【摘要】：起重機(jī)械是隱藏危險因素最多,發(fā)生事故幾率最大,事故后果最嚴(yán)重的機(jī)電類特種設(shè)備之一。目前,我國起重機(jī)械數(shù)量年均增長約20%左右,各類起重機(jī)械保有量已超過250萬臺。與此同時,涉及起重機(jī)械的傷亡事故占各類傷亡事故的比例也逐年上升。目前我國各地區(qū)、各行業(yè)發(fā)生在起重作業(yè)中的傷亡事故約占全部傷亡事故的25%左右。每年涉及起重機(jī)械事故的死亡人數(shù)在所有機(jī)械類事故死亡人數(shù)中居首位。因此,加強(qiáng)起重機(jī)械的安全管理和事故預(yù)防刻不容緩。風(fēng)險評估是事故預(yù)防的前提和基礎(chǔ),目前針對起重機(jī)械的系統(tǒng)性安全評估方法欠缺,對于在役尤其是超期服役的起重設(shè)備而言,系統(tǒng)而實用的風(fēng)險評估方法研究具有較大的理論意義和工程實用價值。目前,行業(yè)內(nèi)采用法定定期檢驗制度來實現(xiàn)起重機(jī)械的安全運行和事故預(yù)防。該制度對于起重設(shè)備的安全運行,在一定程度上起到了基礎(chǔ)性保障作用。然而,由于檢驗項目和檢驗周期基本固定,不區(qū)分企業(yè)和設(shè)備個體的差異,容易造成對一般設(shè)備的過度檢驗和高風(fēng)險設(shè)備的檢驗不足；檢驗結(jié)果僅定性表示為“合格”與“不合格”,由于缺少零部件風(fēng)險的定量計算,其安全狀況的評估結(jié)果對起重機(jī)械事故預(yù)防的參考價值有限。論文圍繞起重機(jī)械風(fēng)險評估方法與預(yù)防性檢修策略及若干相關(guān)問題開展研究工作,完成了起重機(jī)械主要零部件的FMEA分析、失效數(shù)據(jù)與通用失效概率信息的收集、鋼絲繩小樣本可靠性試驗、起重機(jī)械的建模與仿真、零部件風(fēng)險的定性與定量評估計算、起重機(jī)械RCM預(yù)防性檢修策略的制定、起重機(jī)械風(fēng)險評估實施規(guī)范及評估軟件的編制等工作,論文具體研究內(nèi)容如下：(1)在完成380多例起重機(jī)事故故障統(tǒng)計分析的基礎(chǔ)上,建立了起重機(jī)械失效分析數(shù)據(jù)庫。進(jìn)行了失效模式與影響分析,得出了其全部失效模式,進(jìn)而分析了對應(yīng)的失效原因和失效后果。針對鋼絲繩的典型失效模式彎曲疲勞和磨損,開展了小樣本物理試驗,獲取了試驗條件下的失效數(shù)據(jù)。設(shè)計了起重機(jī)零部件失效樣本采集表,采用調(diào)查統(tǒng)計問卷和深入凌鋼、鞍鋼、三洋重工等起重機(jī)使用和制造企業(yè)實地調(diào)研等方式,獲得了部分起重機(jī)零部件的大樣本失效數(shù)據(jù),進(jìn)而完成了相應(yīng)的失效壽命計算。(2)鑒于起重機(jī)零部件的現(xiàn)場失效數(shù)據(jù)通常比較有限,提出了基于Bayes理論的起重機(jī)零部件小樣本可靠壽命預(yù)測方法。根據(jù)零部件研制階段的試驗數(shù)據(jù)和同類或相似部件的相關(guān)檢測記錄確定可靠性評估的驗前分布,結(jié)合小樣本現(xiàn)場可靠性試驗數(shù)據(jù),應(yīng)用Bayes理論融合零部件的驗前信息和現(xiàn)場試驗數(shù)據(jù),得到產(chǎn)品可靠壽命的驗后分布,進(jìn)而實現(xiàn)零部件失效壽命的預(yù)測。在缺少現(xiàn)場失效數(shù)據(jù)的情況下,該方法為起重機(jī)零部件失效壽命的獲取提供了新途徑。(3)利用有限元軟件的二次開發(fā)功能建立了起重機(jī)械虛擬仿真試驗平臺。實現(xiàn)了塔式起重機(jī)的參數(shù)化建模與虛擬工況載荷的施加,利用Ansys軟件自動獲取整機(jī)的強(qiáng)度、剛度和穩(wěn)定性分析結(jié)果,為起重機(jī)械受力結(jié)構(gòu)的安全評估提供了依據(jù)。(4)在完成FMEA分析和獲取主要零部件通用失效概率信息的基礎(chǔ)上,基于RBI技術(shù)建立了起重機(jī)械定性風(fēng)險評估模型,確定了起重機(jī)零部件的風(fēng)險等級排序�；趯哟畏治龇ê突疑C合評價法,建立了起重機(jī)零部件失效概率的修正計算模型,結(jié)合零部件失效后果的定量化經(jīng)濟(jì)性評估,提出了起重機(jī)零部件的定量風(fēng)險評估方法。最后,提出了應(yīng)用上述成果,在起重機(jī)械風(fēng)險評估中,對由定性風(fēng)險評估確定為高風(fēng)險零部件進(jìn)行定量風(fēng)險評估的實用性實施方法。(5)基于ACCESS數(shù)據(jù)庫,以VB軟件為開發(fā)工具編制了起重機(jī)械風(fēng)險評估系統(tǒng)軟件。該軟件能夠自動完成起重機(jī)零部件的定性和定量風(fēng)險評估,輸出WORD格式的評估報告,并給出相應(yīng)故障零部件的檢測部位、檢測方法和檢測周期建議。(6)開展了基于RCM技術(shù)的起重機(jī)械預(yù)防性檢修策略研究。綜合考慮零部件在維修間隔期內(nèi)的可靠性、經(jīng)濟(jì)性和可用度,給出了有限使用期不完全預(yù)防維修周期的計算方法。針對具有可測量潛在退化過程的零部件,考慮其故障的發(fā)生過程,提出了基于首次檢測和重復(fù)檢測的非定期視情檢修策略,基于經(jīng)濟(jì)性和可用度準(zhǔn)則分別給出了首次檢測和重復(fù)檢測的最佳檢測周期的計算方法。(7)綜合理論研究成果,制定了起重機(jī)械風(fēng)險評估實施規(guī)范。實施規(guī)范給出了層次分析法中各因子等級評定的實用量化評估準(zhǔn)則,制定了起重機(jī)零部件定性和定量風(fēng)險評估的標(biāo)準(zhǔn)化實施流程。最后,基于實施規(guī)范和評估軟件完成了近20例典型起重機(jī)的風(fēng)險評估工程應(yīng)用。
[Abstract]:The lifting machinery is one of the special mechanical and electrical equipment which have the greatest hidden danger factors, the biggest accident probability and the most serious accident consequences. At present, the number of lifting machinery in China has increased by about 20% annually, and the quantity of all kinds of lifting machinery has exceeded 2 million 500 thousand. Meanwhile, the proportion of casualties involving heavy machinery accounts for the proportion of all kinds of casualties. There is a rise year by year. At present, there are about 25% of the casualties in all sectors of our country. The