圆锥破碎机腔型的优化设计研究
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摘要
圆锥破碎机是散体物料破碎的主要设备,广泛应用在冶金矿山工业中。然而,国产圆锥破碎机自从20世纪中期仿制成功以来,未得到大的发展,其技术水平基本停留在国外的第一代和第二代水平上。而且,国产圆锥破碎机普遍存在着设计比较保守、机器笨重、效率比较低下、能耗高和破碎产品质量不高等缺点。
围绕着为改善国产圆锥破碎机工作性能的目标,论文将研究课题定位于圆锥破碎机腔型结构的优化设计研究。基于查默斯理工大学学者Evertsson对圆锥破碎机的一些基础研究成果,论文从破碎机工作机理和工作性能的不同角度展开,在层压破碎理论、圆锥破碎机生产能力Q的计算模型、层压腔型模型、腔型设计方法、破碎产品粒度分布模型和腔型多目标优化模型等方面做了如下工作：
(1)分析了国内外圆锥破碎机腔型研究的现状,探讨了圆锥破碎机腔型结构优化设计与改善圆锥破碎机工作性能的意义。
(2)对圆锥破碎机破碎腔内散体物料的运动特性进行了深入研究,探讨了三种不同形式的粒子流动状态,即滑动、自由落体、滑动与自由落体共存状态。分析了破碎腔内散体物料运动状态对破碎机工作性能的影响,建立了圆锥破碎机破碎腔内散体物料运动轨迹模型,提出了圆锥破碎机分层破碎特性,为破碎腔进行分层研究和设计奠定基础。
(3)论文在分析了破碎机腔型对岩石产品粒度分布情况的影响之后,建立了基于总体平衡模型的破碎产品粒度分布的计算模型；充分考虑了在水平截面上沿圆周方向体积填充率μi(α)对圆锥破碎机生产能力Q的影响,提出了圆锥破碎机生产能力Q计算的新公式。
(4)为研制开发高效层压圆锥破碎机,基于圆锥破碎机工作机理和工作性能的研究,建立了圆锥破碎机生产能力Q、破碎产品粒度和腔型结构的多目标优化模型。结合PYB1200弹簧圆锥破碎机腔型结构的多目标优化问题,对破碎机腔型多目标优化模型的求解方法进行了深入研究,采用随机方向搜索算法编制MATLAB程序对多目标优化模型进行求解,绘制出优化后的破碎腔型结构。
(5)为进一步完善圆锥破碎机工作机理和工作性能的研究,论文在展望中分析了研究存在的不足之处,提出了进一步研究的目标、方法和内容。
论文中的研究成果可以为研制开发具有完全自主知识产权的新型、高效、节能和环保的现代高性能圆锥破碎机奠定理论基础,相关的优化程序可以为腔型的商业化软件开发提供借鉴。
Cone crusher is the main equipment of rock material crushing and it is widely used in metallurgical and mining industry. However,home cone crusher have not been developed since they were imitated successfully, and those technology levels basically rested on the first and second generation of foreign advanced product. Furthermore, domestic cone crusher is designing conservatively, manipulating inconveniently and heavy,low efficiency,power wasting and poor product quality.
Encircling in order to improve working performance of the cone crusher, this paper will be positioned to study chamber optimal design of the cone crusher.Based on research basic results of Evertsson who is a scholar of Chalmers University of Technology, the paper was expanded from various eyes of crusher working mechanism and working performance, and several researchs were finished, including crushing mechanism, crusher capacity model, chamber design model, crushing product grain size distribution model and multi-objective optimization model and so on. The paper mainly included these research contents as follows:
(1)The significance of chamber optimization design and improvement working performance of cone crushers was discussed in this paper after analysing home and overseas situations of study on cone crusher.
(2)Kinetic characteristic of spreading and granular materials in crushing chamber was deeper studied and three different forms of particles flowing state,that is sliding, free-falling, sliding and free-falling state of coexistence were discussed in this paper. Moving track model of spreading and granular materials in crushing chamber was built up by analysing the effect of moving state to working performance of cone crusher.The delamination broken point of cone crusher was put forward in this paper.These researchs were laid a foundation for delamination design and study on crushing chamber.
(3)The calculation model of crushing product size distribution of rock based on the overall balance model was built up after analysing the effect of chamber to product size distribution of rock. A new formula calculating production capacity Q was put forward after taking into account fullly the effect of volume filling rateμi(α) at level section to production capacity.
