本文關(guān)鍵詞：水電工程重型纜機(jī)架空索道系統(tǒng)動(dòng)力學(xué)及可靠性研究　出處：《武漢大學(xué)》2013年博士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： 纜機(jī) 承馬 有限元 動(dòng)力學(xué) 優(yōu)化 疲勞壽命

【摘要】：纜索起重機(jī)(以下簡稱纜機(jī))是以懸掛于兩支點(diǎn)之間的鋼索作為承載結(jié)構(gòu),利用載重小車在其上往返移動(dòng)進(jìn)行物料吊運(yùn),兼有垂直運(yùn)輸(通過起升機(jī)構(gòu)的起重繩實(shí)現(xiàn))和水平運(yùn)輸功能的特種起重運(yùn)輸機(jī)械。纜機(jī)主要由塔架、架空承載部分、工作驅(qū)動(dòng)機(jī)構(gòu)、機(jī)電控制設(shè)備及安全保護(hù)裝置等組成,其中架空部分主要由承載索、起重繩、牽引繩、承馬及載重小車等部件組成。纜機(jī)在水利電力建設(shè)工程、橋梁建筑、碼頭施工、森林工業(yè)、采礦工業(yè)、堆料場裝卸以及港口裝卸等方面都有廣泛的用途。 我國在三峽大壩施工中,首次引進(jìn)德國克虜伯所設(shè)計(jì)制造的纜機(jī),并開始對國外先進(jìn)纜機(jī)設(shè)計(jì)與制造技術(shù)進(jìn)行引進(jìn)、消化和吸收。目前我國在纜機(jī)設(shè)計(jì)、制造和使用過程中,塔架、驅(qū)動(dòng)及控制系統(tǒng)等方面的設(shè)計(jì)和制造技術(shù)都較為成熟,使用過程也很少出現(xiàn)故障。但是,在對纜機(jī)中關(guān)鍵部件——架空系統(tǒng)的研究方面與國外類似產(chǎn)品相比仍有差距,反映在對于架空部件的優(yōu)化設(shè)計(jì)、產(chǎn)品精細(xì)化程度不夠,可靠性不高,缺乏基礎(chǔ)性研究的支持。 通過查閱文獻(xiàn)獲知,大量纜機(jī)方面的文獻(xiàn)僅僅涉及纜機(jī)的維護(hù)、保養(yǎng)、運(yùn)行等方面的內(nèi)容。在研究中有兩個(gè)明顯的不足：其一是對于重型纜機(jī)索道系統(tǒng)的動(dòng)力學(xué)特性研究不夠；其二是沒有運(yùn)用現(xiàn)代設(shè)計(jì)分析方法與手段對纜機(jī)架空索道系統(tǒng)設(shè)計(jì)中的關(guān)鍵問題進(jìn)行研究。由于纜機(jī)架空部分的承載索、起重繩、牽引繩及承馬等部件之間存在強(qiáng)耦合關(guān)系,保證纜機(jī)架空部分的平穩(wěn)運(yùn)行成為纜機(jī)設(shè)計(jì)的關(guān)鍵。隨著我國對纜機(jī)速度及載荷量要求的不斷提高,迫切需要應(yīng)用動(dòng)力學(xué)和現(xiàn)代設(shè)計(jì)分析方法與手段,對纜機(jī)架空部分部件的運(yùn)動(dòng)機(jī)理進(jìn)行深入的研究,以提高纜機(jī)運(yùn)行的平穩(wěn)性和使用可靠性。 論文以現(xiàn)代設(shè)計(jì)理論為指導(dǎo),對重型纜機(jī)中的架空系統(tǒng)的動(dòng)力學(xué)特性以及設(shè)計(jì)中的關(guān)鍵問題進(jìn)行了系統(tǒng)的研究,主要研究內(nèi)容和研究成果歸納如下： 1.系統(tǒng)地研究了重型纜機(jī)承載索的動(dòng)力學(xué)建模方法。針對纜機(jī)架空部分中起升系統(tǒng)與承載索之間存在的強(qiáng)耦合作用及纜機(jī)的結(jié)構(gòu)特點(diǎn),把纜機(jī)架空系統(tǒng)合理的抽象成懸掛于兩等高固定端的均質(zhì)彈性連續(xù)體和具有一定質(zhì)量—?jiǎng)偠取枘岬囊苿?dòng)振子的物理模型。然后應(yīng)用漢密爾頓(Hamilton)原理列寫了該系統(tǒng)的運(yùn)動(dòng)方程,通過力和位移協(xié)調(diào)推導(dǎo)出了一組控制索—振子運(yùn)動(dòng)的偏微分方程組,在方程中考慮了科氏(Coriolis)慣性力以及纜索的非線性彈性恢復(fù)力。由于該微分方程組不存在封閉的解析解,因而運(yùn)用伽遼金法(Galerkin)方法,把偏微分方程組轉(zhuǎn)化成了常微分方程組以便利于數(shù)值積分求解。 2.針對控制索-振子運(yùn)動(dòng)的微分方程,對數(shù)值積分和動(dòng)力學(xué)仿真的方法分別進(jìn)行了研究。首先研究了形函數(shù)的階數(shù)對收斂性的影響,根據(jù)重型纜機(jī)架空部分的結(jié)構(gòu)形式,并考慮跨度、垂度以及載重量等因素,選擇正弦函數(shù)作為形函數(shù)并編制了MATLAB程序。應(yīng)用該程序,在纜機(jī)的勻速、緊急加(減)速、加載以及減載等典型工況下,對懸索的動(dòng)力學(xué)特性進(jìn)行了研究。