大吨位履带起重机液压系统的动态特性研究
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摘要
履带起重机是一种广泛应用于港口、水电、铁路及石油化工等大型工程项目中的移动式起重机械，当前，履带式起重机产品正在向大吨位的方向快速发展。由于大型履带起重机产品均为全液压型起重机，因此液压系统性能的好坏直接影响着履带起重机的整机性能。然而，大型履带起重机的液压系统及元件主要依赖于国外进口，核心技术仍需从国外引进，极大地制约了履带起重机行业的发展。因此，针对履带起重机开展液压系统的动态特性研究具有重要的理论意义和应用价值。
近年来，随着集成传感技术以及电液比例控制技术的不断发展、完善，液压系统已能够被成熟地应用在大型履带式起重机产品中。借助于以集成电路及微处理器为核心的集成电子控制技术，履带起重机产品已实现了多液压系统的集成控制，操作者通过控制手柄可对行走驱动、起升、回转乃至变幅系统等进行集成控制。为满足大吨位履带起重机产品追求高自动化程度、可实现精细化操作的发展需求，履带起重机产品对液压系统的动态特性提出了更高的要求，设计者必须使液压系统在响应速度、微动性、控制性能以及稳定性等方面均有着更出色的表现才能够满足产品市场的发展需求。
目前，国内的履带起重机研发机构对液压系统动态特性的研究远远落后于欧美国家。大部分企业在产品的开发过程中仍采用经验类比的方法，对液压系统动态特性研究工作的缺失，使其产品在稳定性、微动性、可控性等方面均与国外先进产品间存在显著差距。本论文结合校企合作“移动式起重机产品整机液压控制回路测试评估系统开发”项目，利用AMESim（Advanced Modeling Environment for Simulations ofengineering systems）软件平台开发出了履带起重机起升系统、行走驱动系统、回转系统等系统的HCD（Hydraulic Component Design）仿真模型，并基于HCD仿真模型对大吨位履带起重机中的典型液压系统的动态特性展开研究。本文研究所得相关结论，可为国内大吨位履带起重机液压系统的设计工作提供理论指导依据，同时也可缩短我国在起重机液压系统研究领域与国外先进技术水平间的差距。
本文针对大吨位履带起重机液压系统主要进行了以下研究工作：
1．详细分析国内外大型履带式起重机的发展现状；对大型履带式起重机起升、行走驱动以及回转液压系统分别进行了介绍；阐述目前液压系统仿真的国内外发展状况，确定使用的AMESim仿真软件；确定了本文主要研究内容。
2．以某大型履带起重机起升系统为研究对象，详细分析该起升系统的组成及工作原理，分别建立了液控先导式平衡阀与恒压变量马达的数学模型，并基于数学模型分析了影响系统性能的主要因素，分析指出减小平衡阀入口处阻尼孔的直径以及主阀芯的开口面积，恒压变量马达最小排量的设定值、恒压设定值以及相关容腔体积等因素均会对起升液压系统性能产生的影响；利用AMESim仿真平台开发了起升液压系统的HCD仿真模型，借助软件模态分析工具对系统在下落工况中易产生压力波动的原因进行了分析，分析指出平衡阀主阀芯面积梯度的变化易导致系统的稳定性变差，马达排量的突变以及恒压阀开启时所引起的流量突变等现象均易引起压力冲击现象；基于仿真平台，提出了改善起升液压系统稳定性的优化方案。
3．介绍了某型履带起重机负荷传感行走液压系统的组成，并对其工作原理进行了分析，推导出了负荷传感行走液压系统的传递函数，通过对传递函数的分析，指出了负载敏感泵输出功率的主要影响因素；开发了负荷传感行走液压系统的HCD仿真模型，并进行了仿真研究，指出负荷传感技术应用在行走液压系统中时易形成由于功率匹配不佳而引起的发动机熄火现象；基于仿真平台提出了改变负载敏感阀弹簧预紧力、在两个行走多路阀的负载反馈口间串联适当的阻尼、限制多路阀主阀芯位移等三种优化方案，并分别对负荷传感系统在应用以上优化方案后的功率自动调节特性进行了分析。
4．介绍了某型履带起重机回转液压系统的组成及其工作原理，并建立了其主要组成元件的数学模型；开发了开式回转液压系统的HCD仿真模型，重点研究了回转换向阀阀口形式、回转缓冲阀阀口形式、回转缓冲阀弹簧刚度以及溢流阀开启压力等因素对回转液压系统性能的影响。仿真分析表明：回转换向阀采用在初始阶段变化梯度较大的开口形式对削弱回转系统作业时的压力冲击以及改善调速性能均是有利的；在初始阶段具有较小变化梯度的缓冲阀开口形式对降低系统压力冲击是有利的；选择适当的缓冲阀弹簧刚度可以减缓系统启动和换向时的压力冲击，并能够缩短制动时间。
5．设计了某大型履带式起重机起升、行走驱动以及回转液压系统性能测试的实验方案，分析了关键液压元件的相关结构参数对系统性能的影响；验证了相关仿真分析结论的正确性以及所提出的系统性能优化方案的可行性。
Crawler Crane is a mobile crane which is widely applied in harbor, hydroelectricity,railway, petrochemical industry and other big projects. At present, it is developing towardslarge tonnage. Because all the large crawler cranes are fully hydraulic cranes, the reliabilityof crawler cranes, to a large degree, is ascribed to the stability of the hydraulic system. Thefact that the hydraulic system and its components are mainly imported from foreigncountries, as well as the core technology, impedes the development of crawler crane industry.Therefore, it is of a great theoretical and practical value to conduct researches on thedynamic characteristics of hydraulic system of crawler cranes.