(4)For researching and developing of high-performance laminated cone crusher, multi-objective optimization model about production capacity Q,crushing product size distribution and chamber based on researchs of working mechanism and working performance was built up.Aimed at multi-objective optimization issue of PYB1200 spring cone crusher, calculation method on optimization issue was deeper studied.By using a random direction search algorithm of MATLAB programs to calculate multi-objective optimization issue,a optimized structure of the crushing chamber was mapped.
(5)In order to further perfect the research on working mechanism and working performance of cone crusher,a analysis of the inadequacies and the objectives, methods and contents on further study were put forward in the end.
Research results of this paper provide the basis for developing the cone crusher of new style,high efficiency,energy saving, environment protection and independent knowledge property right,optimization programs can be related to the commercialization of chamber design software development for reference.
围绕着为改善国产圆锥破碎机工作性能的目标,论文将研究课题定位于圆锥破碎机腔型结构的优化设计研究。基于查默斯理工大学学者Evertsson对圆锥破碎机的一些基础研究成果,论文从破碎机工作机理和工作性能的不同角度展开,在层压破碎理论、圆锥破碎机生产能力Q的计算模型、层压腔型模型、腔型设计方法、破碎产品粒度分布模型和腔型多目标优化模型等方面做了如下工作：
(1)分析了国内外圆锥破碎机腔型研究的现状,探讨了圆锥破碎机腔型结构优化设计与改善圆锥破碎机工作性能的意义。
(2)对圆锥破碎机破碎腔内散体物料的运动特性进行了深入研究,探讨了三种不同形式的粒子流动状态,即滑动、自由落体、滑动与自由落体共存状态。分析了破碎腔内散体物料运动状态对破碎机工作性能的影响,建立了圆锥破碎机破碎腔内散体物料运动轨迹模型,提出了圆锥破碎机分层破碎特性,为破碎腔进行分层研究和设计奠定基础。
(3)论文在分析了破碎机腔型对岩石产品粒度分布情况的影响之后,建立了基于总体平衡模型的破碎产品粒度分布的计算模型；充分考虑了在水平截面上沿圆周方向体积填充率μi(α)对圆锥破碎机生产能力Q的影响,提出了圆锥破碎机生产能力Q计算的新公式。
(4)为研制开发高效层压圆锥破碎机,基于圆锥破碎机工作机理和工作性能的研究,建立了圆锥破碎机生产能力Q、破碎产品粒度和腔型结构的多目标优化模型。结合PYB1200弹簧圆锥破碎机腔型结构的多目标优化问题,对破碎机腔型多目标优化模型的求解方法进行了深入研究,采用随机方向搜索算法编制MATLAB程序对多目标优化模型进行求解,绘制出优化后的破碎腔型结构。
(5)为进一步完善圆锥破碎机工作机理和工作性能的研究,论文在展望中分析了研究存在的不足之处,提出了进一步研究的目标、方法和内容。
论文中的研究成果可以为研制开发具有完全自主知识产权的新型、高效、节能和环保的现代高性能圆锥破碎机奠定理论基础,相关的优化程序可以为腔型的商业化软件开发提供借鉴。
Cone crusher is the main equipment of rock material crushing and it is widely used in metallurgical and mining industry. However,home cone crusher have not been developed since they were imitated successfully, and those technology levels basically rested on the first and second generation of foreign advanced product. Furthermore, domestic cone crusher is designing conservatively, manipulating inconveniently and heavy,low efficiency,power wasting and poor product quality.
Encircling in order to improve working performance of the cone crusher, this paper will be positioned to study chamber optimal design of the cone crusher.Based on research basic results of Evertsson who is a scholar of Chalmers University of Technology, the paper was expanded from various eyes of crusher working mechanism and working performance, and several researchs were finished, including crushing mechanism, crusher capacity model, chamber design model, crushing product grain size distribution model and multi-objective optimization model and so on. The paper mainly included these research contents as follows:
(1)The significance of chamber optimization design and improvement working performance of cone crushers was discussed in this paper after analysing home and overseas situations of study on cone crusher.
(2)Kinetic characteristic of spreading and granular materials in crushing chamber was deeper studied and three different forms of particles flowing state,that is sliding, free-falling, sliding and free-falling state of coexistence were discussed in this paper. Moving track model of spreading and granular materials in crushing chamber was built up by analysing the effect of moving state to working performance of cone crusher.The delamination broken point of cone crusher was put forward in this paper.These researchs were laid a foundation for delamination design and study on crushing chamber.
(3)The calculation model of crushing product size distribution of rock based on the overall balance model was built up after analysing the effect of chamber to product size distribution of rock. A new formula calculating production capacity Q was put forward after taking into account fullly the effect of volume filling rateμi(α) at level section to production capacity.
