1200吨全自动粉煤灰蒸压砖成型装备液压系统研究与设计
摘要
我国人口众多,资源相对不足,而粉煤灰与煤矸石排放量仍在急剧增加,不仅占用大量土地,还造成了严重的环境污染。本课题通过产学研合作,面向粉煤灰和煤矸石等固体废弃物的资源化综合应用需求,研制智能化、集成化、网络化的1200吨粉煤灰蒸压砖成型装备自动化生产线。
本文对该成型装备的液压系统进行了研究与设计。首先,针对液压系统设计需求,基于下缸双套筒结构和充液装置结构的特点,设计了双泵双回路的液压系统,并进行了主要元器件选型；其次,利用软件AMESim对所设计的液压系统进行建模与动态特性仿真,得出了压制部分速度、压力、位移等曲线,根据这些结果,对参数进行了优化和选择；而后,针对仿真结果发现的液压系统冲击及振动问题,对产生冲击的原因进行了理论分析,并对单向节流阀卸荷回路与溢流阀组卸荷回路进行了研究,提出了带有远程控制口的溢流阀释压方法；最后再次利用AMESim对改进后的液压系统进行了二次建模与仿真,通过对比分析,验证了改进方案的合理性。
通过调试验证,本课题设计的1200吨粉煤灰蒸压砖成型装备液压系统达到了预期的功能要求,动作顺序正确,具有较好的可靠性和实用性,满足现场生产的需求。
There are so many people but so little resources to use in our country. Meanwhile, the discharge amount of coal fly ash are increasing, which lead to heavy pollution and massive occupation of land. Through cooperation among industry, universities and research institutes, this project develops the production line of 1200 ton automation coal-ash-brick equipment with Intelligence, integration and network, which relates to the synthesis utilizing solid wastes like coal-ash and gangue.
This thesis does research on the hydraulic system of 1200 ton automation coal-ash-brick equipment. Firstly, the dual pump and dual circuit hydraulic system is designed based on the hydraulic requirements and the structure of the double-cylindrical-shaped lower cylinder and charging valve. Next, a series of dynamic curves of the press part are obtained using AMESim software, and the parameters of the equipment are selected and optimized. Then, for the hydraulic problem of impact and vibration, the reasons are analyzed. Through analyzing the one-way throttle valve relieving loop and the relief manifolds loop, the reliving methods are discussed, and then the reliving loop with remote control port are designed, which is specially used for this equipment. Finally, with AMESim, the optimized press equipment is modeled and simulated again, and the proper result is demonstrated via comparing the old and new designing methods.
Full-scale experiment results showed that the hydraulic system of 1200 ton automation coal-ash-brick equipment reached the expected requirements, has a better adaptability and reliability and satisfied the demand of practical producing.
本文对该成型装备的液压系统进行了研究与设计。首先,针对液压系统设计需求,基于下缸双套筒结构和充液装置结构的特点,设计了双泵双回路的液压系统,并进行了主要元器件选型；其次,利用软件AMESim对所设计的液压系统进行建模与动态特性仿真,得出了压制部分速度、压力、位移等曲线,根据这些结果,对参数进行了优化和选择；而后,针对仿真结果发现的液压系统冲击及振动问题,对产生冲击的原因进行了理论分析,并对单向节流阀卸荷回路与溢流阀组卸荷回路进行了研究,提出了带有远程控制口的溢流阀释压方法；最后再次利用AMESim对改进后的液压系统进行了二次建模与仿真,通过对比分析,验证了改进方案的合理性。
通过调试验证,本课题设计的1200吨粉煤灰蒸压砖成型装备液压系统达到了预期的功能要求,动作顺序正确,具有较好的可靠性和实用性,满足现场生产的需求。
There are so many people but so little resources to use in our country. Meanwhile, the discharge amount of coal fly ash are increasing, which lead to heavy pollution and massive occupation of land. Through cooperation among industry, universities and research institutes, this project develops the production line of 1200 ton automation coal-ash-brick equipment with Intelligence, integration and network, which relates to the synthesis utilizing solid wastes like coal-ash and gangue.
This thesis does research on the hydraulic system of 1200 ton automation coal-ash-brick equipment. Firstly, the dual pump and dual circuit hydraulic system is designed based on the hydraulic requirements and the structure of the double-cylindrical-shaped lower cylinder and charging valve. Next, a series of dynamic curves of the press part are obtained using AMESim software, and the parameters of the equipment are selected and optimized. Then, for the hydraulic problem of impact and vibration, the reasons are analyzed. Through analyzing the one-way throttle valve relieving loop and the relief manifolds loop, the reliving methods are discussed, and then the reliving loop with remote control port are designed, which is specially used for this equipment. Finally, with AMESim, the optimized press equipment is modeled and simulated again, and the proper result is demonstrated via comparing the old and new designing methods.
Full-scale experiment results showed that the hydraulic system of 1200 ton automation coal-ash-brick equipment reached the expected requirements, has a better adaptability and reliability and satisfied the demand of practical producing.
引文
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[2]田野,李少辉,何廷树,赵澜,包先成.粉煤灰的特性及其资源化综合利用[J].混凝土,2010(4)：12-15.
[3]YAN Qing-song, ZHANG Tie, TONG Lei. Body improvement of QA35Y-30 hydraulic combined punching and shearing machine[J]. Forming and Stamping Technology.2010(4), pp. 23-29.
[4]卞正富,金丹,董霁红,牟守国.煤矸石处理与应用的合理途径探讨[J].采矿与安全工程学报,2007,24(2)：132-136.
