盾构机冗余驱动回转系统动态特性研究
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摘要
盾构机是一种隧道掘进的专用工程机械,它广泛地应用于城市地铁、公路隧道等隧道工程之中。国产盾构机于地下施工作业时,其回转系统常常发生刀盘堵转,极端情况下甚至出现电机传动轴断裂等重大事故,导致无法连续施工作业,造成巨大的经济损失。作为直接承担掘进负载的盾构机回转系统,出于大功率大扭矩的需要,一般采用多电机冗余驱动,与此对应采用多点啮合齿轮传动。冗余驱动和多点啮合传动动力传递过程复杂,其动态特性和一般静定机械系统有所不同,面临的新问题是驱动、传动系统的均载性和整个回转系统的稳定性。盾构机冗余驱动回转系统极易发生驱动负荷分配不均和载荷积聚,导致个别传动小齿轮轮齿断裂、驱动电机断轴等重大事故。国产盾构机在设计时大多直接借鉴发达国家的成熟型号,缺乏对盾构机冗余驱动回转系统动态特性的深入理论研究。因此,进行盾构机冗余驱动回转系统动态特性的研究,对于提高其均载性与稳定性,降低载荷分配不均,防止断轴等事故的发生,保证盾构机的正常施工作业具有重要意义。
本文以盾构机冗余驱动回转系统为研究对象,针对其冗余驱动与多点啮合传动特点,提出多点啮合传动动力稳定性判据,基于此建立冗余驱动回转系统均载性判别方法,阐明盾构机冗余驱动回转系统偏载断轴的发生机理。论文首先建立了考虑掘进过程诸多因素的盾构机掘进动力学模型;针对多点啮合齿轮传动,基于Floquet-Lyapunov理论,提出了其动力稳定性判据;在此基础上,进一步提出了冗余驱动回转系统的均载性判别方法;应用上述理论成果,对某型盾构机回转系统复合地层下掘进的动态特性进行仿真与评价,提出参数改进设计方案;研制盾构机回转系统模拟掘进实验台,进行载荷模拟实验加以验证。论文内容包括以下几个部分:
(1)盾构机掘进动力学模型的研究
基于盾构机掘进过程中的受载分析,建立较为完整考虑冗余驱动回转系统、液压推进系统、盾体、地质条件等诸多要素相互作用的盾构机掘进动力学模型。该模型引入多电机矢量控制变频调速驱动、多点啮合齿轮传动、动态变化掘进负载等影响冗余驱动回转系统动力传递的关键因素,为分析盾构机冗余驱动回转系统的动态特性提供前提条件。
(2)多点啮合齿轮传动动力稳定性判据的研究
针对齿轮时变啮合刚度引起的参数振动动力稳定性问题,基于Floquet-Lyapunov理论,提出多点啮合齿轮传动动力稳定性判据。经由计算系统状态方程的最大Floquet乘子,判断其与单位圆关系,判别多点啮合传动动力稳定性,为降低盾构机冗余驱动回转系统动力不稳定性进行了参数研究。
(3)冗余驱动回转系统均载性分析方法的研究
在冗余驱动回转系统稳定性判据的基础上,针对齿轮啮合扭转与支承弹性变形耦合引起的负荷分配不均的问题,基于Floquet-Lyapunov理论,提出了冗余驱动回转系统均载因子,进行系统均载性分析,为预测评价盾构机冗余驱动回转系统均载性提供了理论依据。
(4)盾构机回转系统复合地层掘进动态特性的研究
针对某型盾构机回转系统,对其在复合地层中掘进的动态性能进行仿真,基于其在复杂掘进负载下响应特性与动态均载特性,提出参数改进与结构优化建议。结果表明,采用驱动周向均匀布置方式,用柔性支承取代传统传动小齿轮支承,将传动小齿轮与驱动偏离特定位置,减小盾体前盾长度与盾体总长度之比等措施,可以有效地提高盾构机冗余驱动回转系统均载性,避免动态掘进负载引起的偏载断轴事故发生。
(5)盾构机回转系统掘进模拟实验的研究
以研究盾构机回转系统动态特性为目标,按照相似性理论建立盾构机掘进模拟实验台,验证回转系统结构参数与载荷性质对系统动态均载性的影响。结果表明,轴向与弯矩负载作用下,回转系统各驱动电机间易产生偏载,且负荷分配与传动小齿轮安装布置位置有关;将传动小齿轮与驱动电机布置偏离特定位置能大幅度改善驱动偏载现象,实验结果与理论分析较为吻合。
论文提出了多点啮合传动动力稳定性判据,基于此建立了冗余驱动回转系统均载性分析方法。应用理论成果对某型盾构机回转系统进行了其均载性预测评价,提出了相应的参数改进方案,可以有效改善回转系统在复杂掘进负载下的动态特性,提高其动态均载性能,避免断轴等事故的发生,保证盾构机连续掘进作业。
Shield TBM is a kind of special engineering machine for tunnel excavation, which is widely applied in tunnel constructions such as metro subways and road tunnels. When a domestic-made shield TBM was conducting underground constructions, cutterhead stalls even failures of drive shaft frequently took place in its revolving system. That would lead to the stoppages of the machine and induce great loss. The revolving system of a shield TBM bears the excavation load directly, and so it is usually redundantly driven by multiple motors due to the need of large power and torques, which means the multi-point gear meshing is also employed. The power transmission process of redundant drive and multi-point gear meshing is complex and their dynamic characteristics are different from that of common statically determinated mechanical systems. New problems of the load sharing performance of the drive and transmission system as well as the stability of the revolving system arise. Unevenly load distribution is very inclined to happen in the redundantly driven revolving system of shield TBM, which often leads to catastrophic failures such as some transmission gears broken and even drive shaft failures. Due to the lack of complete and systematic design theories for shield TBMs, most domestic-made ones were still made by directly borrowing ideas from mature designs of foreign ones. Therefore, to study the dynamic characteristics of the revolving system of shield TBM will have great importance on improving its load sharing performance and stability, decreasing unevenly load distribution, preventing shaft failure and ensuring the normal work of shield TBM.
