XSP800型收排线机的结构分析与优化
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摘要
对收排线机的研究大部分是集中于开发新的产品和收排线机的控制方面,而很少涉足于收排线机结构分析与结构优化以及收排线机受力测试的。目前,对收排线机的设计由于缺乏有效的理论依据,大多沿用了以往的设计思想,采用类比的经验设计方法,常常选择过大的安全系数,势必造成所设计的结构尺寸与重量偏大,结构设计不尽合理。而龙门式结构是收排线机中的主流结构形式之一,因此对XSP800龙门式收排线机进行结构分析与优化设计有重要的实际价值。
本文基于有限元理论,以ANSYS有限元软件为工具,对XSP800收排线机进行结构分析和优化设计。根据实际情况,将收排线机分成两个部分:机架和升降机构,分别进行结构分析与结构优化。
首先,利用ANSYS软件对机架进行结构分析。对机架进行受力分析,在ANSYS中建立机架有限元模型,对机架三种工况下的强度和刚度进行校核,验证原始设计的合理性,得知机架结构强度性能有待提高的结论;对机架结构进行模态分析,得出机架结构的固有频率和振型;对机架结构进行疲劳寿命分析,得出机架结构危险部位的疲劳寿命,验证了原始设计的安全性。
其次,利用ANSYS软件对升降机构进行结构分析。在ANSYS软件中建立升降机构有限元模型,施加边界条件进行求解计算,得出升降机构应力和位移分布规律,并对升降机构进行强度和刚度的校核,验证了原始设计的安全性,为进一步结构优化奠定了基础。
接着,进行了收排线机应力测试实验。利用DH-5920动态信号测试分析系统采集到测试点在特定工况下的应力曲线;比较分析了实验结果与有限元模拟结果,验证了有限元模拟结果的正确性。
最后,对收排线机进行结构改进与结构优化。利用ANSYS的优化设计模块对机架和升降机构进行优化设计,得出的最优设计较原始设计强度和刚度性能均有所提高,重量减轻效果也非常明显,达到了优化设计的目的。最优设计可作为该型号收排线机设计的参考,对其它类似机构的设计也有借鉴意义。
Research on the take-up and traverse machine mostly concentrated in developing of new products and control system,but rarely involved in structural analysis and structural optimization and mechanical test. at present, on the design of the take-up and traverse machine structure theoretical basis for the lack of effective, mostly follows the usual design philosophy, the conventional methods, was carried out in an analogy way from experience. Often the safety factor is too large assigned, and inevitably result in the design of the structure is too large in size and weight, Structure design is not quite reasonable. The gantry type traversing machine is one of the main structure, therefore XSP800 take-up and traverse machine structural analysis and optimal design has important practical value.
In this paper, based on finite element theory, using ANSYS finite element software to, completed the structural of the XSP800 take-up and traverse machine for analysis and optimization design. According to actual situation, the traverse machine separate into two parts: frame structure and the lifting structure, to carry out structural analysis and optimization.
Firstly, using ANSYS software to analyze the frame structure, analyze the forces and calculate the loads on the frame, by build a finite element model of the frame in ANSYS, in the three operating conditions, checking the structure of the frame strength and stiffness, verify the reasonableness of the original design. Performance to be improved frame structure strength. Completed modal analysis of the structure, obtained natural frequencies and mode shapes of the frame structure. Completed the fatigue life of the frame structure, obtained dangerous parts fatigue life of the frame structure.
Secondly, using ANSYS software to analyze the structure of lifting system. By build a finite element model of the lifting system in ANSYS, imposed boundary conditions and solving the equation, the stress and displacement distribution is found, and checking structural strength and stiffness, verify the security of the original design, as a basis for further structural optimization.
Thirdly,do the stress-test experiment in the workshop. Stress curves of the test point are gained by DH-5920, a dynamic signal test and analysis system, under a certain working condition. Comparing and analyzing the experiment results and the simulation results can get such a conclusion that the simulation results are correct.
Finally, structural improvement and optimization of the XSP800 take-up and traverse machine are carried out. Using ANSYS optimization design module to the frame and lift system to optimize the design. The optimal design in strength and stiffness properties were improved than the original design. Weight also has obvious reduced, reached the goal of optimal design. This scheme can be regarded as a reference for the XSP800 take-up and traverse machine design, the design of other similar institutions can also referenced.
