双折线式卷筒多层缠绕系统力学分析与试验研究
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摘要
随着海洋工程、港口运输、采矿工程以及水工建设等工程领域的快速发展,各种超大扬程、大钢丝绳容绳量的起重设备需求不断增加。实践证明双折线式卷筒多层缠绕系统是解决此类大扬程、大钢丝绳容绳量问题的最有效方法。目前在进行多层缠绕卷筒系统设计时,卷筒的多层缠绕系数是由钢丝绳的缠绕层数确定的。实际上卷筒的多层缠绕系数不仅与钢丝绳的缠绕层数有关,同时与钢丝绳在卷筒上的排列方式以及钢丝绳的弹性特性有着重要的关系。在轻量化设计要求下,准确地分析卷筒的实际应力,是保证卷筒安全、可靠工作的前提。本文通过有限元数值仿真法定量地分析了钢丝绳的弹性特性,运用理论分析和实物试验的方法,研究了双折线式卷筒的多层缠绕系数、卷筒的受力特征以及钢丝绳弹性特性对多层缠绕系数的影响。所做的主要研究工作及创新点如下：
1、运用空间变换方法建立了不同捻向、不同旋向和不同结构钢丝绳各层钢丝空间曲线的普适参量方程,提出了用Matlab与Pro/E软件建立复杂结构钢丝绳空间几何模型的新方法。应用Abaqus软件建立了复杂结构钢丝绳的有限元分析模型,使用显式动力学法对轴向拉伸与横向压缩载荷作用下钢丝绳应力分布和钢丝绳的弹性特性值进行计算分析。
2、以现代板壳理论为基础,将双折线式多层缠绕钢丝绳卷筒筒体视为均匀受压的旋转对称壳体,将端板视为受层状分布线载荷作用的旋转对称圆板,建立双折线式卷筒筒体及端板变形的数学方程,通过分析不同边界条件,确定方程中的积分常数。
3、通过分析多层缠绕时由于外层钢丝绳的缠绕导致内层钢丝绳张力的衰减机理,建立求解各层钢丝绳由于外层钢丝绳缠绕而引起的张力衰减值方程和多层缠绕系数方程。以底层上爬理论为基础,建立多层缠绕钢丝绳各个绳圈对双折线式卷筒端板轴向作用力与各层钢丝绳圈张力之间关系的方程。应用Matlab编制多层缠绕系数和各层钢丝绳张力的求解软件分析多层缠绕系数的影响因素以及多层缠绕工况下各层钢丝绳张力大小。
4、根据双折线式卷筒多层缠绕系统的工作特征,研发了双折线式钢丝绳卷筒多层缠绕系统实际作业工况的模拟综合试验台。对双折线式卷筒进行应力测试,验证了双折线式卷筒多层缠绕系数的理论计算值与测试值的一致。同时理论分析与试验测试结果也表明,目前双折线式卷筒设计中普遍采用的当钢丝绳缠绕层数大于5时,多层缠绕系数统一选取2.5的设计原则需进行修正。
本文提出的双折线式卷筒多层缠绕系统的研究方法和取得的研究成果为多层缠绕复杂工况下双折线式卷筒的力学分析和卷筒筒体及端板的科学设计提供了理论支撑和计算分析方法。提出的复杂结构钢丝绳有限元分析方法,为数值模拟分析钢丝绳的损伤机理提供了新的思路。
With the rapid development of the marine engineering, port transportation, mining engineering and construction of hydropower stations, the demand of high-lifting hoisting machinery is increasing. It has been found that parallel grooved multi-layer winding system is the best way to solve the problem of high-lifting. In the present design criterion of multi-layer winding drum, multi-layer winding coefficient is chosen according to the number of wire rope layers. However, the actual wire rope arrangement on the drum and the elastic property of wire rope also play decisive roles in determining the multi-layer winding coefficient value. Analyzing the actual stress of the drum accurately is the precondition of ensuring the drums'safety and reliability for meeting the lightweight design requirements. In this dissertation, theory analysis method, finite element numerical simulation method and experimental investigation method are used to explore multi-layer winding coefficient, the pressure acting on the cylinder body and two end plates of parallel grooved drum, wire rope elastic property and the relation between multi-layer winding coefficient and wire rope elastic property according to the actual "pyramid" arrangement of wire rope on parallel grooved drum. The main content and creative aspects are depicted in the following four parts.
1. Based on the spacial transform of graphics, the general mathematical geometric models of different wire ropes with defined initial parameters are presented. The geometric model of a kind of complex structure wire rope is set up by using Matlab and Pro/E and Abaqus/Explicit to analyze the stress distribution and the elastic property of the complex structure wire rope under axial tension and lateral compression loads.
2. The parallel grooved drum's stress is analyzed by its being divided into two parts. One part is rotational symmetric shell; the other is rotational symmetric plate. On the basis of the theory of plates and shells, the deformation differential equations of the cylinder body and end plate of parallel grooved drum are deduced and integration constants of the differential equations are obtained under different boundary conditions.
3. Through analyzing the mechanism of inner layer wire rope tension attenuation due to the outer layer wire rope winding, the multi-layer winding coefficient equation is established. Matlab is employed to solve the equation and analyze the residual tension of each layer wire rope. The equation of the relation between the tension of each layer wire rope and the pressure exerting on the end plate is also deduced.
4. The experimental rig which can simulate the real operation condition of parallel grooved multi-layer winding system is designed and manufactured. Strain-electricity method is applied to test the stress of the cylinder body and the end plates of the drum on the rig. It is found that the multi-layer winding coefficient obtained by the stress test is in general agreement with that obtained by theoretical calculation. Theoretical analysis and experimental tests suggest that the traditional design method, which set the multi-layer winding coefficient as2.5when the winding layer is more than5, is inaccurate.
