本文關鍵詞： 在役流動式起重機 臂架結構 潛在失效模式 風險評估 疲勞剩余壽命評估 可修復性評估與決策　出處：《太原科技大學》2017年博士論文　論文類型：學位論文

【摘要】：流動式起重機作為現(xiàn)代物料搬運的特種設備,廣泛應用于建筑、冶金、造船、電力、石化、能源等領域。臂架結構作為流動式起重機的主要承載結構件,其結構復雜、服役條件苛刻且易損傷失效,是工程機械中附加值較高、量大面廣的共性關鍵部件。如何有效可靠地評價在役流動式起重機臂架結構的現(xiàn)役性能、安全狀態(tài)、剩余壽命,以確保臂架結構修復的最佳準入期,延長其使用壽命,使其材料利用率最大化,實現(xiàn)節(jié)能減排的效果是制造企業(yè)、用戶、特種設備監(jiān)管部門共同關心的問題。迄今為止,在役流動式起重機臂架結構風險評估、壽命評估和可修復性評估與決策尚無相關方法和標準可依。對于如何判定延用、修復、更換、報廢缺乏方法和標準的支撐。針對上述問題,本文主要開展了如下研究工作:1)為有效預測在役流動式起重機臂架結構的潛在失效模式,構建基于實例推理的臂架結構潛在失效模式預測模型。通過調研、收集流動式起重機臂架結構有限失效模式歷史信息,建立流動式起重機臂架結構失效模式模糊數(shù)據(jù)庫,在機型匹配的條件下,構建與待評估起重機同機型、不同典型使用工況的失效模式實例庫,結合實例推理技術,預測待評估起重機臂架結構的潛在失效模式,利用流動式起重機臂架結構參數(shù)化有限元模型和仿真計算平臺,修正潛在失效模式,為后續(xù)風險評估、疲勞剩余壽命評估提供基礎性信息及數(shù)據(jù)。2)針對多重耦合失效模式下在役流動式起重機臂架結構安全性問題,提出基于潛在失效模式的臂架結構風險評估方法。以在役流動式起重機臂架結構潛在失效模式為基礎,采用改進DEMATEL法,建立臂架結構危險點及其各級評價指標間的直接、間接影響模糊關系矩陣,推導各級指標的影響度矩陣與被影響度矩陣,得到各級評價指標的中心度和原因度,分析評價指標間的關聯(lián)性與影響性,根據(jù)關聯(lián)度與影響度分配權重,結合模糊綜合評價理論,量化臂架結構的失效風險,實現(xiàn)多重耦合失效模式下在役流動式起重機臂架結構的風險評估。3)針對流動式起重機工作載荷在時空上間歇、循環(huán)的隨機性,導致實測載荷的隨機性以及試驗條件的局限性,使得大規(guī)模載荷譜試驗難以實施的問題,提出基于數(shù)理統(tǒng)計技術的隨機載荷譜獲取方法和基于人工智能預測技術的當量載荷譜預測方法。通過采集、統(tǒng)計、記錄特定時段內(nèi)不同特征參數(shù)下起重機的工作循環(huán)次數(shù)簇,形成小樣本的實測載荷譜,利用數(shù)理統(tǒng)計技術(按常用的6種概率分布模型對起重量樣本進行分布擬合,應用AIC信息準則對概率分布模型進行評價,給出起重量樣本的最佳概率分布模型)與拉丁超立方抽樣相結合或新型智能優(yōu)化算法的人工智能預測技術,獲取定檢周期內(nèi)的隨機或當量起重量樣本,根據(jù)流動式起重機額定起重量表、起升高度曲線和額定起重力矩表,確定對應起重量的臂架工作長度、工作幅度,刻畫符合工程實際的隨機特征參數(shù)和與之一一對應的工作循環(huán)次數(shù),得到定檢周期內(nèi)的隨機載荷譜或當量載荷譜,為疲勞剩余壽命評估提供基礎性數(shù)據(jù)。4)針對在役流動式起重機服役過程面臨多失效模式耦合,導致其臂架結構安全性難以確定的問題,提出基于工作循環(huán)載荷動力效應及多失效模式耦合的流動式起重機臂架結構疲勞剩余壽命評估方法。以獲取的隨機或當量載荷譜為基礎,根據(jù)流動式起重機工作循環(huán)過程,建立考慮工作循環(huán)載荷動力效應的臂架結構危險點處第一主應力-時間歷程理論仿真模型,模擬再現(xiàn)檢測周期內(nèi)流動式起重機工作循環(huán)過程中臂架結構危險點處第一主應力的時間歷程,利用雨流計數(shù)法,提取對應危險點的雙參應力譜,結合損傷容限設計及斷裂力學理論,構建基于隨機或當量載荷譜的疲勞剩余壽命評估模型,估算單一及耦合失效模式下臂架結構對應危險點處的疲勞剩余壽命,為損傷臂架結構可修復性評估與決策提供門檻條件。5)針對在役流動式起重機損傷臂架結構的延用/修復/更換/報廢問題,從結構現(xiàn)役性能可利用性、修復技術可行性、經(jīng)濟可行性、環(huán)境資源可行性的維度,建立損傷臂架結構可修復性綜合評估與決策模型。對于具有疲勞剩余壽命(修復準入期)的各損傷臂節(jié)截面拉應力區(qū)域(壓應力區(qū)域)的危險點,分析其檢測周期節(jié)點處的可靠性(危險點的強度冗余性),聯(lián)合可靠性閾值(最小強度冗余因子),確定危險點處現(xiàn)役性能的可利用性,根據(jù)修復工藝過程,量化技術可行性評價指標,評價修復技術的可行性,以企業(yè)特定時段內(nèi)流動式起重機損傷臂架結構的修復總費用為基礎,采用作業(yè)成本法,追溯不同失效特征對應損傷臂節(jié)的修復成本,形成修復成本數(shù)據(jù)庫,利用改進相關向量機,預測與待評估流動式起重機各損傷臂節(jié)失效特征對應的修復成本,結合購置新品臂架結構所需費用,評價損傷臂架結構修復的經(jīng)濟性,判斷臂架結構修復的環(huán)境資源效益,給出損傷臂架結構可修復性的綜合決策結果,為報廢及相關標準的制定提供重要的理論依據(jù)。6)為便于工程應用,基于VC++6.0/C#平臺,將以上理論和方法集成,開發(fā)“流動式起重機臂架結構風險與壽命評估及可修復性決策系統(tǒng)”,為在役流動式起重機臂架結構潛在失效模式預測、風險評估、載荷譜預測、疲勞剩余壽命估算、可修復性綜合評估與決策提供軟件技術支持。
[Abstract]:The mobile crane as a special equipment of modern material handling, widely used in building, metallurgy, shipbuilding, electric power, petrochemical, energy and other fields. The mobile crane jib structure as the main bearing structure, its structure is complex, harsh conditions and easy to damage and failure is high value-added service, engineering machinery, common key components a large amount of wide. How to effectively and reliably evaluate the performance in active service, the mobile crane jib structure of the safety state of residual life, to ensure the best access period of boom structure repair, prolong the service life, the material utilization is maximized, achieve the effect of energy saving and emission reduction is a manufacturing enterprise, the user. Common concern of special equipment supervision department. So far, the risk structure of existing mobile crane arm frame evaluation, life assessment and maintainability evaluation and