新型60m~2无起拱带式烧结机关键技术研究及工程实践
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摘要
随着钢铁产量的不断增大,作为高炉原料主要供应设备的带式烧结机的作用显得日益重要。台车执行牵引机构是带式烧结机的核心机构,直接关系到烧结台车的连续运转和烧结矿的正常生产。本文介绍了鲁奇式带式烧结机台车执行牵引机构,分析了运行过程中出现的问题,提出了解决措施。研究成果对于今后提高烧结矿的产量,设计、制造、安装和调试新型无起拱带式烧结机具有重要的理论意义和实用价值。
首先,介绍了新型无起拱带式烧结机的研究内容,包括新型头部和尾部星轮的设计、车轮轨道的设计、下台车列起拱的力控制方法及力控制装置的设计、带式烧结机主要基本参数的确定等。
其次,研究结果表明,新型头尾星轮不但有效解决了带式烧结机台车运行速度不均匀问题,而且对消除下台车列的起拱也有一定作用。因此,根据台车列辊轮轮距的交替变化,确定了星轮相隔布置的两类齿距,以及星轮的齿数是偶数。将啮合原理与星轮和辊轮啮合的具体工况相结合,建立了分段的星轮实际齿廓曲线,并将该分段曲线用统一方程表达。针对星轮在运行中出现的齿面损伤,应用赫兹接触理论对齿面接触应力进行了计算,并从多方面研究了提高星轮齿面承载能力的措施。采用非线性有限元对理想接触工况及实际接触工况进行了模拟,进一步揭示了齿面损伤产生的原因并证明了提高齿面承载能力所采用措施的有效性。在上述研究基础上,设计制造了新型60m2带式烧结机的偶数齿数变齿距、高承载能力的头尾星轮。
再次,通过分析带式烧结机尾部星轮和上、下台车列的力学关系,建立了下台车列无起拱的力学模型,提出了对尾部星轮主轴进行转矩加载和对尾部配重进行合理设置作为下台车列无起拱的力控制方法。在对新型60m2带式烧结机台车执行牵引机构进行多刚体仿真的基础上,得到了尾部星轮转矩、力控制前和力控制后的尾部星轮对上、下台车列推力等数值随时间变化的曲线,并初步确定了进行力控制的一组力值,为设计新型60m2无起拱带式烧结机的力控制装置提供了基本数据。仿真还从可视化角度证明了消除下台车列起拱的力学模型正确、力控制方法有效。根据台车结构尺寸和折算质量,建立了系列带式烧结机的力控制数据库,对今后无起拱带式烧结机的工程设计有一定参考价值。
最后,在确定了尾部星轮主轴液压转矩加载装置的执行机构和加载装置与带式烧结机主机联接方式的基础上,对液压转矩加载机构的工作原理做了详细的说明。结合新型60m2带式烧结机,详细阐述了加载装置的安装方式和液压关键元件的选择计算过程。对新型60m2无起拱带式烧结机进行了工业实验研究,研究内容包括:偶数变齿距头尾星轮的安装和安装后的运行情况分析、液压转矩加载装置与尾部配重的联合调试实验方法、观测数据的详细分析等。在工业现场的实验调试过程中所取得的成绩证明了本文研究理论的正确性和可靠性;同时,对实验过程中出现的不足也做出了说明。
With the increasing yield of steel and iron, the sintering machine supplying raw materials for the blast furnace is becoming more important. The draught mechanism of pallet cars is the core mechanism of the sintering machine, which directly affects the running of the sintering pallet cars and regular production of the sinter. In this paper, the draught mechanism of the Lurgi sintering machine is introduced and the problems during the course of operation are presented. In order to solve these problems, effective methods are proposed. Therefore, the research fruits have great theoretical and practical value not only for increasing the sinter production, but also for design, manufacture, installation and debug of the new type non-arching sintering machine for the future.
Firstly, the development contents of the new type non-arching sintering machine are introduced, including the design of new type front and back sprocket wheels, the design of the wheel roadway, the force control method, the design of force control device to solve the arching of lower pallet cars and the determination of the fundamental parameters of the new type sintering machine, etc..