本文基于有限元理论,以ANSYS有限元软件为工具,对XSP800收排线机进行结构分析和优化设计。根据实际情况,将收排线机分成两个部分:机架和升降机构,分别进行结构分析与结构优化。
首先,利用ANSYS软件对机架进行结构分析。对机架进行受力分析,在ANSYS中建立机架有限元模型,对机架三种工况下的强度和刚度进行校核,验证原始设计的合理性,得知机架结构强度性能有待提高的结论;对机架结构进行模态分析,得出机架结构的固有频率和振型;对机架结构进行疲劳寿命分析,得出机架结构危险部位的疲劳寿命,验证了原始设计的安全性。
其次,利用ANSYS软件对升降机构进行结构分析。在ANSYS软件中建立升降机构有限元模型,施加边界条件进行求解计算,得出升降机构应力和位移分布规律,并对升降机构进行强度和刚度的校核,验证了原始设计的安全性,为进一步结构优化奠定了基础。
接着,进行了收排线机应力测试实验。利用DH-5920动态信号测试分析系统采集到测试点在特定工况下的应力曲线;比较分析了实验结果与有限元模拟结果,验证了有限元模拟结果的正确性。
最后,对收排线机进行结构改进与结构优化。利用ANSYS的优化设计模块对机架和升降机构进行优化设计,得出的最优设计较原始设计强度和刚度性能均有所提高,重量减轻效果也非常明显,达到了优化设计的目的。最优设计可作为该型号收排线机设计的参考,对其它类似机构的设计也有借鉴意义。
Research on the take-up and traverse machine mostly concentrated in developing of new products and control system,but rarely involved in structural analysis and structural optimization and mechanical test. at present, on the design of the take-up and traverse machine structure theoretical basis for the lack of effective, mostly follows the usual design philosophy, the conventional methods, was carried out in an analogy way from experience. Often the safety factor is too large assigned, and inevitably result in the design of the structure is too large in size and weight, Structure design is not quite reasonable. The gantry type traversing machine is one of the main structure, therefore XSP800 take-up and traverse machine structural analysis and optimal design has important practical value.
In this paper, based on finite element theory, using ANSYS finite element software to, completed the structural of the XSP800 take-up and traverse machine for analysis and optimization design. According to actual situation, the traverse machine separate into two parts: frame structure and the lifting structure, to carry out structural analysis and optimization.
Firstly, using ANSYS software to analyze the frame structure, analyze the forces and calculate the loads on the frame, by build a finite element model of the frame in ANSYS, in the three operating conditions, checking the structure of the frame strength and stiffness, verify the reasonableness of the original design. Performance to be improved frame structure strength. Completed modal analysis of the structure, obtained natural frequencies and mode shapes of the frame structure. Completed the fatigue life of the frame structure, obtained dangerous parts fatigue life of the frame structure.
Secondly, using ANSYS software to analyze the structure of lifting system. By build a finite element model of the lifting system in ANSYS, imposed boundary conditions and solving the equation, the stress and displacement distribution is found, and checking structural strength and stiffness, verify the security of the original design, as a basis for further structural optimization.
Thirdly,do the stress-test experiment in the workshop. Stress curves of the test point are gained by DH-5920, a dynamic signal test and analysis system, under a certain working condition. Comparing and analyzing the experiment results and the simulation results can get such a conclusion that the simulation results are correct.
Finally, structural improvement and optimization of the XSP800 take-up and traverse machine are carried out. Using ANSYS optimization design module to the frame and lift system to optimize the design. The optimal design in strength and stiffness properties were improved than the original design. Weight also has obvious reduced, reached the goal of optimal design. This scheme can be regarded as a reference for the XSP800 take-up and traverse machine design, the design of other similar institutions can also referenced.
