figureFileBig=null, tableContent=
项目锤击试验前锤击试验后
结构外观完整无明显变形及裂纹
轴向间隙/mm0.30.33
空载启动电压/V0.840.86
空载转速/$\left({\mathrm{r}\cdot {\mathrm{{min}}}^{-1}}\right)$10 74310 718
空载电流/A0.200.21
额定转速$/\left({\mathrm{r}\cdot {\mathrm{{min}}}^{-1}}\right)$8 9068 882
额定电流/A1.341.36
额定力矩$/\left({\mathrm{N}\cdot \mathrm{m}}\right)$0.0280.028
电阻值/Ω3.0973.096
电感值/mH1.0941.095
绝缘电阻/$\Omega$>500M>500M
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弹载无刷直流电机抗载结构设计及特性分析
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肖磊 1 , 冯治国 1 , 赵磊 2 , 张宇 2 , 旷华聪 1
导弹与航天运载技术(中英文) | 材料与制造技术 2025,48(2): 77-84
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导弹与航天运载技术(中英文) | 材料与制造技术 2025, 48(2): 77-84
弹载无刷直流电机抗载结构设计及特性分析
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肖磊1, 冯治国1, 赵磊2, 张宇2, 旷华聪1
作者信息
  • 1贵州大学机械工程学院,贵阳,550025
  • 2贵州凯敏博机电科技有限公司,贵阳,550025
  • 肖磊(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

    冯治国(1978—),男,博士,教授,主要研究方向为机器人技术及其应用、运动控制技术、材料加工等。

    赵磊(1985—),男,工程师,主要研究方向为无刷直流电机及齿轮油泵。

    张宇(1989—),男,工程师,主要研究研究方向为无刷直流电机。

    旷华聪(1996—),男,硕士研究生,主要研究方向为机械制造及其自动化技术。

Anti-overload Structure Design and Characteristic Analysis of Brushless DC Motor on Projectile
Lei XIAO1, Zhiguo FENG1, Lei ZHAO2, Yu ZHANG2, Huacong KUANG1
Affiliations
  • 1School of Mechanical Engineering,Guizhou University,Guiyang,550025
  • 2Guizhou Kaiminbo Electromechanical Technology Co., Ltd.,Guiyang,550025
出版时间: 2025-04-25 doi: 10.7654/j.issn.2097-1974.20250210
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针对制导炮弹23 000g 高过载环境下弹载电机转轴与轴承易损问题,设计了一种采用碟簧与特制钢球组合缓冲减振的抗高过载无刷直流电机。首先通过计算得到弹载电机加速度载荷曲线,分析了无刷直流电机轴承与转轴为易失效部件。其次根据碟形弹簧与钢球吸能特性,在结构空间有限的情况下设计了一种碟形弹簧与特制钢球结合的无刷直流电机复合缓冲减振结构,并基于该结构设计一种高转速快响应的抗高过载电机。最后对设计的电机进行仿真与试验分析,结果表明冲击过载环境下所设计复合缓冲结构能够有效降低电机轴系零部件所受应力与变形。抗高过载电机经锤击试验后结构无明显损伤,工作性能满足精确制导控制要求。

制导炮弹  /  抗高过载  /  无刷直流电机  /  瞬态动力学  /  缓冲减振

In order to solve the problem of vulnerability of the missile-loaded motor shaft and bearing in the high overload environment of 23 000g guided artillery projectile, the anti-high overload brushless DC motor using a combination of disc spring and special steel ball for buffering and vibration damping is designed. Firstly, the acceleration load curve of the missile-borne motor is obtained by calculation. The bearing and shaft of the brushless DC motor are analyzed to be the failure prone parts. Secondly, according to the energy absorption characteristics of dish spring and steel ball, a composite damping structure of brushless DC motor combining dish spring and special steel ball is designed in the case of limited structural space. And based on this structure, a high speed and fast response anti-high overload motor is designed. Finally, the simulation and experimental analysis of the designed motor show that the design of the composite buffer structure can effectively reduce the stress and deformation of the motor shafting parts under the high overload environment. The structure of the anti-high overload motor has no obvious damage after the Marshall's drop hammer test, and the working performance meets the requirements of precision guidance control.