Secondly, the research results show that the new type front and back sprocket wheels can not only effectively resolve the velocity fluctuation of the pallet cars but also make their contribution to decrease the arching of the lower pallet cars. Hence, two kinds of teeth space arranged alternately and the even number of teeth are determined for the sprocket wheel according to the interval changed wheelbases of the rolling wheels in the pallet cars. By combining the meshing principle with the actual working condition between the sprocket wheel and the pallet cars, the practical tooth profile curve with sectionalized is established and expressed by universal equation. Aimed at the tooth surface damage of the sprocket wheel while working, the contact stress of the tooth surface is calculated by using the Hertz theory, and various measures to improve the load capacity of the sprocket wheel tooth surface are studied. The distributions of the contact stress simulated with nonlinear FEM in the ideal working condition and the actual working condition show further that the damage reasons of the tooth surface and prove the availability of the methods for improving the load capacity. Based on the study results mentioned above, the front and back sprocket wheels with even number of teeth, varying teeth space and high load capacity for new type 60m2 sintering machine are designed and manufactured.
Thirdly, by analyzing the mechanics relation between the back sprocket wheel and the upper and lower pallet cars, the non-arching mechanics model of the lower pallet cars is established. The force control methods of imposing the torque-loading on the main shaft of the back sprocket wheel and correctly collocating the back additional weight are brought forward to carry out the non-arching of the lower pallet cars. By the multi rigid body simulation for the pallet cars’draught mechanism of the new type 60m2 sintering machine, the time depended curves of the torque acted on the main shaft of the back sprocket wheel and the no controlled and controlled thrust forces brought bear from the back sprocket wheel to upper and lower pallet cars are gained, respectively. Meanwhile, basic data used to design new-type 60m2 non-arching sintering machine are obtained on the basis of a set of force control values。From the visualization, the simulation also proves that the mechanics model is correct, and that the force control methods are effective to eliminate the arching of the lower pallet cars. The force control database established according as the structure size and conversion quality of the pallet car of series type sintering machines offers certain reference value for the engineering design of the non-arching sintering machine.
Lastly, based on the determination of the actuator of the hydraulic torque-loading device on the main shaft of the back sprocket wheel and the connection mode between the loading device and the main machine of the sintering machine, the working principle of the loading device is also elucidated in detail. Taking the new type 60m2 sintering machine for example, the installation of the hydraulic torque-loading device is elaborated and the choice of the key hydraulic components is expatiated. Moreover, industry test is proceed for the new type 60m2 non-arching sintering machine, including the installation and the running situations after installation of the sprocket wheels with even number and varying teeth space, the method of united debug test on hydraulic torque-loading device and back additional weight and the detailed analysis of the observed data, and so on. The debugging achievements attained in the field industry test about the new type sintering machine attest the correctness and reliability of the theories in this paper. Simultaneously, the shortages occurring in the debug stage also are illuminated。
首先,介绍了新型无起拱带式烧结机的研究内容,包括新型头部和尾部星轮的设计、车轮轨道的设计、下台车列起拱的力控制方法及力控制装置的设计、带式烧结机主要基本参数的确定等。
其次,研究结果表明,新型头尾星轮不但有效解决了带式烧结机台车运行速度不均匀问题,而且对消除下台车列的起拱也有一定作用。因此,根据台车列辊轮轮距的交替变化,确定了星轮相隔布置的两类齿距,以及星轮的齿数是偶数。将啮合原理与星轮和辊轮啮合的具体工况相结合,建立了分段的星轮实际齿廓曲线,并将该分段曲线用统一方程表达。针对星轮在运行中出现的齿面损伤,应用赫兹接触理论对齿面接触应力进行了计算,并从多方面研究了提高星轮齿面承载能力的措施。采用非线性有限元对理想接触工况及实际接触工况进行了模拟,进一步揭示了齿面损伤产生的原因并证明了提高齿面承载能力所采用措施的有效性。在上述研究基础上,设计制造了新型60m2带式烧结机的偶数齿数变齿距、高承载能力的头尾星轮。
再次,通过分析带式烧结机尾部星轮和上、下台车列的力学关系,建立了下台车列无起拱的力学模型,提出了对尾部星轮主轴进行转矩加载和对尾部配重进行合理设置作为下台车列无起拱的力控制方法。在对新型60m2带式烧结机台车执行牵引机构进行多刚体仿真的基础上,得到了尾部星轮转矩、力控制前和力控制后的尾部星轮对上、下台车列推力等数值随时间变化的曲线,并初步确定了进行力控制的一组力值,为设计新型60m2无起拱带式烧结机的力控制装置提供了基本数据。仿真还从可视化角度证明了消除下台车列起拱的力学模型正确、力控制方法有效。根据台车结构尺寸和折算质量,建立了系列带式烧结机的力控制数据库,对今后无起拱带式烧结机的工程设计有一定参考价值。
最后,在确定了尾部星轮主轴液压转矩加载装置的执行机构和加载装置与带式烧结机主机联接方式的基础上,对液压转矩加载机构的工作原理做了详细的说明。结合新型60m2带式烧结机,详细阐述了加载装置的安装方式和液压关键元件的选择计算过程。对新型60m2无起拱带式烧结机进行了工业实验研究,研究内容包括:偶数变齿距头尾星轮的安装和安装后的运行情况分析、液压转矩加载装置与尾部配重的联合调试实验方法、观测数据的详细分析等。在工业现场的实验调试过程中所取得的成绩证明了本文研究理论的正确性和可靠性;同时,对实验过程中出现的不足也做出了说明。
With the increasing yield of steel and iron, the sintering machine supplying raw materials for the blast furnace is becoming more important. The draught mechanism of pallet cars is the core mechanism of the sintering machine, which directly affects the running of the sintering pallet cars and regular production of the sinter. In this paper, the draught mechanism of the Lurgi sintering machine is introduced and the problems during the course of operation are presented. In order to solve these problems, effective methods are proposed. Therefore, the research fruits have great theoretical and practical value not only for increasing the sinter production, but also for design, manufacture, installation and debug of the new type non-arching sintering machine for the future.