(4)For researching and developing of high-performance laminated cone crusher, multi-objective optimization model about production capacity Q,crushing product size distribution and chamber based on researchs of working mechanism and working performance was built up.Aimed at multi-objective optimization issue of PYB1200 spring cone crusher, calculation method on optimization issue was deeper studied.By using a random direction search algorithm of MATLAB programs to calculate multi-objective optimization issue,a optimized structure of the crushing chamber was mapped.
(5)In order to further perfect the research on working mechanism and working performance of cone crusher,a analysis of the inadequacies and the objectives, methods and contents on further study were put forward in the end.
Research results of this paper provide the basis for developing the cone crusher of new style,high efficiency,energy saving, environment protection and independent knowledge property right,optimization programs can be related to the commercialization of chamber design software development for reference.
引文
[1]朗宝贤.圆锥破碎机[M].北京：机械工业出版社,1998
[2]孙时元等.中国选矿设备手册(上册).北京：科学出版社,2006
[3]秦志钰,容幸福,徐希民.复摆颚式破碎机破碎腔型的设计及优化[J].太原重型机械学院学报,1992,2：28-34
[4]P.P.Rosario, R.A.Hall, D.M.Maijer.Improved gyratory Crushing Operation by the Assessment of Liner Wear and Mantle Profile Redisign [J].Minerals Engineering, 2004,17:1083-1092
[5]L.While, L.Barone, P.Hingston, S.Huband, D.Tuppurainen, R. Bearman.AMulti-objective Evolutionary Algorithm Approach for Crusher Optimization and Flowsheet Design [J]. Minerals Engineering,2004,17:1063-1074
[6]丁培洪,王宏勋,朱俊利.高效颚式破碎机的研究[J].北京矿冶研究总院学报,1992,1(1)：43-47
[7]姜健飞等.数值分析及其MATALAB实验.北京：科学出版社,2004
[8]张可村,李换琴.工程优化方法及其应用.西安：西安交通大学出版社,2007
[9]Evertsson C M. Output prediction of cone crushers. Minerals Engineering, 1997,11(3):215-23
[10]Evertsson C M. Cone crusher performance. Sweden:Machine and Vehicle Design, Chalmers University of Technology,2000.
[11]Evertsson C M. Investigation of Interparticle Breakage as Applied to Cone Crushers. Minerals Engineering Conference,1997,2(10):199-214
[12]Evertsson C M. Size reduction in cone crushers. Minerals Engineering Confer_ence,1999,12:22-24
[13]Evertsson C M. Modeling of flow in cone crushers. Minerals Engineering,1999, 12:1479-1499
[14]Huang Dongming. Multi-objective planning of cone crusher chamber, output and size reduction. Minerals Engineering,2006.
[15]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解.北京：清华大学出 版社,2004
[16]孙靖民.机械优化设计[M].北京：机械工业出版社,2007
[17]谢庆生,罗延科等.机械工程模糊优化方法.北京：机械工业出版社,2002
[18]陈伦军等.机械优化设计遗传算法.北京：机械工业出版社,2005
[19]唐敬麟.破碎与筛分机械设计选用手册.北京：化学工业出版社,2001
[20]戴少生.新型细碎颚式破碎机的研制[J].上海建材学院学报,1991,4(1)：29-36
[21]黄冬明.挤压类破碎机工作机理和工作性能优化研究(博士论文).上海交通大学,2007,9
[22]Barnard,W.J.and Bull, F., "Primary Breakage of Brittle Particles", Fourth Tewksbury Symposium, Melbourne, Australia.February 1979.
[23]Bearman, R.A., " The Application of Rock Mechanics Parameters to the Prediction of Crusher Performance", Ph.D.Thesis.Camborne School of Mines, England,1991.
[24]Bond, F.C., "Third Theory of Comminution", Min.Eng.Trans.AIME, Vol.193, 484-494,1952.
[25]Briggs, C.A., and Bearman, R.A., "An Investigation of Rock Breakage and Damage", Minerals Engineering, Vol.9,489-497, May 1996.
[26]Briggs, C.A."Fundamental Model of a Cone Crusher", Ph.D.Thesis, University of Queensland, Australia, July 1997.
[27]Briggs, C.A., and Evertsson, C.M., "Shape Potential of Rock", Minerals Engineering, Vol.11,125-132, February 1998.
[28]Broadbent.S.r.and Callcott, T.G., "Coal Breakage Processes, LA New Analysis of Coal Breakage Processes", J Inst Fuel,524-528, December 1956.
[29]Broadbent.S.r.and Callcott, T.G., "Coal Breakage Processes, LA New Analysis of Coal Breakage Processes", J Inst Fuel,528-539, December 1956.
