八连杆装载机快卸系统设计及试验研究
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摘要
液压系统在工业领域的应用随着现代化科技的进步和液压系统本身的制造技术的提高而越来越多,尤其是在工程机械这一行业,液压系统的应用更是越来越多技术化,多科技化。装载机已经成为工业、建筑业、矿业等不可缺少的得力助手。随着经济的发展,科技水平的提高,装载机的种类和用途越来越广。而在设计和改进装载机时也不可避免的会遇到一些急需解决的问题,很多的技术问题等待着我们去解决。
本课题研究的对象就是解决在856Ⅲ装载机的改进系统中遇到的一个问题,那就是如何解决装载机卸料速度慢的问题。提高工作效率,减少劳动时间是我们的追求目标。
主要的研究内容就是了解装载机的基本结构和主要的液压系统部分;分析新型装载机卸料速度慢的原因;提出解决问题的几种方案,并对方案进行分析筛选确定合适的方案;设计快速卸料系统,重点设计系统中需要的二位三通换向阀;对改进后的系统建模并用AEMSim软件进行系统仿真;进行相关的试验得到实验数据和试验曲线,分析试验结果,验证该改进后的系统的可行性。
In this paper, the object of study is LIUGONG product 856Ⅲwheel loader. The sum of time of the loader bucket lifting, unloading,and return to material stack is the smaller the better with not only this model, but also other models. So it will save a lot of time and improve work efficiency.
Fast unloading system can be used not only in the eight-link loader, can also be used in other wheel loader.Because mechanical hydraulic system are universal in a certain sense. Fast unloading system can be applied to other engineering machinery, such as bulldozers, bucket before Boom also need the rapid decline with using similar principles. It can improve work efficiency greatly.
In this article, I introduct the development of the loader, development trends briefly,and note the major part hydraulic system of the Loader. Loader has six-bar linkage and eight -bar linkage two agencies working device, and that there are positive and inversion two different connectivity forms for devices. The common link is six inversion and eight positive these two institutions. And now the target of paper is 856Ⅲeight positive loader. This loader is a bit slowly when unloading.So the task of the paper is to solute this issue.
The paper analysis the reasons for the 856Ⅲeight Loader unloading with the slow speed.The reason is that the hydraulic system uses the original six-bar reversal agencies Loader hydraulic system,856Ⅲloader uses eight positive agencies.It is to fight oil into the big cavity of the cylinder, when the bucket discharges, and the original six-bar reversal body cavity size loader when unloading oil from the contrary, but work pump and valve distribution linkage are the same as the six linkage.So eight linkage the large cavity enter the oil is smaller than the six-bar discharge to fight small cavity oil Relatively speaking reduced volume, when the loader bucket cylinder unloading ,at the same time the oil enter the big cavity to achieve maximum pressure lengthy, and the corresponding unloading speed is slower.
We need design quick unloading system to solute the problem of slow, with the principle of the differential loop.We use the two-directional and the three openings hydraulic control directional control valve and user-friendly back-pressure valve. We will link the hydraulic control directional control valve cylinder size between the big and the small cavity of the bucket cylinder to connect the two cavities. That is, bucket cylinder can fight the hydraulic oil of the small cavity into the big cavity, to achieve the purpose of rapid discharge when discharges. A large number of formula applications in the analysis of the valve.
Loader hydraulic system is the cylinder valve control system.We make the mathematical modeling for the system using the control principle, List reversing valve spool valve flow of the linear equation, hydraulic cylinder flow continuity equation, calculated the hydraulic cylinder of the balance equation and the transfer function, etc. We use theoretical analysis and calculation to the system, but also use software AMESim to simulate system.
AMESim offers a time-domain simulation modeling environment, and establishments a new model components using the models have been used, constructs the actual prototype of the Optimization Design needs,with the easily identifiable standard ISO and multi-port diagram simple intuitive icons. The user can establishment complex system and the particular application examples friendly, modify model and simulation parameters, steady-state and dynamic simulation, analysis and mapping of simulation results.The operation is very convenient with the friendly interface. We use software components to Establish the structure of the whole system model, set the parameters of components in the model, and the actual application of numerical similar. We can use 3-D simulation of the software to see the model plans. RUN command of the software can simulate all kinds of curves we want. We can know the design system is improved with the design requirements or not by simulation both before and after improving system using AMESim, and comparing the two simulation results.
