装卸型门机转台筒体开裂成因及修复方案优选
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摘要
现代港口的装卸型门机不断地追求更高的经济指标，在港口装卸生产中起着越来越重要的作用。长期以来，装卸型门机的金属结构的管理一直是港口设备管理的难点，如何有效地提高这些装卸型门机使用的科学性和合理性，有效延长其使用寿命是当前港口机械结构状态检测和故障诊断的重要内容。
本文以天津港第六港埠公司16t／33m门机转台筒体开裂的原因分析和修复裂纹方案优化为主线，研究了装卸型门机结构CAEA的概念和方法，包括模型的生成和处理的方法、单元和网格的控制方法等。运用ANSYS软件对装卸型门机的转台筒体结构进行了分析，得到了结构的应力、变形、应变能等的分布情况和应力、位移等分布图谱，为结构状态监测与诊断、测试提供了理论和技术指导。根据分析结果，给出了修复门机转台筒体裂纹的优化方案和具体的施工工艺，将结构CAEA方法应用于港口机械设备管理，指导港口设备金属结构的管理和检测。
本文的主要创新点是：
系统地研究了装卸型门机结构CAEA建模的技术问题，采用理论建模与实验建模相结合的建模方法与技术，提高了模型及其计算结果的可靠性与科学性。通过对装卸型门机转台筒体结构的实体建模与分析，发现了其在载荷作用下的应力分布情况，为转台筒体裂纹的产生原因提供了有力的证据。并提出和验证了修复方案的正确性，有效地解决了天津港16t／33m门机转台筒体开裂的实际问题，为治理该类门机的钢结构开裂开创了先例，对今后同类机型钢结构开裂的修复及新造同类结构门机提供了设计、工艺要求，均有良好的借鉴价值。为港口设备的安全生产提供了科学保障，大大提高了港口设备管理的科学性和合理性，使整个港口设备管理水平上一个新台阶。
Modem harbour crane has been continuously seeking higher economical efficiency. The stevedoring gantry crane in modern harbours plays a critical role in loading and discharge production. In a long term, management of metal structure is a difficult point in the
management of harbour equipment. How to increase the scientific reasonability of these cranes, and to prolong their lives, is one important harbour of state supervision and fault diagnosis in harbour machinery.
Taking the cause analysis and its repair scheme optimization of the rotating platfome sleeve crack with the 16t/33m gantry of the Sixth Harbour Company of Tianjin Harbour as the main research line, the dissertation makes such researches as on the conception and method of CAEA of stevedoring gantry crane structure, which includes the generating and treating method, the controlling method on the units and meshes. Analysis is carried out in the use of ANS YS software on the sleeve structure of the rotating platform thereof and stress, deformation and strain energy in the respect of distribution and the distribution atlas of stress, shift are acquired for the purpose of structure state monitoring and diagnosis as well as testing both in theory and technology instructions.
The main points of innovation are as follows:
Systematic research is made on the CAEA structure modeling of the stevedoring gantry crane. The combination of theoratic modeling and experimental modeling in its method and technology improves the reliability and scientific reasonability to model and calculate the results. The actual modeling and analysis therefor leads to the discovery of stress distribution under loading, which provides strong evidence for the cause of crack of the rotating platform. Correct repair scheme is proposed and testified, effectively solving the questioa with the 16t/33m gantry crane rotating platform and enhancing the scientific reasonability for a new step in the management level of harbour facilities.
本文以天津港第六港埠公司16t／33m门机转台筒体开裂的原因分析和修复裂纹方案优化为主线，研究了装卸型门机结构CAEA的概念和方法，包括模型的生成和处理的方法、单元和网格的控制方法等。运用ANSYS软件对装卸型门机的转台筒体结构进行了分析，得到了结构的应力、变形、应变能等的分布情况和应力、位移等分布图谱，为结构状态监测与诊断、测试提供了理论和技术指导。根据分析结果，给出了修复门机转台筒体裂纹的优化方案和具体的施工工艺，将结构CAEA方法应用于港口机械设备管理，指导港口设备金属结构的管理和检测。
本文的主要创新点是：
系统地研究了装卸型门机结构CAEA建模的技术问题，采用理论建模与实验建模相结合的建模方法与技术，提高了模型及其计算结果的可靠性与科学性。通过对装卸型门机转台筒体结构的实体建模与分析，发现了其在载荷作用下的应力分布情况，为转台筒体裂纹的产生原因提供了有力的证据。并提出和验证了修复方案的正确性，有效地解决了天津港16t／33m门机转台筒体开裂的实际问题，为治理该类门机的钢结构开裂开创了先例，对今后同类机型钢结构开裂的修复及新造同类结构门机提供了设计、工艺要求，均有良好的借鉴价值。为港口设备的安全生产提供了科学保障，大大提高了港口设备管理的科学性和合理性，使整个港口设备管理水平上一个新台阶。
Modem harbour crane has been continuously seeking higher economical efficiency. The stevedoring gantry crane in modern harbours plays a critical role in loading and discharge production. In a long term, management of metal structure is a difficult point in the
management of harbour equipment. How to increase the scientific reasonability of these cranes, and to prolong their lives, is one important harbour of state supervision and fault diagnosis in harbour machinery.