引文
[1]蒋华伟.各式排线机构特点综述[J].金属制品.1997(8)
[2]黄友锐,魏庆龙.龙门收排线机的PLC控制[J].光纤与电缆及其应用技术,2000,1(01):44-46
[3] Green D.Continuous Extrusion-Forming of Wire Sections[J].Inst.Metals,1972:295-300
[4]刘元文,宋宝韫.铜扁线连续挤压技术[J].锻压技术,2004,(04):49-50
[5]宋宝韫.连续挤压和连续包覆技术的理论研究与工程实践[J].中国机械工程,1998,25(08) :69-73
[6]唐志宇.1250两立柱龙门收排线机的研制[J].成都纺织高等专科学校学报,2004,2(01):24-27
[7]李五田,韩大鹏,张丽华.层绕机排线及恒张力控制的设计[J].金属制品,2007,33(2):45-48
[8]陈云霞,宋宝韫.基于变频器和PLC的收排线机控制[J].自动化技术与应用,2007,26(03):128-130
[9]伍义,徐振越.基于PLC的收排线机恒张力控制系统的设计[J].工业控制计算机,2006,19(12):70-73
[10]陈立周.机械优化设计方法[M].北京:冶金工业出版社,2005
[11]田福祥.机械优化设计理论与应用[M].北京:冶金工业出版社,1998
[12]钱令希.工程结构优化设计[M].北京:水利水电出版社,1983
[13]曾攀.有限元分析及应用[M].北京:清华大学出版社,2003
[14]蒋孝煜.有限元法基础[M].北京:清华大学出版社,1992
[15]傅永华.有限元分析基础[M].武汉:武汉大学出版社,2003
[16]杜平安,甘娥忠,于亚婷.有限元法原理、建模及应用[M].北京:国防工业出版社,2004
[17]吴鸿庆,任侠.结构有限元分析[M].北京:中国铁道出版社,2003
[18]徐新辉.基于ANSYS分析的龙门起重机箱型主梁优化设计.武汉理工大学硕士学位论文.2005
[19]成万值.有限元分析在常规强度计算工作中的地位和作用[J].飞机设计,2002(4)
[20]许尚贤.机械设计中的有限元法[M].北京:高等教育出版社,1992
[21]龚曙光,谢桂兰.ANSYS操作命令与参数化编程[M].北京:机械工业出版社,2004
[22]李黎明.ANSYS有限元分析实用教程[M].北京:清华大学出版社,2005
[23] Reh.Stefan;Beley.Jean-Daniel;Mukherjee.Siddhartha;Khor. Eng Hui.Probabilistic finite element analysis using ANSYS Structural Safety[J],June.2006
[24]武思宇,罗伟.ANSYS工程计算应用教程[M].北京:中国铁道出版社,2004
[25] ANSYS Inc.Structural Analysis Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[26] ANSYS Inc.Operations Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[27]程凯.ANSYS中几种建模方法的研究[J].计算机应用技术,2005,32(6)
[28]刑静忠,李军.ANSYS的建模方法和网格划分[J].中国水运(学术版),2006,06(09)
[29]马奎兴.有限元软件ANSYS简介[J].水利科技与经济,2004,10(3)
[30] ANSYS Inc.Element Reference Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[31]徐芝纶.弹性力学[M].北京:人民教育出版社,1982
[32] K.L.Johnson.接触力学[M].徐秉业,罗学富,刘信声等,译.北京:高等教育出版社,1985
[33]周学军.钢结构设计规范GB50017应用指导[M].济南:山东科学技术出版社,2004
[34]机械设计手册编委会.机械设计手册6卷[M].北京:机械工业出版社,2004
[35]刘瑞堂.机械零件失效分析[M].哈尔滨:哈尔滨工业大学出版社,2003
[36]许本文,焦群英.机械振动与模态分析基础[M].北京:机械工业出版社,1998
[37]唐友刚.高等结构动力学[M].天津:天津大学出版社,2002
[38] J.H.Witkinson.The algebraic Bigenvalue Problem[M].Oxford University Press,Inc.,London,1965
[39]韦树军.高速铁路钢轨的疲劳寿命研究.同济大学硕士学位论文,2006
[40]张敏强.焊接结构疲劳寿命评估问题的研究.大连理工大学硕士学位论文,2005
[41]姚卫星.结构疲劳寿命分析[M].北京:国防工业出版社,2003
[42]陈传尧.疲劳与断裂[M].武汉:华中科技大学出版社,2002
[43]任保才.机械测试与信息处理[M].北京:中国矿业大学出版社,2003
[44]罗次申.动力机械测试技术[M].上海:上海交通大学出版社,2001
[45]王国鼎,袁海庆.桥梁检测与加固[M].北京:人民交通出版社,2003
[46]陶铁男.XSP800型收排线机机械设计与机构仿真.大连交通大学硕士学位论文,2009
[47]杨永亮.基于有限元的车床床身结构优化.大连理工大学硕士学位论文,2006