Making comprehensive hydraulic test experiments to the two-directional three openings valve can test its Orifice pressure loss,oil-flow performance and dynamic characteristics by connecting valves’three mouthes to the test bed pressure sensors and flow sensors respectively, and setting the pilot pressure and the flow of the pump. It is necessary to test the valve open time and the close time because of the reduction valve spring . At last,we can get the result that the calve meet the actual needs.
We install the two-directional and the three openings hydraulic control directional control valve in hydraulic system of the loader connecting between the big cavity and the small cavity of the bucket cylinder, at the same time install the 1.0 MPa back-pressure valve without the need fast unloading for user-friendly discharging slowly in the complete machine test and connect the big and small cavity of the bucket cylinder pressure sensors of the dynamic measurement instrument. Operating Loader to move Boom upgrade , the bucket unloading, or bucket and Boom decline several times,we can know the piston of the bucket cylinder extending and indentation only in the discharge and recovery the bucket. At this time we can get the relationship between pressure of the big cavity and the small cavity of the bucket cylinder and the time can be measured by dynamic measuring instrument. We can draw a conclusion by analysis the experimental results,and compare the experimental results to the actual working of the system without improvement to verify the feasibility of the improving system.
本课题研究的对象就是解决在856Ⅲ装载机的改进系统中遇到的一个问题,那就是如何解决装载机卸料速度慢的问题。提高工作效率,减少劳动时间是我们的追求目标。
主要的研究内容就是了解装载机的基本结构和主要的液压系统部分;分析新型装载机卸料速度慢的原因;提出解决问题的几种方案,并对方案进行分析筛选确定合适的方案;设计快速卸料系统,重点设计系统中需要的二位三通换向阀;对改进后的系统建模并用AEMSim软件进行系统仿真;进行相关的试验得到实验数据和试验曲线,分析试验结果,验证该改进后的系统的可行性。
In this paper, the object of study is LIUGONG product 856Ⅲwheel loader. The sum of time of the loader bucket lifting, unloading,and return to material stack is the smaller the better with not only this model, but also other models. So it will save a lot of time and improve work efficiency.
Fast unloading system can be used not only in the eight-link loader, can also be used in other wheel loader.Because mechanical hydraulic system are universal in a certain sense. Fast unloading system can be applied to other engineering machinery, such as bulldozers, bucket before Boom also need the rapid decline with using similar principles. It can improve work efficiency greatly.
In this article, I introduct the development of the loader, development trends briefly,and note the major part hydraulic system of the Loader. Loader has six-bar linkage and eight -bar linkage two agencies working device, and that there are positive and inversion two different connectivity forms for devices. The common link is six inversion and eight positive these two institutions. And now the target of paper is 856Ⅲeight positive loader. This loader is a bit slowly when unloading.So the task of the paper is to solute this issue.
The paper analysis the reasons for the 856Ⅲeight Loader unloading with the slow speed.The reason is that the hydraulic system uses the original six-bar reversal agencies Loader hydraulic system,856Ⅲloader uses eight positive agencies.It is to fight oil into the big cavity of the cylinder, when the bucket discharges, and the original six-bar reversal body cavity size loader when unloading oil from the contrary, but work pump and valve distribution linkage are the same as the six linkage.So eight linkage the large cavity enter the oil is smaller than the six-bar discharge to fight small cavity oil Relatively speaking reduced volume, when the loader bucket cylinder unloading ,at the same time the oil enter the big cavity to achieve maximum pressure lengthy, and the corresponding unloading speed is slower.
We need design quick unloading system to solute the problem of slow, with the principle of the differential loop.We use the two-directional and the three openings hydraulic control directional control valve and user-friendly back-pressure valve. We will link the hydraulic control directional control valve cylinder size between the big and the small cavity of the bucket cylinder to connect the two cavities. That is, bucket cylinder can fight the hydraulic oil of the small cavity into the big cavity, to achieve the purpose of rapid discharge when discharges. A large number of formula applications in the analysis of the valve.
Loader hydraulic system is the cylinder valve control system.We make the mathematical modeling for the system using the control principle, List reversing valve spool valve flow of the linear equation, hydraulic cylinder flow continuity equation, calculated the hydraulic cylinder of the balance equation and the transfer function, etc. We use theoretical analysis and calculation to the system, but also use software AMESim to simulate system.