[30]Buss, B., Hanische, J.and Schubert, H., "Uber das Zerkleinergungsverhalten seitlich begrenzter and nicht-begrenzter Kornschichten bei Druckbeanspruchung", Neue Bergbautechnik,12, (5),277-283,1982.
[31]Eloranta, J., "Influence of Crushing Process Variables on the Product Quality of Crusherd Rock", Ph.D.Thesis, Tampere University of Technology, Tampere, Finland, 1995.
[32]Everston, C.M., "Prediction of Cone Crusher Performance", Lic.Eng.Thesis, Machine and Vehicle Design, Chalmers University of Technology, Australia, 173-180,4-7September 1995.
[33]Gauldie, K., "Performance of Jaw Crusher", Engineer,456-458, October 9, 485-486, October 16,1953.
[34]Gauldie, K., "The output of Gyratory Crushers", Engnieering,557-559, April 30,1954.
[35]Gilvary, J.J., "Fracture of Brittle Solids, I, Distribution Function for Fragment Size in Single Fracture(Theoretical)", J Applied Physics, Vol.32,391-399, March 1961.
[36]Griffith, A.A., "The Phenomena of Rupture and Flow in Solids", Phil Trans Royal Soo, Vol.7,29-36,1933.
[37]Hulten, J., "Drum Brake Squeal", Ph.D.Thesis, Machine and Vehicle Design, Chalmers University of Technology,1998.
[38]Kick, F., "Contribution to the Knowlegde of Brittle Materials", Dinglers Journal, Vol,247,1-5,1883.
[39]Klimpel, R.R.and Austin, L.G., "The Statistical Theory of Primary Breakage Distribution for Brittle Materials", Trans, SME/AIME,232,88-94,1965.
[40]Kojovic, T.,"Crushing Aggergate and Shape Control", Quarry Australia,24-34, June 1995.
[41]Liu, J, and Schonert, K., "Modelling of Interparticle Breakage", Preprints of 8th European Symposium on Comminution, Stockholm, Sweden,102-115, May 10-12,1994.
[42]Lynch, A.J., Mineral Crushing and Grinding Circuits, Elsevier Scientific Publishing Company,1977.
[43]Nilsson, A., Personal communication, Svedala-Arbra AB, Sweden,1999.
[44]Prasher, C., L., "Crushing and Grinding Process Handbook", John Wiley and Sons Ltd,1987.
[45]Rittinger, P.R, von, Lerbuch der Aufbereitungskunde, Ernst and Korn, Berlin, 1867.
[46]Rose, H.E., "Drop Weight Tests as the basis for Calculations of the performance of Ball Mills", Proc,10th int.Miner.Process.Congr., London, PublIMM (London), 143-147, April 1973.
[47]Rosin, P, and Rammler, E., " The Laws Governing the Fineness of Powdered Coal", Jinst Fuel, Vol.7,29-36,1933.
[48]Schonert, K., " Aspects of the Physics of Breakage Relevant to Comminution ", Proc 4th Tewksbury symposium, Melbourne, Australia, February 1979.
[49]Whiten, W.J.,"The Simulation of Crushing Plants With Models Developed using Multiple Spline Regression", J South African Institude of Mining and Metallargy, 257-264, May 1972.
[50]Whiten, W.J., "Models and Control Techniques for Crushing Plants", Control 84, Min Metall.Process, AIME Annual Meeting, Los Angeles, USA,217-225, February 1984.
[51]李启衡等.粉碎理论概要[M].北京：冶金工业出版社,1993
[52]姚践谦,郭年琴,黄鹏鹏,欧阳镇堂.层压破碎机理[J].中国有色金属学报,1992,2(4)：15-20.
[2]孙时元等.中国选矿设备手册(上册).北京：科学出版社,2006
[3]秦志钰,容幸福,徐希民.复摆颚式破碎机破碎腔型的设计及优化[J].太原重型机械学院学报,1992,2：28-34
[4]P.P.Rosario, R.A.Hall, D.M.Maijer.Improved gyratory Crushing Operation by the Assessment of Liner Wear and Mantle Profile Redisign [J].Minerals Engineering, 2004,17:1083-1092
[5]L.While, L.Barone, P.Hingston, S.Huband, D.Tuppurainen, R. Bearman.AMulti-objective Evolutionary Algorithm Approach for Crusher Optimization and Flowsheet Design [J]. Minerals Engineering,2004,17:1063-1074
[6]丁培洪,王宏勋,朱俊利.高效颚式破碎机的研究[J].北京矿冶研究总院学报,1992,1(1)：43-47
[7]姜健飞等.数值分析及其MATALAB实验.北京：科学出版社,2004
[8]张可村,李换琴.工程优化方法及其应用.西安：西安交通大学出版社,2007
[9]Evertsson C M. Output prediction of cone crushers. Minerals Engineering, 1997,11(3):215-23
[10]Evertsson C M. Cone crusher performance. Sweden:Machine and Vehicle Design, Chalmers University of Technology,2000.