In recent years, thanks to the development in integrated sensoring skills and skills ofcontrolling electro-hydraulic proportional system, electronic control skills of hydraulicsystem have been perfectly adopted in crawler cranes. Thanks to integrated electroniccontrol skills based on integrated circuit and micro-processor, crawler crane products haveachieved integrated control of multi-hydraulic system: by controlling handles, operators cancontrol travel drive, lifting, slewing and luffing systems. Since large-tonnage crawler cranesare expected to become highly automated and sophisticated, they pose a higher standard tothe dynamic characteristics of hydraulic system and designers have to improve hydraulicsystem in such aspects as feedback speed, inching, control and stability.
Currently, at home, research on the dynamic characteristics of hydraulic system haslagged behind European and American counterparts, and most of enterprises still useempirical and analogical methods in exploring products. Compared with advanced foreignproducts, ours need improving in such aspects as stablility, inching, controllability. Thisdissertation, funded by the project——“Development of Design and ManagementPlatform of Hydraulic system of Mobile Crane”, employs AMESim（Advanced ModelingEnvironment for Simulations of engineering systems）software to explore HCD（Hydraulic Component Design）model of hydraulic lifting, travel, slewing systems and does a HDCModel-based research on the typical dynamic characteristics of hydraulic system oflarge-tonnage crawler crane. This dissertation is designed to provide theoretical guidance fordomestic designs of hydraulic system of large-tonnage crawler crane, and meanwhile tonarrow the gap at home and abroad.
The content of this dissertation is as follows:
1. It reviews development of large crawler cranes at home and abroad； It introduceslifting, travel drive and slewing hydraulic systems of large crawler crane respectively；illustrates in details the development of simulation at home and abroad and adopts AMEsimsimulation software.
2. It elaborates the composition and the working theory of lifting system of certain largecrawler crane； It establishes dynamic models of pilot-operated counterbalance valve andvariable displacement motor, and points out the following factors can influence the stabilityof the system: the decrease of the diameter of inlet damping and flow area, the minimumdisplacement, the volume and so on. It employs AMESim simulation platform to deign HCDmodel of hydraulic lifting system； and throug modality analysis, it elaborates the reasons ofpressure fluctuation in falling working state；it points out that changes of several factors caneasily affect system stability: flow area form of counterbalance valve, the motordisplacement, the dynamic characteristics of counterbalance valve and cutoff valve； basedon simulation, it proposes several optimization schemes to improve the stability.
3. The thesis introduces the composition and working theory of load sensor travelhydraulic system.； it deduces transfer function of load sensor system； and accordinglypoints out major factors to influence output power of load sensing pump； it explores HCDmodel of hydraulic traveling system； makes dynamic simulation analysis； points out thefact that load sensory skills, when used in hydraulic traveling system, usually result inengine failure because of power mismatch； it, based on simulation platform, proposes threeoptimization schemes: to change load sensing valve spring stiffness, to connect damping inseries between two travel multi-way valves’ load feedback interface, to limit multi-way valve flow shifting.
4. The thesis introduces the composition and working theory of slewing system, andestablishes mathematical model of main components； It explores HCD simulation model ofhydraulic open slewing system； conducts a detailed study on how dynamic characteristicsof hydraulic slewing system are influenced by such factors as reversing valve form, springstiffness of slewing cushion valve, pressure relief pressure and etc. The findings ofsimulation analysis cover the following aspects: reversing valve, used in the flow area formwith bigger gradient in initial stage, contributes to relieve pressure fluctuation and bettercontrol speed； cushioning valve flow area form, with smaller gradient, helps to lessensystem pressure； proper cushioning spring stiffness can lessen pressure fluctuation ofsystem startup and direction-change and decreases braking time.