number of deaths involved in heavy machinery accidents is the first in all machinery accident deaths each year. Therefore, it is urgent to strengthen the safety management and accident prevention of the lifting machinery. The premise and foundation of accident prevention, the systematic safety assessment method for lifting machinery is lacking. For the lifting equipment in service, especially the overdue service, the research on the systematic and practical risk assessment method has great theoretical significance and practical value. At present, the legal periodic inspection system is adopted in the industry to realize the lifting. The safety operation of machinery and accident prevention. This system has played a basic role in the safe operation of the lifting equipment. However, because the inspection project and the inspection cycle are basically fixed, the difference between the enterprise and the equipment individual is not distinguished, and it is easy to cause the excessive inspection of the general equipment and the insufficient inspection of the high risk equipment. The result of the inspection is only "qualified" and "unqualified". Because of the lack of quantitative calculation of the risk of parts and components, the evaluation result of the safety condition has limited reference value to the prevention of lifting machinery accident. The FMEA analysis of the main parts of the lifting machinery, the collection of failure data and the general failure probability information, the reliability test of the wire rope small sample, the modeling and Simulation of the lifting machinery, the qualitative and quantitative evaluation of the risk of the parts and parts, the formulation of the preventive maintenance strategy of the lifting machinery RCM, the implementation of the lifting machinery risk assessment and the evaluation of the soft. The main contents of the paper are as follows: (1) on the basis of the statistical analysis of more than 380 crane accidents, the failure analysis database of lifting machinery is set up. The failure mode and influence analysis are carried out, and all the failure modes are obtained, and then the corresponding failure causes and the consequences of failure are analyzed. The typical failure mode of the rope is bending fatigue and wear. Small sample physical tests are carried out, and the failure data are obtained under the test conditions. A collection table for the failure sample of the crane parts is designed. The survey statistics questionnaire and the deep Ling steel, Anshan steel, SANYO heavy industry and other cranes are used in the field investigation and so on. The large sample failure data of heavy machine parts have been completed, and the corresponding failure life calculation is completed. (2) in view of the limited site failure data of the crane parts, a reliable life prediction method for small sample parts of the crane parts based on Bayes theory is proposed. The correlation detection records determine the pre test distribution of reliability evaluation, combined with the field reliability test data of small samples, and apply Bayes theory to fuse the pre test information and field test data of parts and components, get the post test distribution of reliable life of