guidance projectile  /  anti high overload  /  brushless DC motor  /  transient dynamics  /  buffer shock absorption
肖磊, 冯治国, 赵磊, 张宇, 旷华聪. 弹载无刷直流电机抗载结构设计及特性分析. 导弹与航天运载技术(中英文), 2025 , 48 (2) : 77 -84 . DOI: 10.7654/j.issn.2097-1974.20250210
Lei XIAO, Zhiguo FENG, Lei ZHAO, Yu ZHANG, Huacong KUANG. Anti-overload Structure Design and Characteristic Analysis of Brushless DC Motor on Projectile[J]. Missiles and Space Vehicles, 2025 , 48 (2) : 77 -84 . DOI: 10.7654/j.issn.2097-1974.20250210
智能制导炮弹已成为中国武器装备的重要配备, 在炮膛发射阶段, 制导炮弹弹丸加速时间短, 膛内火药燃气压力大,弹体将承受高达数万倍重力加速度的瞬时加速度, 炮弹及其内部各组件在短期内承受着高冲击过载, 舵机系统核心部件无刷直流电机容易受损。因此, 研制抗高过载的无刷直流电机已成为弹载器件抗高过载领域的热点方向。
目前,国内外智能制导炮弹的过载量级集中于${8000}\mathrm{\;g}\sim {2000}\mathrm{\;g}$的加速度载荷,其中解决弹载器件抗高过载问题的主要方案分为加装隔振缓冲装置和提高结构的抗冲击能力[1-5]。周优良等[6-8]采用橡胶垫与泡沫铝作为缓冲材料进行吸能, 使弹载测试仪在强冲击载荷下使用时具有较高可靠性。李璀璀[9]通过在无刷直流电机轴承处设计吸能减振垫片和限位块, 提升了轴向20000g冲击载荷下电机的抗载性能,在无刷直流电机的受力端轴承使用碟簧支撑, 碟簧产生弹性变形,从而起到保护轴承的作用[10]。付业旺[11]设计了一种轻量化、高功率密度的弹载电机,并通过在转轴与轴承之间添加碟簧使得电机承受${20000g}$瞬时冲击过载后仍能正常工作。Zhang等[12]从提高结构的自身抗高过载能力出发进行研究。惠江海等${}^{\lfloor {13}\rfloor }$通过改变引信自旋式微电机外转子机架的轴肩和底螺尺寸, 有效降低了球轴承所受应力,在承受${12000}\mathrm{g}$冲击过载下保证电机的正常工作。
综合当前研究现状, 单一依靠减载材料或者改善结构不易于满足超过23000g冲击过载的缓冲需求, 电机性能无法在冲击后得到保障。
针对贵州凯敏博机电科技有限公司研制超过23 000g抗高过载弹载电机的需求, 构建了弹载无刷直流电机冲击动力学模型, 研究了弹载无刷直流电机在冲击环境下的受力特性, 分析了弹载无刷直流电机可能存在的失效模式, 优化设计了一种采用碟形弹簧与特制钢球组合缓冲减振的无刷直流电机。仿真与试验结果表明,电机承受的23000g加速度过载经该结构缓冲减振后不会造成电机零部件损坏。此研究具有较强的工程实践意义, 可为超高加速度冲击过载条件下弹载电机的研制能够提供指导。
制导炮弹在发射时, 弹丸所受载荷有火药气压力、惯性力、摩擦力等,其中火药气压力是弹丸承受的主要载荷。弹丸受内弹道火药燃烧气压力的作用, 产生轴向瞬时高加速运动, 同时会产生径向惯性力与切向惯性力, 如图1所示。
炮弹发射过程中, 弹丸承受的主要作用力含轴向惯性力${F}_{n}$、径向惯性力${F}_{\mathrm{r}}$、切向惯性力${F}_{\mathrm{t}}$。由于弹载电机主要用于制导炮弹, 炮弹发射过程中转速较低, 与转速相关的力相对于轴向上的力对电机结构影响程度很小, 可以忽略[14], 故在后续分析中主要研究在轴向高过载环境下炮弹的受力过载情况。