decision method and standard. Shang Wuxiang closed on On how to determine the use, repair, replacement, scrap the lack of methods and standards support. To solve the above problems, this paper carried out research work as follows: 1) for predicting the potential in the service mode of mobile crane boom structure failure, construction of CBR arm structure prediction model based on potential failure mode. Through research. Collect the mobile crane jib structure finite failure mode of historical information, establish the mobile crane boom structure failure mode in fuzzy database, models, conditions, construction and evaluation for the same type of crane, the failure mode of different working conditions of the typical case base, combined with case-based reasoning technology to evaluate the potential prediction model of crane jib structure the failure of the mobile crane with jib structure parametric finite element model and simulation platform, correction of potential failure mode for the subsequent risk assessment, The remaining fatigue life provides the basic information and data.2 assessment) for multiple failure mode coupling in existing mobile crane boom structure security assessment method of jib structure risk potential failure mode is proposed. The existing mobile crane boom structure potential failure mode based on improved DEMATEL method, set up the arm frame structure and its risk evaluation at all levels between direct and indirect effects of the fuzzy relation matrix, affect the derived indicators at all levels of the matrix and influence matrix, at all levels of evaluation index centrality and causes analysis, relevance and impact evaluation index, according to the correlation degree and influencing degree of weight distribution, combined with the the theory of fuzzy comprehensive evaluation, the failure risk of the boom structure, realize the coupling multiple failure modes in the risk assessment of existing mobile crane boom structure for mobile.3) Crane work load in time and space, intermittent, random cycle, resulting in limitation of measured load randomness and test conditions, the test load spectrum is difficult to implement large-scale problems, put forward random load spectrum acquisition method of mathematical statistics and prediction method of equivalent load forecasting technology based on artificial intelligence. By collecting the spectrum, statistics, records within a particular time period of different characteristic parameters of crane operation cycles of clusters, forming small samples of measured load spectrum, using statistical techniques (according to 6 kinds of commonly used to sample weight distribution fitting, probability distribution model and application of AIC information criteria for evaluation of the probability distribution model gives the best probability distribution model the weight of the sample) and Latin hypercube sampling combined with artificial intelligence or intelligent optimization prediction technology, obtain periodic inspection in random Or the equivalent weight of the sample, according to the mobile crane rating table, lifting height curve and rated load moment, determine the corresponding arm working length, the weight of the working range, describe the stochastic parameters in accordance with engineering practice and corresponding work cycles, get the random load periodic inspection the spectrum or equivalent load spectrum, fatigue life