為了對動(dòng)力學(xué)分析結(jié)果進(jìn)行驗(yàn)證,在動(dòng)力學(xué)仿真軟件ADAMS平臺上建立了纜機(jī)承載索的動(dòng)力學(xué)模型并進(jìn)行了仿真,仿真結(jié)果與數(shù)值積分的求解結(jié)果基本一致。研究結(jié)果表明：小車的運(yùn)動(dòng)速度、吊重等對懸索的動(dòng)力學(xué)特性有比較明顯的影響,而其中對纜機(jī)運(yùn)行平穩(wěn)性影響最大的是載重小車的運(yùn)行速度。對于目前使用最多的30t級纜機(jī)及其相應(yīng)的架空結(jié)構(gòu),小車的最大勻速不宜超過7.5m/s,否則會(huì)導(dǎo)致纜索的急劇跳動(dòng),對纜機(jī)的平穩(wěn)運(yùn)行十分不利。結(jié)論解釋了為何纜機(jī)載重小車的工作速度存在速度限制閩值。 3.運(yùn)用三維建模軟件和機(jī)械系統(tǒng)動(dòng)力學(xué)分析軟件,對架空系統(tǒng)中的重要部件——承馬的結(jié)構(gòu)進(jìn)行了優(yōu)化設(shè)計(jì)研究。論文結(jié)合承馬的結(jié)構(gòu)特征和設(shè)計(jì)流程,具體研究了承馬的三維設(shè)計(jì)方法,并用實(shí)例進(jìn)行了驗(yàn)證；在ADAMS平臺上對承馬進(jìn)行了動(dòng)力學(xué)仿真,通過參數(shù)優(yōu)化設(shè)計(jì),確定了保證承馬托輪臂得到合理張開角度時(shí)托輪臂鉸點(diǎn)的最優(yōu)位置,在此基礎(chǔ)上通過對承馬關(guān)閉彈簧的剛度和阻尼參數(shù)的優(yōu)化,可整體提高承馬啟閉過程的平穩(wěn)性和可靠性,并提高承馬啟閉響應(yīng)的靈敏度。 4.通過對纜機(jī)不同工況和載荷下的運(yùn)行狀況分析,求解狀態(tài)方程確定了纜機(jī)工作時(shí)各個(gè)承馬中從空中脫落風(fēng)險(xiǎn)最大的承馬。以該承馬的載荷和受力特性為基礎(chǔ),選擇空載、輕載以及滿載等典型工況對纜機(jī)運(yùn)行過程中承馬的受力狀況進(jìn)行有限元結(jié)構(gòu)分析,確定了承馬結(jié)構(gòu)中最為薄弱的部分。研究方法和結(jié)果可直接應(yīng)用于承馬的設(shè)計(jì)工作,對承馬結(jié)構(gòu)輕型化、提高承馬工作的可靠性具有一定參考價(jià)值。 5.對于纜機(jī)承載索的疲勞問題進(jìn)行了理論研究。通過單根鋼絲及整條纜索的受力分析,證明纜機(jī)承載索的疲勞與懸索橋等其他懸索結(jié)構(gòu)中索的疲勞有所不同,懸索橋等其他懸索結(jié)構(gòu)中索的疲勞屬于軸向疲勞問題,而纜機(jī)承載索的疲勞屬于彎曲疲勞問題,并從理論上論證了纜機(jī)承載索的疲勞發(fā)生在承載索的表面而非靠近索中性面的原因。通過對承載索進(jìn)行有限元分析,計(jì)算出載重小車運(yùn)行過程中承載索交變應(yīng)力的幅值,并結(jié)合經(jīng)典的應(yīng)力-壽命S—N曲線,對纜機(jī)承載索的疲勞壽命的主要影響因素進(jìn)行了研究,證明了承載索的疲勞壽命與纜機(jī)載重小車的循環(huán)次數(shù)、吊運(yùn)重量及承載索直徑等參數(shù)的關(guān)聯(lián)度。通過工程實(shí)例的驗(yàn)算,計(jì)算出某30t級纜機(jī)在吊運(yùn)300kN載荷時(shí)承載索的壽命僅僅略高于30萬個(gè)工作循環(huán),從理論上論證了承載索的國外供貨方不愿對承載索的壽命做出高于30萬個(gè)工作循環(huán)承諾的原因,對目前承載索安全系數(shù)的選擇是一個(gè)很好的補(bǔ)充,并可提高纜機(jī)的使用安全性。 論文對工程對象進(jìn)行分析與綜合,原始參數(shù)來源于工程案例,研究成果均有相應(yīng)的工程實(shí)例驗(yàn)證,對纜機(jī)設(shè)計(jì)具有指導(dǎo)意義。
[Abstract]:Cable crane (hereinafter referred to as the winch) is suspended from the two pivot between the cable as the bearing structure, the trolley on the move for material lifting, both vertical transportation (by hoisting rope ascending mechanism) and transport function of special hoisting and conveying machinery. The cable machine is mainly composed of the tower overhead, bearing parts, work driving mechanism