根据内弹道学, 膛压曲线是指炮弹发射时膛内气体的平均压力, 其值为
$ p =\frac{1}{2}\left({{p}_{\mathrm{t}}+ {p}_{\mathrm{d}}}\right)$
式中${p}_{\mathrm{t}}$为炮膛底部压力最大值;${p}_{\mathrm{d}}$为炮弹底部所受的压力。
${p}_{\mathrm{t}}= {p}_{\mathrm{d}}\left({1 +\frac{{m}_{\mathrm{w}}}{2\varphi m}}\right)$
式中${m}_{\mathrm{w}}$为总装发射火药质量;$m$为炮弹质量;$\varphi$为阻尼系数。
炮弹底部压力为
${p}_{\mathrm{d}}= \frac{p}{1 +\frac{{m}_{\mathrm{w}}}{4\varphi m}}$
对炮弹进行受力分析, 近似地将火药燃烧膛压简化在炮弹底部, 得:
${F}_{\mathrm{d}}= {p}_{\mathrm{d}}\pi {r}^{2}$
式中${F}_{\mathrm{d}}$为炮弹底部受力;$r$为炮弹半径。
根据牛顿第二定律, 得:
$ a =\frac{\mathrm{d}v}{\mathrm{\;d}t}= \frac{{p}_{\mathrm{d}}\pi {r}^{2}}{m}$
弹体在加速度的作用下, 其截面上受到轴向加速度,任意截面$n - n$上的受力为${F}_{n}$
${F}_{n}= {p\pi }{r}^{2}\frac{{m}_{n}}{m}$
式中${m}_{n}$为断面$n - n$以上弹体部分的质量。
各截面上的质量不等,因此所受到的惯性力也不同,其中截面离弹丸底部越近,${F}_{n}$随着${m}_{n}$的增大而加大, 但是炮弹发射时各断面的高过载加速度是相同的。
由式(5)可得炮弹在膛内发射时任一截面的平均高过载加速度为
$ a =\frac{{P}_{\mathrm{d}}\pi {r}^{2}}{m}$
式中${P}_{\mathrm{d}}$为发射时内弹道的计算膛压;$r$为火炮的口径。
弹载电机固定安装于炮弹内部, 将炮弹与电机视为一体。由式(7)即可计算炮弹发射时所受的高过载加速度, 再根据文献[15]基于高阶黎曼近似解的膛内多相燃烧过程的研究, 得到弹载电机在膛内弹道的高过载瞬时加速度曲线, 如图2所示, 幅值达到${23000}\mathrm{\;g}$左右。
传统无刷直流电机轴系结构由转轴、磁钢、前后端轴承及调整垫圈组成, 传统无刷直流电机没有进行高过载环境下缓冲减振结构设计, 当炮弹承受膛内火药燃烧产生的瞬时高温高压能量时, 电机转轴会产生量级极大的瞬时冲击力作用在电机端盖轴承, 导致轴承内圈产生塑性变形甚至碎裂。转轴也会发生轴向位移和塑性变形, 影响与端盖之间的接触, 使得电机轴向预压力减小甚至消失, 增大电机的轴向间隙, 导致电机工作性能降低, 甚至出现完全损坏、无法正常工作的现象。因此, 传统无刷直流电机结构无法承受23 000g加速度冲击,需要针对转轴与轴承设计缓冲减振结构,进行抗过载保护,保障电机的正常运转。
针对前节传统无刷直流电机在承受${23000}\mathrm{\;g}$瞬时高过载时电机轴承与转轴损坏的情况, 首先开展了钢球+弹簧复合结构研究,如图3所示。
该结构承受高过载的设计机理: 在高过载力作用下, 转子向后端移动的过程中, 轴承只受到弹簧变形产生的压力, 当钢珠与后端盖接触时, 由钢珠来承受高过载力,轴承不受高过载力的影响。
根据该结构研制抗高过载无刷直流电机, 型号为J22ZWXG0215,在某兵器试验场地进行了火炮地面过载试验。试验后对工装结构外观进行检查, 安装连接处无损坏变形, 各部件的安装紧固件无断裂和松动现象。
进行运转测试发现电机出现异常: 轴向间隙为${0.7}\mathrm{\;{mm}}$、空载转速升高、空载电流降低、声音异常。 将异常电机进行拆解, 发现后端盖上轴承挡圈和钢珠轴档处粘合在一起, 轴承挡圈剪切出毛刺环, 轴承声音异常有损坏现象,见图4。其余定子和转子零组件均正常。