This text focuses on the redundantly driven revolving system of shield TBM, aiming at the redundant driven and multi-point gear meshing, investigates the reason of drive shaft failure in virtue of studying the load sharing performance under complicated excavation loads. The study starts from the bending-torsional coupled vibration, and then puts forwards the determination theory of stability of redundantly driven revolving system. Based on that, the analysis method of load sharing performance of the system is established and the mechanism of shaft failure is studied. The dynamic model of the shield TBM, considering all the factors during excavation, is established, firstly. Based on the Floquet-Lyapunov theory, the analysis methods of the dynamic stability and load-sharing performance by calculating the Floquet multiplier and the load sharing factor are proposed. The dynamic characteristics of a typical shield TBM under complex excavation loads are investigated and evaluated. The test rig of the shield TBM revolving system is then built to verify the method. The main contents are listed as follows:
(1) Comprehensive dynamic model of shield TBM tunneling
Through load analysis during excavation, the theoretical dynamic model of the shield TBM has been established, considering the interactions between the redundantly driven revolving system, the hydraulic propulsion system, the shield body and the geologic conditions. Multiple vector-controlled variable frequency electric motors, multi-point gear meshing, dynamic excavation loads are taken into consideration.
(2) Dynamic stability conditions of the multi-point gear meshing
The parameter vibration problem due to the time-varying mesh stiffness in the multi-point gear meshing process is analyzed. In virtue of Floquet-Lyapunov theory, the analysis method of dynamic stability of shield TBM revolving system is studied and key parameters’influence on the instability conditions have been deeply investigated.
(3) Load sharing performance of the redundantly driven revolving system
The load sharing performance of the redundantly driven revolving system is studied. Based on the Floquet-Lyapunov theory, the analysis method for load-sharing performance of the redundantly driven revolving system of the shield TBM has been proposed. By calculating the load sharing factor, parameters’influences on the load sharing performance have been studied.
(4) Dynamic characteristics of shield TBM revolving system in mixed-face conditions
The dynamic behavior of a typical shield TBM revolving system has been simulated and evaluated. The results show that, while adjusting the cutterhead reference speed in time could effectively reduce the torque loads and overcome the adverse excavation environments. Reasonable distribution of the pinion gears and drive motors could improve the load sharing performance of the revolving system, and therefore the failure of drive shaft could be avoided.