[2]黄友锐,魏庆龙.龙门收排线机的PLC控制[J].光纤与电缆及其应用技术,2000,1(01):44-46
[3] Green D.Continuous Extrusion-Forming of Wire Sections[J].Inst.Metals,1972:295-300
[4]刘元文,宋宝韫.铜扁线连续挤压技术[J].锻压技术,2004,(04):49-50
[5]宋宝韫.连续挤压和连续包覆技术的理论研究与工程实践[J].中国机械工程,1998,25(08) :69-73
[6]唐志宇.1250两立柱龙门收排线机的研制[J].成都纺织高等专科学校学报,2004,2(01):24-27
[7]李五田,韩大鹏,张丽华.层绕机排线及恒张力控制的设计[J].金属制品,2007,33(2):45-48
[8]陈云霞,宋宝韫.基于变频器和PLC的收排线机控制[J].自动化技术与应用,2007,26(03):128-130
[9]伍义,徐振越.基于PLC的收排线机恒张力控制系统的设计[J].工业控制计算机,2006,19(12):70-73
[10]陈立周.机械优化设计方法[M].北京:冶金工业出版社,2005
[11]田福祥.机械优化设计理论与应用[M].北京:冶金工业出版社,1998
[12]钱令希.工程结构优化设计[M].北京:水利水电出版社,1983
[13]曾攀.有限元分析及应用[M].北京:清华大学出版社,2003
[14]蒋孝煜.有限元法基础[M].北京:清华大学出版社,1992
[15]傅永华.有限元分析基础[M].武汉:武汉大学出版社,2003
[16]杜平安,甘娥忠,于亚婷.有限元法原理、建模及应用[M].北京:国防工业出版社,2004
[17]吴鸿庆,任侠.结构有限元分析[M].北京:中国铁道出版社,2003
[18]徐新辉.基于ANSYS分析的龙门起重机箱型主梁优化设计.武汉理工大学硕士学位论文.2005
[19]成万值.有限元分析在常规强度计算工作中的地位和作用[J].飞机设计,2002(4)
[20]许尚贤.机械设计中的有限元法[M].北京:高等教育出版社,1992
[21]龚曙光,谢桂兰.ANSYS操作命令与参数化编程[M].北京:机械工业出版社,2004
[22]李黎明.ANSYS有限元分析实用教程[M].北京:清华大学出版社,2005
[23] Reh.Stefan;Beley.Jean-Daniel;Mukherjee.Siddhartha;Khor. Eng Hui.Probabilistic finite element analysis using ANSYS Structural Safety[J],June.2006
[24]武思宇,罗伟.ANSYS工程计算应用教程[M].北京:中国铁道出版社,2004
[25] ANSYS Inc.Structural Analysis Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[26] ANSYS Inc.Operations Guide Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[27]程凯.ANSYS中几种建模方法的研究[J].计算机应用技术,2005,32(6)
[28]刑静忠,李军.ANSYS的建模方法和网格划分[J].中国水运(学术版),2006,06(09)
[29]马奎兴.有限元软件ANSYS简介[J].水利科技与经济,2004,10(3)
[30] ANSYS Inc.Element Reference Release 10.0 Documentation for ANSYS[M].ANSYS Inc,2006
[31]徐芝纶.弹性力学[M].北京:人民教育出版社,1982
[32] K.L.Johnson.接触力学[M].徐秉业,罗学富,刘信声等,译.北京:高等教育出版社,1985
[33]周学军.钢结构设计规范GB50017应用指导[M].济南:山东科学技术出版社,2004
[34]机械设计手册编委会.机械设计手册6卷[M].北京:机械工业出版社,2004
[35]刘瑞堂.机械零件失效分析[M].哈尔滨:哈尔滨工业大学出版社,2003
[36]许本文,焦群英.机械振动与模态分析基础[M].北京:机械工业出版社,1998
[37]唐友刚.高等结构动力学[M].天津:天津大学出版社,2002
[38] J.H.Witkinson.The algebraic Bigenvalue Problem[M].Oxford University Press,Inc.,London,1965
[39]韦树军.高速铁路钢轨的疲劳寿命研究.同济大学硕士学位论文,2006
[40]张敏强.焊接结构疲劳寿命评估问题的研究.大连理工大学硕士学位论文,2005
[41]姚卫星.结构疲劳寿命分析[M].北京:国防工业出版社,2003
[42]陈传尧.疲劳与断裂[M].武汉:华中科技大学出版社,2002
[43]任保才.机械测试与信息处理[M].北京:中国矿业大学出版社,2003
[44]罗次申.动力机械测试技术[M].上海:上海交通大学出版社,2001
[45]王国鼎,袁海庆.桥梁检测与加固[M].北京:人民交通出版社,2003
[46]陶铁男.XSP800型收排线机机械设计与机构仿真.大连交通大学硕士学位论文,2009
[47]杨永亮.基于有限元的车床床身结构优化.大连理工大学硕士学位论文,2006