composed of electrical control equipment and safety protection device, which is mainly composed of overhead cable, lifting rope, rope, the horse and trolley and other components. The cable machine in water conservancy and electric power construction engineering, bridge construction, pier construction, forest industry, mining industry. Yard handling and port loading and unloading and other aspects of a wide range of uses.
Our country in the Three Gorges dam construction, first introduced the German Krupp designed cable machine manufacturing, and began to design and manufacture of foreign advanced technology of cable machine introduction, digestion and absorption. At present in the design of cable crane, tower manufacturing and using process, design and manufacturing technology, drive and control system etc. are more mature, the use of the process but also rarely fails. However, in the research on the key components of the overhead system of the cable machine in hand compared with foreign similar products is still reflected in the optimization design for aerial parts, product refinement degree is not enough, the reliability is not high, the lack of basic research support.
Through the literature that maintain a large number of literature on cable machine involves only cable machine maintenance, operation and other aspects. There are two obvious shortcomings in the study: one is for the study of dynamic characteristics of cable system of heavy cable machine is not enough; the other is not the use of modern design methods and means of analysis the key problems of the design of cable crane ropeway system. Because the bearing part of the overhead cable of cable crane, hoisting rope, there is a strong coupling relationship between traction rope and horse bearing parts, ensure the smooth operation of the cable machine becomes the key part of overhead cable machine design. With China's increasing demand on cable machine speed and the load, the urgent need to analyze the methods and means of application of dynamics and modern design, the movement mechanism of overhead cable machine parts in-depth study, in order to improve the stability and the use of cable machine running reliability. .