Taking the cause analysis and its repair scheme optimization of the rotating platfome sleeve crack with the 16t/33m gantry of the Sixth Harbour Company of Tianjin Harbour as the main research line, the dissertation makes such researches as on the conception and method of CAEA of stevedoring gantry crane structure, which includes the generating and treating method, the controlling method on the units and meshes. Analysis is carried out in the use of ANS YS software on the sleeve structure of the rotating platform thereof and stress, deformation and strain energy in the respect of distribution and the distribution atlas of stress, shift are acquired for the purpose of structure state monitoring and diagnosis as well as testing both in theory and technology instructions.
The main points of innovation are as follows:
Systematic research is made on the CAEA structure modeling of the stevedoring gantry crane. The combination of theoratic modeling and experimental modeling in its method and technology improves the reliability and scientific reasonability to model and calculate the results. The actual modeling and analysis therefor leads to the discovery of stress distribution under loading, which provides strong evidence for the cause of crack of the rotating platform. Correct repair scheme is proposed and testified, effectively solving the questioa with the 16t/33m gantry crane rotating platform and enhancing the scientific reasonability for a new step in the management level of harbour facilities.
引文
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[3] 陈玮璋，起重机械金属结构，北京：人民交通出版社，1986
[3] 高镇同等，结构全寿命主动可靠性设计与失效智能在线预示——未来机械设计领域的发展趋势，中国机械工程，2000，v11，n1-2，p53-55
[4] 盂宪颐等，在用塔式起重机金属结构剩余寿命的估算，建筑机械，1998，n7，p8-9
[6] 阮跃，振动故障模糊诊断方法的研究，电站系统工程，1999，v14 n4 p26-30
[7] 赵则祥等，机械故障计算机辅助简易诊断，中国机械工程，1998 n9 p45-47
[8] 黄安雅等，模糊信息处理技术在故障诊断中的应用，传动技术，1999，v13 nl p10-17
[9] 程瑞琪等，人工神经网络在设备故障诊断中的应用，机械研究与应用，1999，V12 n1 p13-14
[10] 张新江，旋转机械模糊故障诊断方法研究，煤矿机械，1999，n5 p15-17
[10] 张定会等，基于神经网络的故障诊断推理方法，上海交通大学学报，1999，v33 n5 p619-621
[12] 须雷，起重机可靠性指标的综合评定，起重运输机械，1999 n9 p1-4
[13] 邱忠宇等，基于知识与模糊神经网络的故障诊断技术，热能动力工程，1999 n5 p390-392
[14] 杜设亮等，基于BP神经网络的齿轮故障诊断系统研究，机电工程，1999，V16 n5 p81-82
[15] 沈国重等，基于小波变换预处理的一种神经网络故障诊断方法的研究，中国机械工程，1999，v10 n11 p1253-1255
[16] 何德芳等，失效分析与故障预防，北京：冶金工业出版社，1990
[17] 中国机械工程学会材料分会，失效分沂的思路与诊断，北京：机械工业出版社，1993
[18] 邝朴生等，设备诊断工程，北京：中国农业科技出版社，
[19] Chen, H.P. Damage identification in continuum structures from vibration modal data. Mater Res Soc Symp Proc 1998, USA, p281-286
[20] Bovsunovsky, Anotoly P. Comparative analysis of sensitivity of vibration damage indicators by the results of laboratory tests. Proc Int Modal And Conf v2 1999, USA p1909-1915
[21 ] Farrar, Charles R. Comparative study of damage identification algorithms applied to a bridge. Smart Mater Struct v7 n5 1998 p720-731
[22] Duron, Ziyad H. Condition assessment of large structures. S V Sound Vib v32 n8 1998 p16-20
[23] Zimmerman, David C Experimental study of damage detection using modal, strain, and Ritz properties. Proc Int Modal Anal Conf, Part 1, 1997 USA, p586-592
[24] Brown John. Finite element modal updating of a damaged structure. Proc Int Modal Anal Conf, 1999 USA p457-462
[25] Wang, M. L. Health monitoring system for large structural systems. Smart Mater Struct v7 n5 1998 p606-616
[26] Hassiotis S. Identification of damage using natural frequencies and system moments. Struct EngMech v8 n3 1999 p285-297
[27] Jenkins, C. H. Sensitivity of parameter changes in structural damage detection. Shock Vib v4 n1 1997 p27-37
[28] Law, S. S. Structural damage detection from incomplete and noisy modal test data. J Eng Mech v124 n11 1998 p1280-1288
[29] Gusella, Vitiorio. Safety estimation method for structures with cumulative damage. J Eng Mech v124 n11 1998, p1200-1209
[30] Ciampoli, Marcello. Probabilistic methodology to assess the reliability of deteriorating structural elements. Comput Methods Appl Mech Eng v168 n1-4 1999 p207-220
[31] Sawyer, J. P. Strength-based reliability and fracture assessment of fuzzy mechanical and structural systems. A1AA J v37 n1 1999 USA p84-92
[32] Godoy, Luis A. Stresses and pressures in thin-walled structures with damage and imperfections. Thin-walled Struct v32 n1-3 1997 p181-206
[33] Staszewski, W.J. Structural and mechanical damage detection using wavelet. Shock Vib Dig v30 n6 1998． p457-472
[34] Shi, Tianyun Approach to fault on-line detection and diagnosis based on neural networks for robot in FMS. Chinese J Mech Eng (in English) v11 n2 1998 p 115-121
[35] Lu, Chung-Jen, Application of wavelet transform to structural damage detection. Proc Iht Modal And Conf vl, 1999 USA, p840-845
[36] Pereira, Joao Antonio. Automation in fault detection using neural networks and model updating. Revista Brasileira Crencias Mecanicas v21 nl 1999, p99-108
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