带式输送机绿色设计关键技术与应用研究
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摘要
带式输送机是当今世界最重要的散状物料运输设备,被广泛应用于煤矿、电力、港口、化工、环保、物流等行业。由于传统设计方法的限制,带式输送机存在着能源资源耗费量大、安全系数取值高、整机造价成本高、技术含量低、噪声粉尘污染等问题。本文将绿色设计技术应用于带式输送机设计领域,以环境保护为设计理念,综合考虑带式输送机产品的环境属性、资源属性、能源属性以及经济性,对带式输送机动态设计技术、虚拟样机技术以及可拆卸设计等绿色设计关键技术进行研究,对节约产品成本,降低能耗,提高产品可维护性及可靠性,减少环境污染有着重要的意义。主要研究内容和特色如下：
1.带式输送机的动态特性取决于输送带的性质,在考虑输送带内部摩擦效应的前提下,以BERG模型为基础,提出了一种包含内部摩擦的输送带力学模型,给出了模型内部参数的确定方法,建立了计算机模型,并对其进行仿真和试验验证；利用离散单元法,推导出了基于包含内摩擦输送带力学模型的带式输送机系统动力学方程,其动态仿真结果与启动工况相一致,表明了包含内摩擦的输送带力学模型的正确性及动态设计方法的有效性。
2.利用功率键合图方法推导出了带式输送机液压自动拉紧装置的数学模型；并以此为理论基础,采用多领域统一建模方法,建立了液压自动拉紧装置虚拟样机；进而对拉紧装置稳定性和快速性的相关因素进行了仿真研究。研究结果表明,带式输送机液压拉紧装置虚拟样机还原了物理样机的功能性,可以方便地取代昂贵的物理样机进行试验。通过改变虚拟样机的相关参数,能够对不同设计方案进行性能测试,从而完成液压拉紧装置的系统优化,达到节约能源材料,降低设计成本,提高系统稳定性和可靠性的目的。
3.零件的可拆卸性决定了带式输送机在使用过程中的可维护性,以及系统报废后的零件重用性和材料回收性,是带式输送机绿色设计中重要的一环。以带式输送机关键部件滚筒作为研究对象进行可拆卸设计研究,针对现阶段普通整体式滚筒的缺点,提出一种可拆卸式滚筒结构,对其进行可拆卸性及工作性能评价分析,结果表明可拆卸式滚筒不仅具有良好的可拆卸性,同时还具备可靠的工作性能。
4.以带式输送机绿色设计关键技术为基础,提出了带式输送机绿色设计方法的基本步骤,并对一带式输送机设计方案进行绿色设计开发实例研究,经过方案选型,系统动态分析,零部件虚拟设计,可拆卸设计等环节,得到改进的带式输送机绿色设计方案；绿色设计方案比原方案节约成本约8.51%；应用多层次模糊评价方法对设计方案进行绿色评价,结果表明带式输送机绿色设计方案比原方案具有更好的绿色环保性。
Belt conveyor, the most important equipment for bulk material transportation, is widely used in coal mines, power plants, ports, chemical plants, environmental plants, warehouses and other areas. Because of the limitation of traditional design method, belt conveyor has some problems, such as large consumption of energy resources, high safety factor, high cost, low-tech, serious environmental pollution, noise and vibration. The green design technology was applied to belt conveyor in this paper, with its environmental protection concept. Considering belt conveyor's attributes of environment resources, property and energy, the key technologies of belt conveyor green design, which consists of dynamic design, disassembly design and virtual design, were studied to save the cost, reduce the energy consumption, improve the reliability, alleviate environmental pollution in the conveyor's design, manufacture and use process。The main research content and the characteristics are as follows.
1. The belt conveyer's dynamic characteristic is decided by conveyor belt's nature. Considering the conveyor belt's internal friction effect, a belt model with internal frictional element was proposed on the basis of the BERG model. And its computer model and simulation result were given, then validated by the experiment. Using discrete elements method, the system dynamic formula based on the belt model with internal friction was built and simulated. The result of dynamic simulation was consistent with the start work condition, what proved the correctness of the belt dynamic model and the feasibility of dynamic design for belt conveyor.
2. The virtual prototyping of hydraulic automatic take-up device of belt conveyor was built on the theoretical basis of mathematical model that deduced by the power bond graph method. Then the virtual prototyping simulation study on take-up system's stability and rapidity was finished. The research indicated that the virtual prototyping of hydraulic automatic take-up device which had the same functionality as the physical prototype can substitute for the expensive prototype to carry on the experiment conveniently. And the different design proposals were tested to optimize hydraulic automatic take-up device by changing related parameters by changing the relevant parameters to save the energy material, reduce the design cost, enhance the system stability and the reliability.
3. The parts' disassembly determines the belt conveyor's maintainability in use process, reusability and recyclability after abandonment, which is the important part in the green design process. The drum, the key components of belt conveyor, was studied for disassembly design. In view of the ordinary integral drum's shortcomings at the present stage, a new detachable drum was proposed in this paper. And the results of its disassembling and performance evaluation show its good disassembly and reliability.
