2m路面铣刨机总体方案的设计研究
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摘要
本文综述了国内外铣刨机的发展现状及其发展趋势,总结了国内外2 m铣刨机性能特点和整机参数。阐述了铣刨机的分类方法,并对铣刨机的工作原理进行了说明。根据功能将2 m铣刨机整体划分为12个子系统,详细阐述了各子系统的组成、功能、工作原理。总结市场上现有的各子系统的结构形式,分析了各种结构形式的优缺点,并选择或提出了合理的各子系统的结构形式,指出各子系统设计时需要重点解决的问题;对各子系统的选型计算进行了分析,提出了较为合理的计算公式或经验数据。在此基础上,总结了2 m铣刨机的整机性能参数,并提出了三种可行的总体设计方案,分析了各自的优缺点及其成本构成,推荐了最佳的总体设计方案。
The Research of 2 m Road Miller’s Collectivity Scheme According to the“7918”scheme of Chinese highway net, to 2010, the“five radial two vertical seven horizontal”fourteen roads of the“7918 net”will be connected. The mileage of Chinese highway will be added to sixty-five thousands kilometers; Until 2020 the will be added to eighty-five thousands kilometers. The highway maintenance work begins when the highway has been built ten years. The highways maintenance work will be a task to be urgently solved in the next twenty to thirty years.
Cold road miller is a high efficiency road maintenance machine with low cost, wide cutting depth range, no pollution. It’s mainly used in crashing great area road, familiar road failures’finishing and roughing the road.
The milling drum is the main working equipment of the road miller, the milling cutter is arranged on the milling drum according to the eudipleural gyroidal line rule. The milling drum feeds in vertical and horizontal direction. The road miller runs in work speed, the milling cutters circumrotate along with the milling drum, the milling cutter touch the road surface one by one, the road is crashed by the action of impact and extrusion, at the same time the scrap is collected to the center of the milling drum, and the collecting plate casts the scrap to the conveyer belt, the scrap is transferred to the appointed place or the camion by the conveyer belt.
The two meters miller is divided into twelve subsystems according to the function: dynamical system, transmission, milling system, lifting system, traveling system, steering system, frame system, hydraulic system, collecting system, cover system, electric system, sprinkling system.
The dynamical system provides the miller with power, the power range in two hundreds an ninety to four hundreds and seventy kilowatts, the extensive use engine is the full electric control model of Caterpillar, Daimler Chrysler, DEUTZ, Cummins. The cooling system is hydrostatic transmission. The road miller has the best economical efficiency when the engine’s power is in the range of four hundreds and twenty and four hundreds and seventy kilowatts. The lifting system depends on the lifting hydraulic cylinders to perform the different milling depth. The material group of the inner and outer cylinder is very important.
The engines power is transferred to the milling drum by the hydraulic clutch and the driving texrope belt and to hydraulic pumps by the distributing dynamic box. The driving model is defined one end output and two end output according to the fixing location of the clutch and the distributing dynamic box. The extensive use clutch is Desch hydraulic model. The extensive use distributing dynamic box is the Stieble 4in1 and 5in1 model.
The milling system is the working equipment of the road miller, the arrangement of the milling cutter and the structure of the cutter is the key factor of the miller’s performance. the milling cutter is arranged on the milling drum according to the eudipleural gyroidal line rule, the diameter of the milling drum is between eight hundreds and one thousand millimeters, the best line milling speed is between four to six meter per second, the space in the milling drum axle direction between two cutters is between fifteen and twenty millimeters, the arc space between two cutters’end is between one hundred and two hundreds millimeters. The best structure of the milling cutter is quick change model.
Usually, the two meters road miller adopts the hydraulic driving crawler structure. The right stretch structure can assure the work stability of road miller. The pretightening force of the stretch spring is 2.4 to 2.8 times gradient resistance of single crawler chain, the maximum tightening force of the stretch spring is 3.0 to 4.0 times gradient resistance of single crawler chain. The droop of the crawler chain is 0.015 to 0.03 times the centre-to-centre distance of the oriented wheel and driving wheel.
The road miller has two steering model: four leg unattached steering and two bridge linkage steering. Usually, uses two bridge linkage steering, respectively links the front two leg with the synchronous link rod, performs the synchronous steering of the two front legs and the two rear legs. The road miller can perform the front bridge steering, the rear bridge steering, origin steering, stagger travel.
The two meters road miller uses the integrative structure frame. The frame is bulky and difficult to make. The anticorrosion of the water tank and the machining of the four leg’s lifting path must be settled. After the every structure has been confirmed the intensity of the frame must to be verified. The hydraulic system of the two meter road miller is divided into four subsystems according to the function: traveling, cooling, collecting, assistant.
The traveling system is controlled by the power automatic distributing function of the control system, can perform the maximum productivity under relevant power. The hydrostatic transmission cooling system can perform the best economical efficiency and cooling effect. Usually, the collecting system chooses the group of piston-type pump and cycloid motor. The assistant system performs other action. The Rexroth and Sauer hydraulic component is in common use.