the product, and then realize the prediction of the failure life of the parts and components. The method provides a new way for obtaining the failure life of the crane parts. (3) a virtual simulation test platform for lifting machinery is established by using the two development functions of the finite element software. The parameterized modeling of the tower crane and the application of the load of the virtual working condition are realized. The strength, stiffness and stability of the whole machine are obtained by using the Ansys software. The result provides a basis for the safety assessment of the lifting mechanism. (4) on the basis of the FMEA analysis and the acquisition of the general failure probability information of the main parts, the qualitative risk assessment model of the lifting machinery is established based on the RBI technology, and the risk ranking of the crane parts is determined. Based on the analytic hierarchy process and the grey comprehensive evaluation, The modified calculation model of the failure probability of the crane parts is established, and the quantitative risk assessment method of the crane parts is put forward according to the quantitative economic evaluation of the failure consequences of the parts. Finally, the above results are put forward and the qualitative risk assessment is used to determine the risk of the high risk components in the risk assessment of the lifting machinery. The practical implementation method of quantitative risk assessment. (5) based on the ACCESS database and using VB software as the development tool, the lifting machinery risk assessment system software is developed. The software can automatically complete the qualitative and quantitative risk assessment of the crane components, output the evaluation report of the WORD format, and give the detection parts of the corresponding fault parts. The methods of detection and detection cycle are suggested. (6) a study on the preventive maintenance strategy of lifting machinery based on RCM technology is carried out. Considering the reliability, economy and availability of the parts during the maintenance interval, a calculation method for the incomplete maintenance period in the limited period of use is given. Considering the process of the failure, an unscheduled inspection strategy based on the first detection and repeated detection is proposed. Based on the economic and availability criteria, the calculation method of the best detection period for the first detection and repeated detection is given respectively. (7) the comprehensive theoretical research results have been made to implement the implementation standard of the risk assessment of the lifting machinery. The practical quantitative evaluation criteria for the evaluation of each factor in the analytic hierarchy process are given, and the standardized implementation process of the qualitative and quantitative risk assessment of the crane parts is formulated. Finally, the application of the risk assessment process for nearly 20 typical cranes is completed based on the implementation specification and evaluation software.
【學(xué)位授予單位】：東北大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2013
【分類號】：TH21

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