Under the guidance of modern design theory, the dynamic characteristics and key problems in design of heavy duty cable cranes are systematically studied. The main research contents and research results are summarized as follows:
1. we studied the dynamic modeling method of the load bearing cable of cable machine. For heavy lift system and bearing structure characteristics of strong coupling between the cable and cable machine overhead cable machine part, the homogeneous elastic continuum of overhead cable machine system is abstracted into reasonable hanging on the two high and has a fixed end the quality and stiffness of mobile vibrator damping physical model. Then the application of Hamilton principle (Hamilton) introduced the equation of motion of the system, through the force and displacement coordination derived partial differential equations of a set of control cable vibration, the equation considering the Coriolis inertia (Coriolis) the cable force and the nonlinear elastic restoring force. Because of the differential equations are not closed analytical solution, so the use of Galerkin method (Galerkin) method, the partial differential equations into ordinary differential equations for numerical integral Solve.
The differential equation for the vibration control of cable - 2., method of numerical integration and dynamic simulation are studied. First the influence of order shape function on convergence, according to the structure of heavy overhead cable machine part, and considering the factors of span, sag and load, select the sine function as the shape function and MATLAB program. The program is used in the cable machine speed, emergency plus (minus) speed, loading and unloading etc. under typical conditions, dynamic characteristics of the suspension are studied. In order to verify the results of dynamic analysis, the dynamic simulation software is developed on ADAMS cable machine bearing the dynamic model of cable and simulation, simulation results and numerical results are consistent. The results show that: the movement speed of the car, there is obvious influence of crane dynamic characteristics of suspension. , which effect on the running stability of the cable machine is the largest speed trolley. For the overhead structure currently used 30t cable machine up and the corresponding maximum speed, not the car more than 7.5m/s, otherwise it will lead to the rapid beating of the cable, smooth operation of the cable machine explains why is very unfavorable. Winch trolley work speed speed limit threshold.
3. using 3D modeling software and dynamic analysis software of mechanical system, the structure of the important components of overhead system -- the carrier is optimized. According to the structure characteristics and design process for the horse, specific research 3D design method of the horse, and verified on ADAMS platform is made; dynamic simulation of the carrier, through the parameter optimization design, ensured the optimal location of roller arm joint bearing wheel arm reasonable opening angle mahto when, on the basis of the optimization of the horse off the spring stiffness and damping parameters, thereby improving the stability and reliability of the process of opening and closing the horse. Ma Kai sensitivity and improve the bearing close response.
4. by analyzing the operation conditions of the cable machine in different conditions and under load, to solve the state equations to determine the work of each bearing cable machine horse from the air off the biggest risk for the horse. The horse to load bearing and force characteristics as the basis, select the load, light load and full load and other typical conditions on stress condition during the operation of the cable machine horse of finite element analysis, the weak part of the horse bearing structure. The research methods and results can be directly applied to the design work of the horse, the horse bearing light structure, which has a certain reference value to improve the reliability of the horse work.
5. for cable machine bearing fatigue problem of cable are studied. The stress of single wire and the whole cable of cable machine bearing fatigue proof cable fatigue and suspension bridge and other cable structures are different, the axial fatigue problem of cable fatigue belongs to the suspension bridge and other suspension structure, and cable machine bearing cable fatigue belongs to bending fatigue problems, and demonstrates the winch cable bearing fatigue occurred on the surface of bearing cable and non cable near the neutral plane reasons theoretically. Through the finite element analysis of bearing cable, calculate the trolley running process of bearing cable alternating stress amplitude, combined with the classic the stress - life of S - N curve, the main factors of the cable machine bearing fatigue life of cable are studied, proved that the cycles of fatigue life and carrying trolley cable machine cable, lifting weight bearing and straight cable Correlation of size parameters. Through the calculation of an engineering example, calculate a 30t cable crane in lifting 300kN load carrying rope life is only slightly higher than 300 thousand cycles, theoretically bearing cable overseas supplier to make higher than 300 thousand working cycle commitment to carrying cable life. Is a good complement to the current carrying cable safety factor selection, and can improve the safety of the cable machine.
In this paper, engineering objects are analyzed and synthesized. The original parameters are derived from engineering cases. The research results are verified by corresponding engineering examples, which is of guiding significance for design of cable cranes.

【學(xué)位授予單位】：武漢大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2013
【分類號】：TH213

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