[5]聂轶苗,刘淑贤,牛福生,张晋霞,白丽梅.粉煤灰研究进展及展望[J].混凝土2010(4)：62-65.
[6]Michael Thomasa, Andrew Dunsterb, Philip Nixonb & Barry Blackwellc. Effect of Fly Ash on the Expansion of Concrete Due to Alkali-Silica Reaction.-Exposure Site Studies. Cement and Concrete Composites,2010(11), pp.24-29.
[7]Li Hua-luan;Gao Peifa; Bo Zhang; Wang Lin; Research on Mineralogy Properties of Fly AshBioinformatics and Biomedical Engineering (iCBBE) [C],2010 4th International Conference.2010(7), pp.1-4.
[8]高国强.蒸压灰砂砖和粉煤灰砖的模压成型能耗分析[J].建筑砌块与砌块建筑,2010(4)：52-54.
[9]A. Johansson, J.O. Ivander2,& J-O Palmberg, Experimental verification of cross-angle for noise reduction in hydraulic piston pumps, Proc. ImechE Part I:J.Systems and Control Engineering,2007(221), pp.321-330.
[10]赵周民.大型粉煤灰烧结砖生产线设计优化[J].砖瓦,2005(10)：61-63.
[11]朱展鹏,刘小云.国产全自动液压压砖机的技术创新分析[J],陶瓷,2007(8)：36-38.
[12]冯长印,张伯清,国产陶瓷传自动液压压砖机的市场与技术进步[J].陶瓷,2006(10)：30-32.
[13]JU Da-weil,LI Sen. Loading analysis of frame type hydraulic press body structure[J]. Journal of Machine Desugn.2010(9),45-49.
[14]张柏清.全自动液压压砖机[J].江西科学技术出版社,2000(10)：25-26.
[15]Ramzi Othmana, Pierrick Guegana, Georges Challitaa, Franck Pascoa & Daniel LeBreton. A modified servo-hydraulic machine for testing at intermediate strain rates[J]. International Journal of Impact Engineering.2009(36), pp.460-467.
[16]刘海丽,李华聪.液压机械系统建模仿真软件AMEsim及其应用[J].机床与液压,2006(3)：10-12.
[17]Christopher C. Schroeder, Amin Mohaghegh Motlagh, The M. Nguyen, and Mohammad H. Elahinia. Modeling of a Hydraulic Hybrid Pump Motor for Evaluation of Vibration Characteristics[C]. ASME Conf. Proc.2007(5):21-27.
[18]Y.L. Fu, X.Y. Qi, "System modeling and simulation based on AMESim" [M], Beijing University of Aeronautics & Astronautics Press, Beijing,2006.
[19]X.C. Liu, Q.T Huang & D.C. Cong. New modeling and analysis of three-stage electro-hydraulic servo valve.2008 International Workshop on Modelling[J], Simulation and Optimization,2008(8), pp.146-150.
[20]寇伟光,周慧群,杨静.液压系统建模方法研究[J].机械与电子,2010(5)：24-27.
[21]岳立鹏.基于AMESim的汽车TCS液压控制系统建模与分析[D].吉林大学,2009.
[22]肖岱宗AMESim仿真技术及其在液压元件设计和性能分析中的应用[J].舰船科学技术,2007(9)：142-145.
[23]包海涛.基于功率键合图的液压缸动态特性研究[J].煤矿机械,2008(10)：47-48.
[24]边海岸,戴双献.四柱式万能液压机液压系统原理研究[J].中国机械工程师,2007,(7)：92-93.
[25]周恩涛.液压系统设计元器件选型手册[M].机械工业出版社,2009.
[26]L.J. Fu, J.H. Wei & M.X. Qiu. Dynamic characteristics of large flow rating electro-hydraulic proportional cartridge valve[J]. Chinese Journal of Mechanical Engineering, 2008(21), pp.57-62.
[27]M.A. Milad, S.N. Sinba, Stress-strain characteristics of brick masonry under cyclic biaxial compression, Journal of Structural Engineering,2000(9), pp.1004-1007.
[28]Q.S. Zhao, Something about hydraulic impactb & remove of oil press[J], Metal Forming and Industrial Furnace,2004(5), pp.48-49.
[29]N.Li, Y.M. Gao, X.W. Wei, W.N. Dong, Study of relieving impact on hydraulic press[J], Digital Technique & Machining Technological Equipment,2009(4), pp.15-16.
[30]Wei Liu, Huayong Yang, Bing Xu,& Zhongyu Wu. Simulation Study on the Control Valve in Hydraulic Operating Mechanism of the High Voltage Circuit Breaker [J], ASME Conf. Proc,2008(2):12.
[31]栗晓华.德国TROESTOR公司双复合挤出机液压系统分析[J].工艺与装备.2005(31)：41-47.
[32]张利平.液压控制系统及设计[M].北京：化学工业出版社,2006.
[33]谭兴强,曾保国.液压系统的改造方法及应用[J].液压与气动,2008(6)：21-23.
[34]王勇,张作龙,杨东泽.基于功率键合图的恒压变量泵建模与仿真[J].液压气动与密封,2010(3)：30-32.
[35]许勇,邓华,夏毅敏,李群明.利用键合图的高频响插装阀非线性建模方法研究[J].现代制造工程,2009(07)：24-27.
[36]李永堂,雷步芳,高雨茁.液压系统建模与仿真[M].冶金工业出版社,2003.
[37]刘海丽.基于AMESim的液压系统建模与仿真技术研究[D].西安：西北工业大学,2006.
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