The two meters road miller uses two grades prepositive conveyer belt collecting system. The first grade performs the scrap collecting and transfers the scrap to the second grade, the second grade transfers the scrap to the appointed place. Usually, the width of the conveyer belt is 800 millimeter. The two meters road miller adopts the MC micro controller control system based on the CAN-bus. The MC micro controller control system is the perfect and the most extensive use controller of the electric-hydraulic control system. The system uses the rotate speed of engine as control signal, the controller alters the output electrical current and the flux of the driving pump according to the change of the rotate speed of engine. When the actual rotate speed under the rated rotate speed, the control electrical current diminishes, the flux of the driving pump diminishes and the travelling speed diminishes, at last the actual rotate speed equals to the rated rotate speed; When the actual rotate speed hyper the rated rotate speed, the control electrical current largens, the flux of the driving pump largens and the travelling speed largens, at last the actual rotate speed equals to the rated rotate speed; sequentially the miller makes the best of engine power and the machine works in the best economical efficiency.
Usually, the Moba automatic level adjusting system contains cord sensor, gradient sensor and automatic controller. In normal work condition, the cords of two cord sensor connect to the floating plate, the exserted length of the cord shows the height of the floating plate, i.e. the change of the milling depth, the cord sensor transforms the change to electric signal and send the signal to automatic controller, automatic controller transforms this data to the milling depth and compares this depth to the required milling depth, then adjusts the lifting leg according to the result, assures the milling depth. In the condition that only one floating plate touches the ground, the system uses the group, the cord sensor what is in the side that the floating plate touches ground and gradient sensor, to adjust the level. At the beginning of the milling work, the system adjusts the gradient sensor to zero values, in course of milling, the controller adjusts the milling depth according to the signal of the cord sensor, and calculates the actual milling depth of the other side, then adjusts the depth of the other side according to the calculating result.
The sprinkling system assures the cooling of the milling drum and the conveyer belt, this can effectually prolong the useful-life of the milling drum and the conveyer belt.
The cover system can effectually protect the key parts of the road miller. This dissertation analyses the necessary design calculation and brings forward the reasonable design formula as the reference of the congener product developing. Basing on the analysis of the existing miller and the understanding of the development trend of miller, this dissertation confirms the machine parameters of the two-meter miller, brings forward three feasible design project for the two-meter miller, analyses the advantage of every project and recommends the optimal project.
The Research of 2 m Road Miller’s Collectivity Scheme According to the“7918”scheme of Chinese highway net, to 2010, the“five radial two vertical seven horizontal”fourteen roads of the“7918 net”will be connected. The mileage of Chinese highway will be added to sixty-five thousands kilometers; Until 2020 the will be added to eighty-five thousands kilometers. The highway maintenance work begins when the highway has been built ten years. The highways maintenance work will be a task to be urgently solved in the next twenty to thirty years.
Cold road miller is a high efficiency road maintenance machine with low cost, wide cutting depth range, no pollution. It’s mainly used in crashing great area road, familiar road failures’finishing and roughing the road.
The milling drum is the main working equipment of the road miller, the milling cutter is arranged on the milling drum according to the eudipleural gyroidal line rule. The milling drum feeds in vertical and horizontal direction. The road miller runs in work speed, the milling cutters circumrotate along with the milling drum, the milling cutter touch the road surface one by one, the road is crashed by the action of impact and extrusion, at the same time the scrap is collected to the center of the milling drum, and the collecting plate casts the scrap to the conveyer belt, the scrap is transferred to the appointed place or the camion by the conveyer belt.
The two meters miller is divided into twelve subsystems according to the function: dynamical system, transmission, milling system, lifting system, traveling system, steering system, frame system, hydraulic system, collecting system, cover system, electric system, sprinkling system.
The dynamical system provides the miller with power, the power range in two hundreds an ninety to four hundreds and seventy kilowatts, the extensive use engine is the full electric control model of Caterpillar, Daimler Chrysler, DEUTZ, Cummins. The cooling system is hydrostatic transmission. The road miller has the best economical efficiency when the engine’s power is in the range of four hundreds and twenty and four hundreds and seventy kilowatts. The lifting system depends on the lifting hydraulic cylinders to perform the different milling depth. The material group of the inner and outer cylinder is very important.
The engines power is transferred to the milling drum by the hydraulic clutch and the driving texrope belt and to hydraulic pumps by the distributing dynamic box. The driving model is defined one end output and two end output according to the fixing location of the clutch and the distributing dynamic box. The extensive use clutch is Desch hydraulic model. The extensive use distributing dynamic box is the Stieble 4in1 and 5in1 model.
The milling system is the working equipment of the road miller, the arrangement of the milling cutter and the structure of the cutter is the key factor of the miller’s performance. the milling cutter is arranged on the milling drum according to the eudipleural gyroidal line rule, the diameter of the milling drum is between eight hundreds and one thousand millimeters, the best line milling speed is between four to six meter per second, the space in the milling drum axle direction between two cutters is between fifteen and twenty millimeters, the arc space between two cutters’end is between one hundred and two hundreds millimeters. The best structure of the milling cutter is quick change model.