[11]Evertsson C M. Investigation of Interparticle Breakage as Applied to Cone Crushers. Minerals Engineering Conference,1997,2(10):199-214
[12]Evertsson C M. Size reduction in cone crushers. Minerals Engineering Confer_ence,1999,12:22-24
[13]Evertsson C M. Modeling of flow in cone crushers. Minerals Engineering,1999, 12:1479-1499
[14]Huang Dongming. Multi-objective planning of cone crusher chamber, output and size reduction. Minerals Engineering,2006.
[15]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解.北京：清华大学出 版社,2004
[16]孙靖民.机械优化设计[M].北京：机械工业出版社,2007
[17]谢庆生,罗延科等.机械工程模糊优化方法.北京：机械工业出版社,2002
[18]陈伦军等.机械优化设计遗传算法.北京：机械工业出版社,2005
[19]唐敬麟.破碎与筛分机械设计选用手册.北京：化学工业出版社,2001
[20]戴少生.新型细碎颚式破碎机的研制[J].上海建材学院学报,1991,4(1)：29-36
[21]黄冬明.挤压类破碎机工作机理和工作性能优化研究(博士论文).上海交通大学,2007,9
[22]Barnard,W.J.and Bull, F., "Primary Breakage of Brittle Particles", Fourth Tewksbury Symposium, Melbourne, Australia.February 1979.
[23]Bearman, R.A., " The Application of Rock Mechanics Parameters to the Prediction of Crusher Performance", Ph.D.Thesis.Camborne School of Mines, England,1991.
[24]Bond, F.C., "Third Theory of Comminution", Min.Eng.Trans.AIME, Vol.193, 484-494,1952.
[25]Briggs, C.A., and Bearman, R.A., "An Investigation of Rock Breakage and Damage", Minerals Engineering, Vol.9,489-497, May 1996.
[26]Briggs, C.A."Fundamental Model of a Cone Crusher", Ph.D.Thesis, University of Queensland, Australia, July 1997.
[27]Briggs, C.A., and Evertsson, C.M., "Shape Potential of Rock", Minerals Engineering, Vol.11,125-132, February 1998.
[28]Broadbent.S.r.and Callcott, T.G., "Coal Breakage Processes, LA New Analysis of Coal Breakage Processes", J Inst Fuel,524-528, December 1956.
[29]Broadbent.S.r.and Callcott, T.G., "Coal Breakage Processes, LA New Analysis of Coal Breakage Processes", J Inst Fuel,528-539, December 1956.
[30]Buss, B., Hanische, J.and Schubert, H., "Uber das Zerkleinergungsverhalten seitlich begrenzter and nicht-begrenzter Kornschichten bei Druckbeanspruchung", Neue Bergbautechnik,12, (5),277-283,1982.
[31]Eloranta, J., "Influence of Crushing Process Variables on the Product Quality of Crusherd Rock", Ph.D.Thesis, Tampere University of Technology, Tampere, Finland, 1995.
[32]Everston, C.M., "Prediction of Cone Crusher Performance", Lic.Eng.Thesis, Machine and Vehicle Design, Chalmers University of Technology, Australia, 173-180,4-7September 1995.
[33]Gauldie, K., "Performance of Jaw Crusher", Engineer,456-458, October 9, 485-486, October 16,1953.
[34]Gauldie, K., "The output of Gyratory Crushers", Engnieering,557-559, April 30,1954.
[35]Gilvary, J.J., "Fracture of Brittle Solids, I, Distribution Function for Fragment Size in Single Fracture(Theoretical)", J Applied Physics, Vol.32,391-399, March 1961.
[36]Griffith, A.A., "The Phenomena of Rupture and Flow in Solids", Phil Trans Royal Soo, Vol.7,29-36,1933.
[37]Hulten, J., "Drum Brake Squeal", Ph.D.Thesis, Machine and Vehicle Design, Chalmers University of Technology,1998.
[38]Kick, F., "Contribution to the Knowlegde of Brittle Materials", Dinglers Journal, Vol,247,1-5,1883.
[39]Klimpel, R.R.and Austin, L.G., "The Statistical Theory of Primary Breakage Distribution for Brittle Materials", Trans, SME/AIME,232,88-94,1965.
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