4. Integrated the above key technologies, the basic steps of the belt conveyor green design was proposed, and a belt conveyor design was studied as an example in this paper. After the type-selection design, system dynamic analysis, parts of the virtual design, and disassembly design, the improved design proposal had saved the total cost approximately8.51%. The fuzzy analytic hierarchy process was applied to its green evaluation. As a conclusion, the green design of belt conveyor had a better environmental green degree than the original.
1.带式输送机的动态特性取决于输送带的性质,在考虑输送带内部摩擦效应的前提下,以BERG模型为基础,提出了一种包含内部摩擦的输送带力学模型,给出了模型内部参数的确定方法,建立了计算机模型,并对其进行仿真和试验验证；利用离散单元法,推导出了基于包含内摩擦输送带力学模型的带式输送机系统动力学方程,其动态仿真结果与启动工况相一致,表明了包含内摩擦的输送带力学模型的正确性及动态设计方法的有效性。
2.利用功率键合图方法推导出了带式输送机液压自动拉紧装置的数学模型；并以此为理论基础,采用多领域统一建模方法,建立了液压自动拉紧装置虚拟样机；进而对拉紧装置稳定性和快速性的相关因素进行了仿真研究。研究结果表明,带式输送机液压拉紧装置虚拟样机还原了物理样机的功能性,可以方便地取代昂贵的物理样机进行试验。通过改变虚拟样机的相关参数,能够对不同设计方案进行性能测试,从而完成液压拉紧装置的系统优化,达到节约能源材料,降低设计成本,提高系统稳定性和可靠性的目的。
3.零件的可拆卸性决定了带式输送机在使用过程中的可维护性,以及系统报废后的零件重用性和材料回收性,是带式输送机绿色设计中重要的一环。以带式输送机关键部件滚筒作为研究对象进行可拆卸设计研究,针对现阶段普通整体式滚筒的缺点,提出一种可拆卸式滚筒结构,对其进行可拆卸性及工作性能评价分析,结果表明可拆卸式滚筒不仅具有良好的可拆卸性,同时还具备可靠的工作性能。
4.以带式输送机绿色设计关键技术为基础,提出了带式输送机绿色设计方法的基本步骤,并对一带式输送机设计方案进行绿色设计开发实例研究,经过方案选型,系统动态分析,零部件虚拟设计,可拆卸设计等环节,得到改进的带式输送机绿色设计方案；绿色设计方案比原方案节约成本约8.51%；应用多层次模糊评价方法对设计方案进行绿色评价,结果表明带式输送机绿色设计方案比原方案具有更好的绿色环保性。
Belt conveyor, the most important equipment for bulk material transportation, is widely used in coal mines, power plants, ports, chemical plants, environmental plants, warehouses and other areas. Because of the limitation of traditional design method, belt conveyor has some problems, such as large consumption of energy resources, high safety factor, high cost, low-tech, serious environmental pollution, noise and vibration. The green design technology was applied to belt conveyor in this paper, with its environmental protection concept. Considering belt conveyor's attributes of environment resources, property and energy, the key technologies of belt conveyor green design, which consists of dynamic design, disassembly design and virtual design, were studied to save the cost, reduce the energy consumption, improve the reliability, alleviate environmental pollution in the conveyor's design, manufacture and use process。The main research content and the characteristics are as follows.
1. The belt conveyer's dynamic characteristic is decided by conveyor belt's nature. Considering the conveyor belt's internal friction effect, a belt model with internal frictional element was proposed on the basis of the BERG model. And its computer model and simulation result were given, then validated by the experiment. Using discrete elements method, the system dynamic formula based on the belt model with internal friction was built and simulated. The result of dynamic simulation was consistent with the start work condition, what proved the correctness of the belt dynamic model and the feasibility of dynamic design for belt conveyor.
2. The virtual prototyping of hydraulic automatic take-up device of belt conveyor was built on the theoretical basis of mathematical model that deduced by the power bond graph method. Then the virtual prototyping simulation study on take-up system's stability and rapidity was finished. The research indicated that the virtual prototyping of hydraulic automatic take-up device which had the same functionality as the physical prototype can substitute for the expensive prototype to carry on the experiment conveniently. And the different design proposals were tested to optimize hydraulic automatic take-up device by changing related parameters by changing the relevant parameters to save the energy material, reduce the design cost, enhance the system stability and the reliability.
3. The parts' disassembly determines the belt conveyor's maintainability in use process, reusability and recyclability after abandonment, which is the important part in the green design process. The drum, the key components of belt conveyor, was studied for disassembly design. In view of the ordinary integral drum's shortcomings at the present stage, a new detachable drum was proposed in this paper. And the results of its disassembling and performance evaluation show its good disassembly and reliability.
4. Integrated the above key technologies, the basic steps of the belt conveyor green design was proposed, and a belt conveyor design was studied as an example in this paper. After the type-selection design, system dynamic analysis, parts of the virtual design, and disassembly design, the improved design proposal had saved the total cost approximately8.51%. The fuzzy analytic hierarchy process was applied to its green evaluation. As a conclusion, the green design of belt conveyor had a better environmental green degree than the original.
引文
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