Usually, the two meters road miller adopts the hydraulic driving crawler structure. The right stretch structure can assure the work stability of road miller. The pretightening force of the stretch spring is 2.4 to 2.8 times gradient resistance of single crawler chain, the maximum tightening force of the stretch spring is 3.0 to 4.0 times gradient resistance of single crawler chain. The droop of the crawler chain is 0.015 to 0.03 times the centre-to-centre distance of the oriented wheel and driving wheel.
The road miller has two steering model: four leg unattached steering and two bridge linkage steering. Usually, uses two bridge linkage steering, respectively links the front two leg with the synchronous link rod, performs the synchronous steering of the two front legs and the two rear legs. The road miller can perform the front bridge steering, the rear bridge steering, origin steering, stagger travel.
The two meters road miller uses the integrative structure frame. The frame is bulky and difficult to make. The anticorrosion of the water tank and the machining of the four leg’s lifting path must be settled. After the every structure has been confirmed the intensity of the frame must to be verified. The hydraulic system of the two meter road miller is divided into four subsystems according to the function: traveling, cooling, collecting, assistant.
The traveling system is controlled by the power automatic distributing function of the control system, can perform the maximum productivity under relevant power. The hydrostatic transmission cooling system can perform the best economical efficiency and cooling effect. Usually, the collecting system chooses the group of piston-type pump and cycloid motor. The assistant system performs other action. The Rexroth and Sauer hydraulic component is in common use.
The two meters road miller uses two grades prepositive conveyer belt collecting system. The first grade performs the scrap collecting and transfers the scrap to the second grade, the second grade transfers the scrap to the appointed place. Usually, the width of the conveyer belt is 800 millimeter. The two meters road miller adopts the MC micro controller control system based on the CAN-bus. The MC micro controller control system is the perfect and the most extensive use controller of the electric-hydraulic control system. The system uses the rotate speed of engine as control signal, the controller alters the output electrical current and the flux of the driving pump according to the change of the rotate speed of engine. When the actual rotate speed under the rated rotate speed, the control electrical current diminishes, the flux of the driving pump diminishes and the travelling speed diminishes, at last the actual rotate speed equals to the rated rotate speed; When the actual rotate speed hyper the rated rotate speed, the control electrical current largens, the flux of the driving pump largens and the travelling speed largens, at last the actual rotate speed equals to the rated rotate speed; sequentially the miller makes the best of engine power and the machine works in the best economical efficiency.
Usually, the Moba automatic level adjusting system contains cord sensor, gradient sensor and automatic controller. In normal work condition, the cords of two cord sensor connect to the floating plate, the exserted length of the cord shows the height of the floating plate, i.e. the change of the milling depth, the cord sensor transforms the change to electric signal and send the signal to automatic controller, automatic controller transforms this data to the milling depth and compares this depth to the required milling depth, then adjusts the lifting leg according to the result, assures the milling depth. In the condition that only one floating plate touches the ground, the system uses the group, the cord sensor what is in the side that the floating plate touches ground and gradient sensor, to adjust the level. At the beginning of the milling work, the system adjusts the gradient sensor to zero values, in course of milling, the controller adjusts the milling depth according to the signal of the cord sensor, and calculates the actual milling depth of the other side, then adjusts the depth of the other side according to the calculating result.
The sprinkling system assures the cooling of the milling drum and the conveyer belt, this can effectually prolong the useful-life of the milling drum and the conveyer belt.
The cover system can effectually protect the key parts of the road miller. This dissertation analyses the necessary design calculation and brings forward the reasonable design formula as the reference of the congener product developing. Basing on the analysis of the existing miller and the understanding of the development trend of miller, this dissertation confirms the machine parameters of the two-meter miller, brings forward three feasible design project for the two-meter miller, analyses the advantage of every project and recommends the optimal project.
引文
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[2]甘建兵.维特根铣刨机及其发展.筑路机械与施工机械化, 2004,1.
[3]周里群,许武全,龙国键.路面铣刨机的发展历程与研究进展.筑路机械与施工机械化. 2005,4.
[4]曾卫兵,赵敏,何挺继.沥青路面铣刨机作业性能分析与验证.长安大学学报,2004,5 ,第24卷.
[5]谢长宇.力士乐MC微控制器在冷铣刨机中的运用.筑路机械与施工机械化,2003,1.
[6] Manual For The Application Of Cold Milling Machines (From www.wirtgen.com Include following contents: Goal of road maintenance、Milling method、Principle and requirement of milling、Benefits of cold milling、Selection and use of equipment、Applications of small milling machines、Applications of large milling machines、Calculating the milling performance、Flexible cutter system、Fine milling、Cutting tools and tool systems、Levelling systems、A special applications) .
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