The results and creative points obtained in this dissertation solved the problems of stress analysis of parallel grooved drums under multi-layer winding and provided a system design theory and calculation methods for designing the accurate thickness with the lightweight design requirements. Finite element analysis method of complex structure wire rope also laid a foundation for studying the mechanism of wire rope damage by numerical simulation analysis method.
1、运用空间变换方法建立了不同捻向、不同旋向和不同结构钢丝绳各层钢丝空间曲线的普适参量方程,提出了用Matlab与Pro/E软件建立复杂结构钢丝绳空间几何模型的新方法。应用Abaqus软件建立了复杂结构钢丝绳的有限元分析模型,使用显式动力学法对轴向拉伸与横向压缩载荷作用下钢丝绳应力分布和钢丝绳的弹性特性值进行计算分析。
2、以现代板壳理论为基础,将双折线式多层缠绕钢丝绳卷筒筒体视为均匀受压的旋转对称壳体,将端板视为受层状分布线载荷作用的旋转对称圆板,建立双折线式卷筒筒体及端板变形的数学方程,通过分析不同边界条件,确定方程中的积分常数。
3、通过分析多层缠绕时由于外层钢丝绳的缠绕导致内层钢丝绳张力的衰减机理,建立求解各层钢丝绳由于外层钢丝绳缠绕而引起的张力衰减值方程和多层缠绕系数方程。以底层上爬理论为基础,建立多层缠绕钢丝绳各个绳圈对双折线式卷筒端板轴向作用力与各层钢丝绳圈张力之间关系的方程。应用Matlab编制多层缠绕系数和各层钢丝绳张力的求解软件分析多层缠绕系数的影响因素以及多层缠绕工况下各层钢丝绳张力大小。
4、根据双折线式卷筒多层缠绕系统的工作特征,研发了双折线式钢丝绳卷筒多层缠绕系统实际作业工况的模拟综合试验台。对双折线式卷筒进行应力测试,验证了双折线式卷筒多层缠绕系数的理论计算值与测试值的一致。同时理论分析与试验测试结果也表明,目前双折线式卷筒设计中普遍采用的当钢丝绳缠绕层数大于5时,多层缠绕系数统一选取2.5的设计原则需进行修正。
本文提出的双折线式卷筒多层缠绕系统的研究方法和取得的研究成果为多层缠绕复杂工况下双折线式卷筒的力学分析和卷筒筒体及端板的科学设计提供了理论支撑和计算分析方法。提出的复杂结构钢丝绳有限元分析方法,为数值模拟分析钢丝绳的损伤机理提供了新的思路。
With the rapid development of the marine engineering, port transportation, mining engineering and construction of hydropower stations, the demand of high-lifting hoisting machinery is increasing. It has been found that parallel grooved multi-layer winding system is the best way to solve the problem of high-lifting. In the present design criterion of multi-layer winding drum, multi-layer winding coefficient is chosen according to the number of wire rope layers. However, the actual wire rope arrangement on the drum and the elastic property of wire rope also play decisive roles in determining the multi-layer winding coefficient value. Analyzing the actual stress of the drum accurately is the precondition of ensuring the drums'safety and reliability for meeting the lightweight design requirements. In this dissertation, theory analysis method, finite element numerical simulation method and experimental investigation method are used to explore multi-layer winding coefficient, the pressure acting on the cylinder body and two end plates of parallel grooved drum, wire rope elastic property and the relation between multi-layer winding coefficient and wire rope elastic property according to the actual "pyramid" arrangement of wire rope on parallel grooved drum. The main content and creative aspects are depicted in the following four parts.
1. Based on the spacial transform of graphics, the general mathematical geometric models of different wire ropes with defined initial parameters are presented. The geometric model of a kind of complex structure wire rope is set up by using Matlab and Pro/E and Abaqus/Explicit to analyze the stress distribution and the elastic property of the complex structure wire rope under axial tension and lateral compression loads.
2. The parallel grooved drum's stress is analyzed by its being divided into two parts. One part is rotational symmetric shell; the other is rotational symmetric plate. On the basis of the theory of plates and shells, the deformation differential equations of the cylinder body and end plate of parallel grooved drum are deduced and integration constants of the differential equations are obtained under different boundary conditions.
3. Through analyzing the mechanism of inner layer wire rope tension attenuation due to the outer layer wire rope winding, the multi-layer winding coefficient equation is established. Matlab is employed to solve the equation and analyze the residual tension of each layer wire rope. The equation of the relation between the tension of each layer wire rope and the pressure exerting on the end plate is also deduced.
4. The experimental rig which can simulate the real operation condition of parallel grooved multi-layer winding system is designed and manufactured. Strain-electricity method is applied to test the stress of the cylinder body and the end plates of the drum on the rig. It is found that the multi-layer winding coefficient obtained by the stress test is in general agreement with that obtained by theoretical calculation. Theoretical analysis and experimental tests suggest that the traditional design method, which set the multi-layer winding coefficient as2.5when the winding layer is more than5, is inaccurate.
The results and creative points obtained in this dissertation solved the problems of stress analysis of parallel grooved drums under multi-layer winding and provided a system design theory and calculation methods for designing the accurate thickness with the lightweight design requirements. Finite element analysis method of complex structure wire rope also laid a foundation for studying the mechanism of wire rope damage by numerical simulation analysis method.
引文
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