复查产品设计图纸, 轴承挡圈在极限状态下会出现较紧的配合。故障电机该处的配合紧,在高过载力作用下, 轴承挡圈不能压缩弹簧移动, 上述情况造成抗高过载结构能力减弱, 此时后端轴承先受力, 造成轴承、轴承挡圈和后端盖直接接触来抵抗高过载力, 将轴承损坏, 轴承挡圈在后移的过程中与钢珠轴档处粘合, 并将轴承挡圈剪切出一个毛刺环, 未起到钢珠和后端盖接触来抵抗高过载力的作用。
旋转前后轴承外圈均有卡滞现象, 证明轴承有不同程度的损坏, 这也是电机运转时声音异常的原因。
采用弹簧+钢球的减载结构电机在高过载后由于轴承挡圈和钢珠轴档之间粘合, 弹簧不能移动, 轴承受力损坏。
该结构无法满足23000$g$高过载环境抗载需求, 电机部件无法正常完成后续制导工作。因此, 需要对该抗载结构进行改进, 进一步优化设计。
优化设计组合碟簧与钢球组合的复合减振缓冲结构, 该结构包括主辅两级缓冲。第1级是由前后端轴承处加装的对合碟形弹簧组成的主缓冲结构;第2级缓冲是辅助缓冲结构, 将特制钢球置于转轴和端盖之间的球形凹槽中,起到吸能减振作用。
设计如图5所示采用复合缓冲减振结构的抗高过载无刷直流电机。电机主体部件由定子、转子、机壳及其附件组成, 附件包括碟形弹簧、轴承、特制钢球以及端盖等,表1为主要零部件材料参数。
从能量吸收角度考虑, 碟簧吸收了转轴在发射过程中向轴承传递的能量, 降低了轴承吸收的能量。特制钢球产生应变, 吸收一部分转轴的能量, 进一步减少轴承承受的冲击。设转轴在炮弹发射过程中产生的瞬时冲击能量为${Q}_{\mathrm{w}}$,向轴承传递能量为${Q}_{\mathrm{z}}$,碟簧吸收的能量为${Q}_{\mathrm{d}}$,钢球吸收的能量为${Q}_{\mathrm{q}}$,则:
${Q}_{\mathrm{w}}= {Q}_{\mathrm{d}}+ {Q}_{\mathrm{q}}+ {Q}_{\mathrm{z}}$
根据缓冲吸能原理,特制钢球吸能表达式为
${Q}_{\mathrm{q}}= {\int }_{0}^{{\varepsilon }_{\mathrm{m}}}\sigma \mathrm{d}\varepsilon $
式中${\varepsilon }_{\mathrm{m}}$为任意应变;$\sigma$为对应的应力。
单片碟簧变形能为
$ Q =\frac{2E}{1 -{\mu }^{2}}\cdot \frac{{t}^{5}}{{K}_{1}{D}^{2}}\cdot {K}_{4}^{2}{\left(\frac{f}{t}\right)}^{2}\left({{K}_{4}^{2}{\left(\frac{{h}_{0}}{t}- \frac{f}{2t}\right)}^{2}+ 1}\right)$
式中$E$为弹性模量;$\mu$为泊松比;$f$为单片碟簧的变形量;${h}_{0}$为无支承面碟簧压平时变形量的计算值;${K}_{1}$,${K}_{4}$为计算系数。
则组合碟簧的变形能表示为
${Q}_{\mathrm{d}}= i \cdot n \cdot Q $
式中$i$为组合碟簧中碟簧组数;$n$为组合碟簧中对合碟簧片数。
由此可知, 转轴与轴承所受的冲击过载经过组合碟簧与特质钢球的吸能得到缓冲释放。加速度冲击力经碟簧与钢球得到缓冲后会产生约${2000}\mathrm{\;g}$大小的反向冲击力, 前端轴承处的碟簧发生弹性形变对此冲击加速度进行缓冲。
为验证所提出复合缓冲减载结构的有效性, 在Ansys Workbench中采用瞬态结构模块(Transient Structural)对电机进行瞬态动力冲击仿真研究。在仿真分析中, 为便于计算分析, 对弹载电机模型进行简化:
a)忽略电机自身重力影响;
b)炮弹发射时,火药燃烧膛压作用在炮弹底部;
c)忽略各零部件的倒角、圆角等影响。