(5) Simulation test of reduandantly driven revolving system of shield TBM
In virtue of similarity theory, the test rig for shield TBM redundant driven revolving system has been set up. Through applying the torque and bending moment loads by load simulating set and measuring the output torque and speed of each driving motor, the influence of key structural parameters on load distribution of driving pinions have been verified. The results show that, under the axial force load and bending moment load, the torque load on each driving motor would be unevenly distributed; by arranging the driving pinions and motors at proper positions could effectively improve the load-sharing performance.
Based on the analysis method of dynamic stability and load sharing performance for redundantly driven revolving system established in this text, parameter design and optimization could be carried out on the redundantly driven revolving system of shield TBM. By means of that, the dynamic characteristics would get improved, the shaft failure accident would be prevented and continuous operation of the shield TBM could be realized.
本文以盾构机冗余驱动回转系统为研究对象,针对其冗余驱动与多点啮合传动特点,提出多点啮合传动动力稳定性判据,基于此建立冗余驱动回转系统均载性判别方法,阐明盾构机冗余驱动回转系统偏载断轴的发生机理。论文首先建立了考虑掘进过程诸多因素的盾构机掘进动力学模型;针对多点啮合齿轮传动,基于Floquet-Lyapunov理论,提出了其动力稳定性判据;在此基础上,进一步提出了冗余驱动回转系统的均载性判别方法;应用上述理论成果,对某型盾构机回转系统复合地层下掘进的动态特性进行仿真与评价,提出参数改进设计方案;研制盾构机回转系统模拟掘进实验台,进行载荷模拟实验加以验证。论文内容包括以下几个部分:
(1)盾构机掘进动力学模型的研究
基于盾构机掘进过程中的受载分析,建立较为完整考虑冗余驱动回转系统、液压推进系统、盾体、地质条件等诸多要素相互作用的盾构机掘进动力学模型。该模型引入多电机矢量控制变频调速驱动、多点啮合齿轮传动、动态变化掘进负载等影响冗余驱动回转系统动力传递的关键因素,为分析盾构机冗余驱动回转系统的动态特性提供前提条件。
(2)多点啮合齿轮传动动力稳定性判据的研究
针对齿轮时变啮合刚度引起的参数振动动力稳定性问题,基于Floquet-Lyapunov理论,提出多点啮合齿轮传动动力稳定性判据。经由计算系统状态方程的最大Floquet乘子,判断其与单位圆关系,判别多点啮合传动动力稳定性,为降低盾构机冗余驱动回转系统动力不稳定性进行了参数研究。
(3)冗余驱动回转系统均载性分析方法的研究
在冗余驱动回转系统稳定性判据的基础上,针对齿轮啮合扭转与支承弹性变形耦合引起的负荷分配不均的问题,基于Floquet-Lyapunov理论,提出了冗余驱动回转系统均载因子,进行系统均载性分析,为预测评价盾构机冗余驱动回转系统均载性提供了理论依据。
(4)盾构机回转系统复合地层掘进动态特性的研究
针对某型盾构机回转系统,对其在复合地层中掘进的动态性能进行仿真,基于其在复杂掘进负载下响应特性与动态均载特性,提出参数改进与结构优化建议。结果表明,采用驱动周向均匀布置方式,用柔性支承取代传统传动小齿轮支承,将传动小齿轮与驱动偏离特定位置,减小盾体前盾长度与盾体总长度之比等措施,可以有效地提高盾构机冗余驱动回转系统均载性,避免动态掘进负载引起的偏载断轴事故发生。
(5)盾构机回转系统掘进模拟实验的研究
以研究盾构机回转系统动态特性为目标,按照相似性理论建立盾构机掘进模拟实验台,验证回转系统结构参数与载荷性质对系统动态均载性的影响。结果表明,轴向与弯矩负载作用下,回转系统各驱动电机间易产生偏载,且负荷分配与传动小齿轮安装布置位置有关;将传动小齿轮与驱动电机布置偏离特定位置能大幅度改善驱动偏载现象,实验结果与理论分析较为吻合。
论文提出了多点啮合传动动力稳定性判据,基于此建立了冗余驱动回转系统均载性分析方法。应用理论成果对某型盾构机回转系统进行了其均载性预测评价,提出了相应的参数改进方案,可以有效改善回转系统在复杂掘进负载下的动态特性,提高其动态均载性能,避免断轴等事故的发生,保证盾构机连续掘进作业。
Shield TBM is a kind of special engineering machine for tunnel excavation, which is widely applied in tunnel constructions such as metro subways and road tunnels. When a domestic-made shield TBM was conducting underground constructions, cutterhead stalls even failures of drive shaft frequently took place in its revolving system. That would lead to the stoppages of the machine and induce great loss. The revolving system of a shield TBM bears the excavation load directly, and so it is usually redundantly driven by multiple motors due to the need of large power and torques, which means the multi-point gear meshing is also employed. The power transmission process of redundant drive and multi-point gear meshing is complex and their dynamic characteristics are different from that of common statically determinated mechanical systems. New problems of the load sharing performance of the drive and transmission system as well as the stability of the revolving system arise. Unevenly load distribution is very inclined to happen in the redundantly driven revolving system of shield TBM, which often leads to catastrophic failures such as some transmission gears broken and even drive shaft failures. Due to the lack of complete and systematic design theories for shield TBMs, most domestic-made ones were still made by directly borrowing ideas from mature designs of foreign ones. Therefore, to study the dynamic characteristics of the revolving system of shield TBM will have great importance on improving its load sharing performance and stability, decreasing unevenly load distribution, preventing shaft failure and ensuring the normal work of shield TBM.