5. It designs pilot schemes to test dynamic characteristics of hydraulic lifting, travel,slewing systems of large crawler crane； analyses how the system is influenced by thestructural parameter of key hydraulic components； and proves the validity of simulationanalysis and the feasibility of optimization schemes proposed by this dissertation.
近年来，随着集成传感技术以及电液比例控制技术的不断发展、完善，液压系统已能够被成熟地应用在大型履带式起重机产品中。借助于以集成电路及微处理器为核心的集成电子控制技术，履带起重机产品已实现了多液压系统的集成控制，操作者通过控制手柄可对行走驱动、起升、回转乃至变幅系统等进行集成控制。为满足大吨位履带起重机产品追求高自动化程度、可实现精细化操作的发展需求，履带起重机产品对液压系统的动态特性提出了更高的要求，设计者必须使液压系统在响应速度、微动性、控制性能以及稳定性等方面均有着更出色的表现才能够满足产品市场的发展需求。
目前，国内的履带起重机研发机构对液压系统动态特性的研究远远落后于欧美国家。大部分企业在产品的开发过程中仍采用经验类比的方法，对液压系统动态特性研究工作的缺失，使其产品在稳定性、微动性、可控性等方面均与国外先进产品间存在显著差距。本论文结合校企合作“移动式起重机产品整机液压控制回路测试评估系统开发”项目，利用AMESim（Advanced Modeling Environment for Simulations ofengineering systems）软件平台开发出了履带起重机起升系统、行走驱动系统、回转系统等系统的HCD（Hydraulic Component Design）仿真模型，并基于HCD仿真模型对大吨位履带起重机中的典型液压系统的动态特性展开研究。本文研究所得相关结论，可为国内大吨位履带起重机液压系统的设计工作提供理论指导依据，同时也可缩短我国在起重机液压系统研究领域与国外先进技术水平间的差距。
本文针对大吨位履带起重机液压系统主要进行了以下研究工作：
1．详细分析国内外大型履带式起重机的发展现状；对大型履带式起重机起升、行走驱动以及回转液压系统分别进行了介绍；阐述目前液压系统仿真的国内外发展状况，确定使用的AMESim仿真软件；确定了本文主要研究内容。
2．以某大型履带起重机起升系统为研究对象，详细分析该起升系统的组成及工作原理，分别建立了液控先导式平衡阀与恒压变量马达的数学模型，并基于数学模型分析了影响系统性能的主要因素，分析指出减小平衡阀入口处阻尼孔的直径以及主阀芯的开口面积，恒压变量马达最小排量的设定值、恒压设定值以及相关容腔体积等因素均会对起升液压系统性能产生的影响；利用AMESim仿真平台开发了起升液压系统的HCD仿真模型，借助软件模态分析工具对系统在下落工况中易产生压力波动的原因进行了分析，分析指出平衡阀主阀芯面积梯度的变化易导致系统的稳定性变差，马达排量的突变以及恒压阀开启时所引起的流量突变等现象均易引起压力冲击现象；基于仿真平台，提出了改善起升液压系统稳定性的优化方案。
3．介绍了某型履带起重机负荷传感行走液压系统的组成，并对其工作原理进行了分析，推导出了负荷传感行走液压系统的传递函数，通过对传递函数的分析，指出了负载敏感泵输出功率的主要影响因素；开发了负荷传感行走液压系统的HCD仿真模型，并进行了仿真研究，指出负荷传感技术应用在行走液压系统中时易形成由于功率匹配不佳而引起的发动机熄火现象；基于仿真平台提出了改变负载敏感阀弹簧预紧力、在两个行走多路阀的负载反馈口间串联适当的阻尼、限制多路阀主阀芯位移等三种优化方案，并分别对负荷传感系统在应用以上优化方案后的功率自动调节特性进行了分析。
4．介绍了某型履带起重机回转液压系统的组成及其工作原理，并建立了其主要组成元件的数学模型；开发了开式回转液压系统的HCD仿真模型，重点研究了回转换向阀阀口形式、回转缓冲阀阀口形式、回转缓冲阀弹簧刚度以及溢流阀开启压力等因素对回转液压系统性能的影响。仿真分析表明：回转换向阀采用在初始阶段变化梯度较大的开口形式对削弱回转系统作业时的压力冲击以及改善调速性能均是有利的；在初始阶段具有较小变化梯度的缓冲阀开口形式对降低系统压力冲击是有利的；选择适当的缓冲阀弹簧刚度可以减缓系统启动和换向时的压力冲击，并能够缩短制动时间。
5．设计了某大型履带式起重机起升、行走驱动以及回转液压系统性能测试的实验方案，分析了关键液压元件的相关结构参数对系统性能的影响；验证了相关仿真分析结论的正确性以及所提出的系统性能优化方案的可行性。
Crawler Crane is a mobile crane which is widely applied in harbor, hydroelectricity,railway, petrochemical industry and other big projects. At present, it is developing towardslarge tonnage. Because all the large crawler cranes are fully hydraulic cranes, the reliabilityof crawler cranes, to a large degree, is ascribed to the stability of the hydraulic system. Thefact that the hydraulic system and its components are mainly imported from foreigncountries, as well as the core technology, impedes the development of crawler crane industry.Therefore, it is of a great theoretical and practical value to conduct researches on thedynamic characteristics of hydraulic system of crawler cranes.