表1中的零部件材料参数在Workbench中分别赋给无刷直流电机的各零部件。为了保证计算精度, 网格划分中钢球、螺栓及滚动体以补丁适形法设为${0.3}\mathrm{\;{mm}}$的四面体单元,其余零件设为${0.5}\mathrm{\;{mm}}$的六面体单元。该模型共生成514040个节点、 261023个单元, 网格划分如图6所示。电机转轴与前后端轴承过盈配合, 设置为摩擦接触, 摩擦系数设置为0.5 。另外电机转轴与碟簧、特制钢球, 轴承与碟簧、端盖、机壳等之间均设为摩擦接触, 端盖与机壳、螺栓设为绑定接触, 能够模拟真实情况下各零部件之间的接触状态。
针对所设计的抗高过载电机, 分别对仅采取碟簧的减载结构与采取复合缓冲的减载结构施加如图2所示的冲击过载加速度。
图7图8为弹载无刷直流电机在承受${23000}\mathrm{g}$冲击过载加速度时两种结构所产生的最大轴向位移变形与承受的最大应力云图。如图7a所示,仅采取碟簧缓冲的结构在冲击作用下最大轴向位移达到${0.51}\mathrm{\;{mm}}$, 而采取特制钢球与碟簧复合缓冲结构时, 最大轴向位移如图7b所示仅约${0.39}\mathrm{\;{mm}}$,轴向位移减小了${20}\%$。 仅采取碟簧缓冲时最大等效应力位于后端碟簧处, 如图8a,达到约${1390}\mathrm{{MPa}}$,超过了碟簧材料的屈服应力强度, 而采取复合缓冲结构的最大等效应力从约${1390}\mathrm{{MPa}}$降到了约${1249}\mathrm{{MPa}}$,低于材料的屈服应力强度。
可见, 放置于转轴和端盖之间的特制钢球起到了辅助缓冲作用, 冲击力经转轴后端传递至特制钢球, 再经钢球传递给端盖。如图9所示, 特制钢球在冲击作用下最大等效应力为${346.07}\mathrm{{MPa}}$,超过了结构钢的屈服强度,产生了约${0.092}\mathrm{\;{mm}}$的塑性形变。球体与端盖起到吸能缓冲作用, 进一步减小了冲击力, 进而提高整个电机抗高过载能力,保证电机的正常运转。
图10为弹载无刷直流电机在承受${23000}\mathrm{\;g}$加速度冲击过载时不同时刻的等效应力云图, 能够直观反映电机在受载过程中应力波的传递与电机结构的响应过程。由图10可知, 电机承受轴向冲击过载时, 转轴产生的冲击力一部分经轴承的内圈和外圈传递至组合碟簧, 另一部分经特制钢球传递至端盖, 组合碟簧与钢球产生形变。在$t = 4\mathrm{{ms}}$时刻电机后端组合碟簧应力达到最大值, 继而等效应力值随时间减小, 冲击能量得到缓冲。
根据图11a位移时间曲线可知,转轴与轴承在承受轴向冲击过载时发生轴向位移, 组合碟簧产生弹性压缩,在约$4\mathrm{\;{ms}}$时达到峰值,转轴最大轴向位移达到${0.39}\mathrm{\;{mm}}$。之后组合碟簧轴向压缩量有一定恢复,最终组合碟簧最大位移量约为${0.06}\mathrm{\;{mm}}$,转轴与轴承无永久变形。
图11b图12a可知,转轴最大应力位于尾端处,为353.43 MPa,小于$2\mathrm{{Cr}}{13}$屈服强度。由图11b图12b可知, 前后端轴承最大等效应力位于滚动体处,峰值达到${472.57}\mathrm{{MPa}}$,也小于轴承钢的屈服强度。综上可知所设计的复合缓冲减载结构能有效存储与消耗瞬时加速度的冲击能量, 减小并延缓结构受到的冲击, 对弹载无刷直流电机的转轴与轴承起到保护作用。
${23000}\mathrm{\;g}$瞬时加速度下转轴产生的冲击力传递至轴承经碟簧和钢球缓冲吸能, 得到释放, 有效保护了轴承与转轴。但是碟簧与端盖的反振产生2000g左右的反向冲击力, 可能造成端盖与机壳的螺栓连接因受剪切失效, 加装与前段轴承处的对合碟簧对此反向冲击力同样起到吸能缓冲作用。针对此螺栓可能存在的失效情况, 进行瞬态结构分析, 设置载荷条件为大小2 000g、时间为$1\mathrm{\;{ms}}$的加速度冲击。