This text focuses on the redundantly driven revolving system of shield TBM, aiming at the redundant driven and multi-point gear meshing, investigates the reason of drive shaft failure in virtue of studying the load sharing performance under complicated excavation loads. The study starts from the bending-torsional coupled vibration, and then puts forwards the determination theory of stability of redundantly driven revolving system. Based on that, the analysis method of load sharing performance of the system is established and the mechanism of shaft failure is studied. The dynamic model of the shield TBM, considering all the factors during excavation, is established, firstly. Based on the Floquet-Lyapunov theory, the analysis methods of the dynamic stability and load-sharing performance by calculating the Floquet multiplier and the load sharing factor are proposed. The dynamic characteristics of a typical shield TBM under complex excavation loads are investigated and evaluated. The test rig of the shield TBM revolving system is then built to verify the method. The main contents are listed as follows:
(1) Comprehensive dynamic model of shield TBM tunneling
Through load analysis during excavation, the theoretical dynamic model of the shield TBM has been established, considering the interactions between the redundantly driven revolving system, the hydraulic propulsion system, the shield body and the geologic conditions. Multiple vector-controlled variable frequency electric motors, multi-point gear meshing, dynamic excavation loads are taken into consideration.
(2) Dynamic stability conditions of the multi-point gear meshing
The parameter vibration problem due to the time-varying mesh stiffness in the multi-point gear meshing process is analyzed. In virtue of Floquet-Lyapunov theory, the analysis method of dynamic stability of shield TBM revolving system is studied and key parameters’influence on the instability conditions have been deeply investigated.
(3) Load sharing performance of the redundantly driven revolving system
The load sharing performance of the redundantly driven revolving system is studied. Based on the Floquet-Lyapunov theory, the analysis method for load-sharing performance of the redundantly driven revolving system of the shield TBM has been proposed. By calculating the load sharing factor, parameters’influences on the load sharing performance have been studied.
(4) Dynamic characteristics of shield TBM revolving system in mixed-face conditions
The dynamic behavior of a typical shield TBM revolving system has been simulated and evaluated. The results show that, while adjusting the cutterhead reference speed in time could effectively reduce the torque loads and overcome the adverse excavation environments. Reasonable distribution of the pinion gears and drive motors could improve the load sharing performance of the revolving system, and therefore the failure of drive shaft could be avoided.
(5) Simulation test of reduandantly driven revolving system of shield TBM
In virtue of similarity theory, the test rig for shield TBM redundant driven revolving system has been set up. Through applying the torque and bending moment loads by load simulating set and measuring the output torque and speed of each driving motor, the influence of key structural parameters on load distribution of driving pinions have been verified. The results show that, under the axial force load and bending moment load, the torque load on each driving motor would be unevenly distributed; by arranging the driving pinions and motors at proper positions could effectively improve the load-sharing performance.
Based on the analysis method of dynamic stability and load sharing performance for redundantly driven revolving system established in this text, parameter design and optimization could be carried out on the redundantly driven revolving system of shield TBM. By means of that, the dynamic characteristics would get improved, the shaft failure accident would be prevented and continuous operation of the shield TBM could be realized.
引文
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