In recent years, thanks to the development in integrated sensoring skills and skills ofcontrolling electro-hydraulic proportional system, electronic control skills of hydraulicsystem have been perfectly adopted in crawler cranes. Thanks to integrated electroniccontrol skills based on integrated circuit and micro-processor, crawler crane products haveachieved integrated control of multi-hydraulic system: by controlling handles, operators cancontrol travel drive, lifting, slewing and luffing systems. Since large-tonnage crawler cranesare expected to become highly automated and sophisticated, they pose a higher standard tothe dynamic characteristics of hydraulic system and designers have to improve hydraulicsystem in such aspects as feedback speed, inching, control and stability.
Currently, at home, research on the dynamic characteristics of hydraulic system haslagged behind European and American counterparts, and most of enterprises still useempirical and analogical methods in exploring products. Compared with advanced foreignproducts, ours need improving in such aspects as stablility, inching, controllability. Thisdissertation, funded by the project——“Development of Design and ManagementPlatform of Hydraulic system of Mobile Crane”, employs AMESim（Advanced ModelingEnvironment for Simulations of engineering systems）software to explore HCD（Hydraulic Component Design）model of hydraulic lifting, travel, slewing systems and does a HDCModel-based research on the typical dynamic characteristics of hydraulic system oflarge-tonnage crawler crane. This dissertation is designed to provide theoretical guidance fordomestic designs of hydraulic system of large-tonnage crawler crane, and meanwhile tonarrow the gap at home and abroad.
The content of this dissertation is as follows:
1. It reviews development of large crawler cranes at home and abroad； It introduceslifting, travel drive and slewing hydraulic systems of large crawler crane respectively；illustrates in details the development of simulation at home and abroad and adopts AMEsimsimulation software.
2. It elaborates the composition and the working theory of lifting system of certain largecrawler crane； It establishes dynamic models of pilot-operated counterbalance valve andvariable displacement motor, and points out the following factors can influence the stabilityof the system: the decrease of the diameter of inlet damping and flow area, the minimumdisplacement, the volume and so on. It employs AMESim simulation platform to deign HCDmodel of hydraulic lifting system； and throug modality analysis, it elaborates the reasons ofpressure fluctuation in falling working state；it points out that changes of several factors caneasily affect system stability: flow area form of counterbalance valve, the motordisplacement, the dynamic characteristics of counterbalance valve and cutoff valve； basedon simulation, it proposes several optimization schemes to improve the stability.
3. The thesis introduces the composition and working theory of load sensor travelhydraulic system.； it deduces transfer function of load sensor system； and accordinglypoints out major factors to influence output power of load sensing pump； it explores HCDmodel of hydraulic traveling system； makes dynamic simulation analysis； points out thefact that load sensory skills, when used in hydraulic traveling system, usually result inengine failure because of power mismatch； it, based on simulation platform, proposes threeoptimization schemes: to change load sensing valve spring stiffness, to connect damping inseries between two travel multi-way valves’ load feedback interface, to limit multi-way valve flow shifting.
4. The thesis introduces the composition and working theory of slewing system, andestablishes mathematical model of main components； It explores HCD simulation model ofhydraulic open slewing system； conducts a detailed study on how dynamic characteristicsof hydraulic slewing system are influenced by such factors as reversing valve form, springstiffness of slewing cushion valve, pressure relief pressure and etc. The findings ofsimulation analysis cover the following aspects: reversing valve, used in the flow area formwith bigger gradient in initial stage, contributes to relieve pressure fluctuation and bettercontrol speed； cushioning valve flow area form, with smaller gradient, helps to lessensystem pressure； proper cushioning spring stiffness can lessen pressure fluctuation ofsystem startup and direction-change and decreases braking time.
5. It designs pilot schemes to test dynamic characteristics of hydraulic lifting, travel,slewing systems of large crawler crane； analyses how the system is influenced by thestructural parameter of key hydraulic components； and proves the validity of simulationanalysis and the feasibility of optimization schemes proposed by this dissertation.
引文
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