图13a所示,在承受反向冲击力时,前端碟簧产生最大${0.178}\mathrm{\;{mm}}$的轴向压缩变形,对冲击能量进行吸能缓冲。反向冲击力经碟簧变形吸收大部分能量后, 剩余能量对机壳进行冲击。机壳与端盖通过螺栓连接,冲击能量对螺栓形成剪切作用。由图13b可知,螺栓承受最大剪切应力为${15.67}\mathrm{{MPa}}$,远小于螺栓材料结构钢的屈服强度, 不会损坏螺栓连接。
采用马歇特锤击试验平台进行弹载电机抗高冲击过载能力评估。马歇特锤击试验加速度最高能够达到50 000g量级,脉宽则可至几十微秒[16]。根据所设计结构研制抗高过载无刷直流电机并进行试验验证, 如图14所示, 将试验电机绑在击锤上撞击铁砧平台, 在撞击瞬间产生极大冲击过载, 以此模拟瞬时超高加速度环境, 获取电机关键部件及整机变形状态, 验证电机的减载缓冲试验效果及耐受特性[17]
图15所示的电机运转性能测试平台上进行测试。运转测试结果如表2所示, 对比马歇特锤击试验前后运转性能数据, 抗高过载电机基本参数无明显变化,电机轴向间隙增大${0.03}\mathrm{\;{mm}}$。抗高过载试验后电机输出特性表现良好, 可见冲击过载对电机性能影响较小。本文所设计的抗高过载电机经高过载冲击后仍满足智能炮弹对弹载电机控制的要求。
抗高过载无刷直流电机在锤击试验与实弹靶试后电机形貌如图16所示, 各零部件并未出现显著变形或裂纹, 转轴端面出现细微划痕, 试验表明研制的抗高过载无刷直流电机可以满足弹用高过载条件要求。
针对弹载电机在23000g高过载应用场景下电机转轴与轴承易损问题, 设计了一种碟簧与特制钢球组合的复合缓冲减载结构,基于该结构设计了一种抗高过载电机。经仿真分析及测试试验验证, 本文所提出的复合缓冲结构能够满足弹载电机的抗高过载要求, 电机输出性能能够保证制导炮弹正常工作。
  • 贵州省科技计划项目(黔科合支撑[2021]一般280)
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2025年第48卷第2期
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doi: 10.7654/j.issn.2097-1974.20250210
  • 接收时间:2024-02-04
  • 首发时间:2025-07-21
  • 出版时间:2025-04-25
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  • 收稿日期:2024-02-04
  • 修回日期:2024-05-15
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贵州省科技计划项目(黔科合支撑[2021]一般280)
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    1贵州大学机械工程学院,贵阳,550025
    2贵州凯敏博机电科技有限公司,贵阳,550025
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2种不同金属材料的力学参数

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属数
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genus
种数
Number of
species
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Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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