AMESim offers a time-domain simulation modeling environment, and establishments a new model components using the models have been used, constructs the actual prototype of the Optimization Design needs,with the easily identifiable standard ISO and multi-port diagram simple intuitive icons. The user can establishment complex system and the particular application examples friendly, modify model and simulation parameters, steady-state and dynamic simulation, analysis and mapping of simulation results.The operation is very convenient with the friendly interface. We use software components to Establish the structure of the whole system model, set the parameters of components in the model, and the actual application of numerical similar. We can use 3-D simulation of the software to see the model plans. RUN command of the software can simulate all kinds of curves we want. We can know the design system is improved with the design requirements or not by simulation both before and after improving system using AMESim, and comparing the two simulation results.
Making comprehensive hydraulic test experiments to the two-directional three openings valve can test its Orifice pressure loss,oil-flow performance and dynamic characteristics by connecting valves’three mouthes to the test bed pressure sensors and flow sensors respectively, and setting the pilot pressure and the flow of the pump. It is necessary to test the valve open time and the close time because of the reduction valve spring . At last,we can get the result that the calve meet the actual needs.
We install the two-directional and the three openings hydraulic control directional control valve in hydraulic system of the loader connecting between the big cavity and the small cavity of the bucket cylinder, at the same time install the 1.0 MPa back-pressure valve without the need fast unloading for user-friendly discharging slowly in the complete machine test and connect the big and small cavity of the bucket cylinder pressure sensors of the dynamic measurement instrument. Operating Loader to move Boom upgrade , the bucket unloading, or bucket and Boom decline several times,we can know the piston of the bucket cylinder extending and indentation only in the discharge and recovery the bucket. At this time we can get the relationship between pressure of the big cavity and the small cavity of the bucket cylinder and the time can be measured by dynamic measuring instrument. We can draw a conclusion by analysis the experimental results,and compare the experimental results to the actual working of the system without improvement to verify the feasibility of the improving system.
引文
[1] 吉林工业大学工程机械教研室. 轮式装载机设计 机械工业出版社,1982
[2] 冶金工业部长沙矿山研究.露天装载机.人民交通出版社,1974
[3] 杨占敏,王智明,张春秋. 轮式装载机.化学工业出版社,2006
[4] 张全根.装载机. 中国建筑工业出版社,1980.8
[5] 何正忠. 装载机.械工业出版社,冶金工业出版社 1999.1
[6] 潘科第.装载机的构造、使用与维修. 机械工业出版社,1993.7
[7] 许福玲,陈尧明.液压与气压传动[M].机械工业出版社,2005
[8] 林建亚,何存兴. 液压元件.北京:机械工业出版社,2005.1
[9] Alain Pages. Michel Godran.System Reliaiiity - Evaluation and Prediction in Engineering. North Oxford Academic,1986.
[10] 章宏甲,黄谊,王积伟.液压与气压传动.北京:机械工业出版社,2000
[11] Diane Byme,Jim Quinlan.Robust function for at taining high reliability at low cost. Annual Reliability and Maintainability Symposium,1993.
[12]徐灏.机械设计手册.北京:机械工业出版社,1992
[13]雷天觉.液压工程手册.北京:机械工业出版社,1990
[14]章宏甲,黄谊,王积伟.液压与气压传动.北京:机械工业出版社,2000
[15]李永堂,雷步芳,高雨茁.液压系统建模与仿真.北京:冶金工业出版 社,2003
[16] Henley Emest.Reliability Engineering and Risk Assessment. Prentice-Hall,1981
[17]官忠范,李笑,杨敢.液压系统设计、调节失误实例分析.北京:机械工业出版社,1974
[18] Hays,R.M.Wheelloaders,SurfaceMiningB.A.Kennedy,p715.1990
[19] Walther Kaufmann,Technische Hydro-und Aeromechanik,2002
[20]余佑国,龚国芳,胡国良,AMESim 仿真技术及其在液压系统中的应用,液压气动与密封,2005.3
[21] 陆远章,液压系统建模与仿真,上海交通大学出版社,1989
[22] 贾培起,液压缸,北京科学技术出版社,1987
[23] Ahmad Hemami.Motion trajectory study in scooping operation of an LHD-Loader. IEEE transaction,2003
[24] SAPATA Shigeru.Model-based task planning for loading operationin mining,Proceedings of the 2001 IEEE/RSJ Intl.
[25] 液压阀联合设计组,液压阀设计与计算说明,1977
[26] 液压阀联合设计组,液压阀选型报告,1974
[27] 液压阀联合设计组,液压阀试验报告,1974
[28] 陈愈等.液压阀。中国铁道出版社,1982
[29] XU Binshi , MA Shining, WANG Jianjun Long Wu.Application of Electric Arc Technique to Enhance Corrosion Resistance of Steel Structures on Ships. Surface Engineering, 1995, 11(1)
[30] Long Wu.A Study on Automatic Control of Wheel Loaders in Rock/Soil Loading,Ph.D. Dissertation University of Arizona, 2003.