Firstly, the development contents of the new type non-arching sintering machine are introduced, including the design of new type front and back sprocket wheels, the design of the wheel roadway, the force control method, the design of force control device to solve the arching of lower pallet cars and the determination of the fundamental parameters of the new type sintering machine, etc..
Secondly, the research results show that the new type front and back sprocket wheels can not only effectively resolve the velocity fluctuation of the pallet cars but also make their contribution to decrease the arching of the lower pallet cars. Hence, two kinds of teeth space arranged alternately and the even number of teeth are determined for the sprocket wheel according to the interval changed wheelbases of the rolling wheels in the pallet cars. By combining the meshing principle with the actual working condition between the sprocket wheel and the pallet cars, the practical tooth profile curve with sectionalized is established and expressed by universal equation. Aimed at the tooth surface damage of the sprocket wheel while working, the contact stress of the tooth surface is calculated by using the Hertz theory, and various measures to improve the load capacity of the sprocket wheel tooth surface are studied. The distributions of the contact stress simulated with nonlinear FEM in the ideal working condition and the actual working condition show further that the damage reasons of the tooth surface and prove the availability of the methods for improving the load capacity. Based on the study results mentioned above, the front and back sprocket wheels with even number of teeth, varying teeth space and high load capacity for new type 60m2 sintering machine are designed and manufactured.
Thirdly, by analyzing the mechanics relation between the back sprocket wheel and the upper and lower pallet cars, the non-arching mechanics model of the lower pallet cars is established. The force control methods of imposing the torque-loading on the main shaft of the back sprocket wheel and correctly collocating the back additional weight are brought forward to carry out the non-arching of the lower pallet cars. By the multi rigid body simulation for the pallet cars’draught mechanism of the new type 60m2 sintering machine, the time depended curves of the torque acted on the main shaft of the back sprocket wheel and the no controlled and controlled thrust forces brought bear from the back sprocket wheel to upper and lower pallet cars are gained, respectively. Meanwhile, basic data used to design new-type 60m2 non-arching sintering machine are obtained on the basis of a set of force control values。From the visualization, the simulation also proves that the mechanics model is correct, and that the force control methods are effective to eliminate the arching of the lower pallet cars. The force control database established according as the structure size and conversion quality of the pallet car of series type sintering machines offers certain reference value for the engineering design of the non-arching sintering machine.
Lastly, based on the determination of the actuator of the hydraulic torque-loading device on the main shaft of the back sprocket wheel and the connection mode between the loading device and the main machine of the sintering machine, the working principle of the loading device is also elucidated in detail. Taking the new type 60m2 sintering machine for example, the installation of the hydraulic torque-loading device is elaborated and the choice of the key hydraulic components is expatiated. Moreover, industry test is proceed for the new type 60m2 non-arching sintering machine, including the installation and the running situations after installation of the sprocket wheels with even number and varying teeth space, the method of united debug test on hydraulic torque-loading device and back additional weight and the detailed analysis of the observed data, and so on. The debugging achievements attained in the field industry test about the new type sintering machine attest the correctness and reliability of the theories in this paper. Simultaneously, the shortages occurring in the debug stage also are illuminated。
引文
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