assessment to provide the basic data for.4) in the service of mobile crane service faces many failure modes coupling, the safety of arm frame structure is difficult to determine, a job evaluation method based on cyclic loading dynamic effect and multiple failure modes coupled flow frame the structure of the crane arm fatigue residual life. In order to obtain the random or equivalent load spectrum as the basis, according to the process of the mobile crane work cycle, considering the dynamic effect of cyclic loading The jib structure of dangerous point of the first principal stress time history simulation model, simulation of flow detection cycle time history of jib structure of dangerous point process crane work cycle in the first principal stress, the rain flow counting method, the extraction of the dangerous point corresponding to two parameter stress spectrum with damage tolerance the design and the theory of fracture mechanics, evaluation model of random fatigue life or equivalent load spectrum based on the estimation of the remaining fatigue life of single and coupled failure risk of jib structure corresponding to mode, damage to the jib structure repair assessment and decision-making threshold condition.5) in battle of mobile crane arm injury frame use / repair / replace / scrap, from the existing performance availability, feasibility, repair technical and economic feasibility of environmental resources, the feasibility of the establishment of jib structure dimension, damage repair The complex of comprehensive evaluation and decision making model. With the remaining fatigue life (access repair period) the injury of brachial sections of tensile stress area (compressive stress) risk, reliability analysis of its detection nodes (strength redundancy of the dangerous point), combined with the reliability threshold (the minimum strength redundancy factor) sure, the dangerous point of service performance can be used, according to the repair process, the feasibility of quantitative evaluation index, feasibility evaluation of repair technology, with the enterprise specific time period flow repair total cost of crane jib structure damage based on the activity-based costing, repair cost tracing different failure characteristics corresponding to damage the boom the cost of repair, the formation of the database, using the improved relevance vector machine, prediction and assessment for the repair cost of mobile crane arm joint failure characteristics corresponding to different damage, combined with the purchase of new jib structure The expenses needed for the economic evaluation of damage repair of jib structure, environmental resources effectiveness judgment of jib structure repair, given the damage of jib structure may be the result of comprehensive remediation decisions, provide an important theoretical basis for the formulation of.6 for scrap and related standards) for the convenience of engineering application, based on the VC++6.0/C# platform, the above theory and method integrated assessment of mobile crane boom structure risk and life development "and repair decision system" for the risk assessment of existing mobile crane boom structure prediction, potential failure mode, load spectrum prediction, fatigue residual life estimation, maintainability comprehensive evaluation and decision making to provide software technical support.

【學位授予單位】：太原科技大學
【學位級別】：博士
【學位授予年份】：2017
【分類號】：TH21
，

本文編號：1449920