[31] 宋鸿尧 丁忠尧 等 液压阀设计与计算[M] 机械工业出版社,1979
[32] 宋一平,国内外液压阀的设计,液压与气动,1978.
[33] 李谨,邓卫华.AMESim 与 MATLAB/Simulink 联合仿真技术及应用[J] 情报指挥控制系统与仿真技术,2004,26(5)
[34] Navin Govind. Fuzzy Logic Control with the Intel8XC196 Embedded Micro controller,Intel Corporation,1995
[35] Tom Williamson.Designing Micro controller Systems for Electrically Noisy Environment. Intel Corporation December,1993
[36] 李寿刚.液压传动.北京:北京理工大学出版社,1994
[37] Kapur. Reliability in Engneering Design. John Willey and Sons,1977
[38] 杨文林,廖生行,周恩涛.基于 Simulink 分析泄漏对非对称液压动力机构的影响.液压与气动,2003.6
[39] Gilbert Bastien MSME. P.E. Introduction to HALT and HASS. COTS Journal2001
[40] WEdward Koss.Software--Reliability Metrics for Military System. Proceeding Annual Reliability and Maintainability Symposium,1987
[41] 官忠范.液压传动系统.北京:机械工业出版社,2004.8
[42] JohnR .Hul and others.The united states Air Force R&M2000 Process. Proceeding Annual Reliability and Maintain ability Symposiu,2003
[43] JosephR.Fragoia. Designing for success:Reliability technology in the concurrent engneering. Annual Reliability and Maintainability Symposium,2006
[44] 赵刚. 多功能路面清雪车电液比例阀控系统的模糊-PID 控制.吉林大学硕士论文,2005
[45] 秦家升,游善兰.AMESim 软件的特征及其应用[J].工程机械,2004 (12):6-8.
[46] 杨立志. 杨立志-基于小波分析/AMESim 的液压缸泄漏诊断故障的仿真研究.吉林大学硕士毕业论文,2007
[47] 李永堂,雷步芳,高雨茁,液压系统建模与仿真,冶金工业出版社,2000
[48] 刘海丽,李华聪.液压机械系统建模仿真软件 AMESim 及其应用,液压与机床,2006.6
[49] AMESim 4.0 用户手册[MI],1984
[50] John J. Pippenger. Hydraulic Valves and Controls. Marcel Dekker,INC. 1984
[51] Lambeck R P. Hydraulic Pumps and Motors: Selection and Application for Hydraulic Power Control System. New York : Marcel Dekker Inc . 1983
[52] MAURICER Vibrations in mechanical systems analytical methods and application,Springer-Verlag,1997
[53] 盛敬超,液压流体力学,机械工业出版社,1980
[54] 黎启柏.液压元件手册.冶金工业出版社,2000
[55]《机械设计手册》联合编写组编 机械设计手册(第二版),化学工业出版社,1982
[2] 冶金工业部长沙矿山研究.露天装载机.人民交通出版社,1974
[3] 杨占敏,王智明,张春秋. 轮式装载机.化学工业出版社,2006
[4] 张全根.装载机. 中国建筑工业出版社,1980.8
[5] 何正忠. 装载机.械工业出版社,冶金工业出版社 1999.1
[6] 潘科第.装载机的构造、使用与维修. 机械工业出版社,1993.7
[7] 许福玲,陈尧明.液压与气压传动[M].机械工业出版社,2005
[8] 林建亚,何存兴. 液压元件.北京:机械工业出版社,2005.1
[9] Alain Pages. Michel Godran.System Reliaiiity - Evaluation and Prediction in Engineering. North Oxford Academic,1986.
[10] 章宏甲,黄谊,王积伟.液压与气压传动.北京:机械工业出版社,2000
[11] Diane Byme,Jim Quinlan.Robust function for at taining high reliability at low cost. Annual Reliability and Maintainability Symposium,1993.
[12]徐灏.机械设计手册.北京:机械工业出版社,1992
[13]雷天觉.液压工程手册.北京:机械工业出版社,1990
[14]章宏甲,黄谊,王积伟.液压与气压传动.北京:机械工业出版社,2000
[15]李永堂,雷步芳,高雨茁.液压系统建模与仿真.北京:冶金工业出版 社,2003
[16] Henley Emest.Reliability Engineering and Risk Assessment. Prentice-Hall,1981
[17]官忠范,李笑,杨敢.液压系统设计、调节失误实例分析.北京:机械工业出版社,1974
[18] Hays,R.M.Wheelloaders,SurfaceMiningB.A.Kennedy,p715.1990
[19] Walther Kaufmann,Technische Hydro-und Aeromechanik,2002
[20]余佑国,龚国芳,胡国良,AMESim 仿真技术及其在液压系统中的应用,液压气动与密封,2005.3
[21] 陆远章,液压系统建模与仿真,上海交通大学出版社,1989
[22] 贾培起,液压缸,北京科学技术出版社,1987
[23] Ahmad Hemami.Motion trajectory study in scooping operation of an LHD-Loader. IEEE transaction,2003
[24] SAPATA Shigeru.Model-based task planning for loading operationin mining,Proceedings of the 2001 IEEE/RSJ Intl.
[25] 液压阀联合设计组,液压阀设计与计算说明,1977
[26] 液压阀联合设计组,液压阀选型报告,1974
[27] 液压阀联合设计组,液压阀试验报告,1974
[28] 陈愈等.液压阀。中国铁道出版社,1982
[29] XU Binshi , MA Shining, WANG Jianjun Long Wu.Application of Electric Arc Technique to Enhance Corrosion Resistance of Steel Structures on Ships. Surface Engineering, 1995, 11(1)
[30] Long Wu.A Study on Automatic Control of Wheel Loaders in Rock/Soil Loading,Ph.D. Dissertation University of Arizona, 2003.
[31] 宋鸿尧 丁忠尧 等 液压阀设计与计算[M] 机械工业出版社,1979
[32] 宋一平,国内外液压阀的设计,液压与气动,1978.
[33] 李谨,邓卫华.AMESim 与 MATLAB/Simulink 联合仿真技术及应用[J] 情报指挥控制系统与仿真技术,2004,26(5)
[34] Navin Govind. Fuzzy Logic Control with the Intel8XC196 Embedded Micro controller,Intel Corporation,1995
[35] Tom Williamson.Designing Micro controller Systems for Electrically Noisy Environment. Intel Corporation December,1993
[36] 李寿刚.液压传动.北京:北京理工大学出版社,1994
[37] Kapur. Reliability in Engneering Design. John Willey and Sons,1977
[38] 杨文林,廖生行,周恩涛.基于 Simulink 分析泄漏对非对称液压动力机构的影响.液压与气动,2003.6
[39] Gilbert Bastien MSME. P.E. Introduction to HALT and HASS. COTS Journal2001
[40] WEdward Koss.Software--Reliability Metrics for Military System. Proceeding Annual Reliability and Maintainability Symposium,1987
[41] 官忠范.液压传动系统.北京:机械工业出版社,2004.8
[42] JohnR .Hul and others.The united states Air Force R&M2000 Process. Proceeding Annual Reliability and Maintain ability Symposiu,2003
[43] JosephR.Fragoia. Designing for success:Reliability technology in the concurrent engneering. Annual Reliability and Maintainability Symposium,2006
[44] 赵刚. 多功能路面清雪车电液比例阀控系统的模糊-PID 控制.吉林大学硕士论文,2005
[45] 秦家升,游善兰.AMESim 软件的特征及其应用[J].工程机械,2004 (12):6-8.
[46] 杨立志. 杨立志-基于小波分析/AMESim 的液压缸泄漏诊断故障的仿真研究.吉林大学硕士毕业论文,2007
[47] 李永堂,雷步芳,高雨茁,液压系统建模与仿真,冶金工业出版社,2000
[48] 刘海丽,李华聪.液压机械系统建模仿真软件 AMESim 及其应用,液压与机床,2006.6
[49] AMESim 4.0 用户手册[MI],1984
[50] John J. Pippenger. Hydraulic Valves and Controls. Marcel Dekker,INC. 1984
[51] Lambeck R P. Hydraulic Pumps and Motors: Selection and Application for Hydraulic Power Control System. New York : Marcel Dekker Inc . 1983
[52] MAURICER Vibrations in mechanical systems analytical methods and application,Springer-Verlag,1997
[53] 盛敬超,液压流体力学,机械工业出版社,1980
[54] 黎启柏.液压元件手册.冶金工业出版社,2000
[55]《机械设计手册》联合编写组编 机械设计手册(第二版),化学工业出版社,1982