基于虚拟样机技术的采煤机建模与仿真研究
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摘要
采煤机是煤矿开采过程的主要设备之一,它主要包括截割部、行走部、牵引部以及相关的其他设备。由于井下的工作环境十分恶劣,其各部分所受到的负载也十分复杂,采用传统的研究方法很难全面了解采煤机在截割过程中的动态特性。而虚拟样机技术则为研究提供了一种新的方法。
以某煤机公司设计的MG300/700-WD型电机牵引采煤机为工程对象,应用MATLAB建立了采煤机受力的数学模型,并应用三维实体建模软件Pro/E为采煤机建立实体模型,在ANSYS中生成关键零件的模态中性文件,应用相应的接口技术导入到ADAMS,最终在ADAMS中形成采煤机刚-柔耦合模型。解决了采煤机在截割过程中负载输入的实现,以及添加约束、边界条件等关键技术。同时,提出了保证仿真精度、提高仿真速度、缩短仿真时间的具体措施,从而大大提高了Pro/E、MATLAB、ADAMS和ANSYS四款软件协同仿真的可操作性;基于虚拟样机技术的刚-柔耦合采煤机仿真分析,发现了采煤机关键零件设计上存在的诸如行走壳体应力过大、变形剧烈以及行走部二级行星部分动态同轴度超差等问题。依据仿真结果提出了改进措施及优化方案,为大型复杂环境下工作的采煤装备的设计与研究提供了一种新的方法和手段,具有巨大的意义和广阔的应用前景。
Shearer is one of the main equipment in coal mining process, which includes cutting units, travel units, haulage units and other related equipment. The underground working environment is very serious, so the loads on the shearer’s parts are very complex. It is difficult to fully understand the dynamic characteristics during the process of coal mining by using traditional methods. But virtual prototyping technology provides a new approach to study.
Taking a coal company designed MG300/700-WD electrical traction shearer as project object, force mathematical model has been built by MATLAB, and solid model of the shearer has been built by three-dimensional solid modeling software Pro/E,modal neutral files of the key parts have been generated by ANSYS and imported to ADAMS by using corresponding modal interface technology. At last rigid-flexible coupled model has been formed in ADAMS. Key technologies like loads input, adding constraints and boundary conditions during the cutting process have been solved. At the same time, specific measures about ensuring simulation accuracy, improving simulation speed and shortening the simulation time have proposed. Thus co-simulation’s operability about Pro/E, MATLAB, ADAMS and ANSYS has been greatly improved. Based on simulation analysis of the rigid-flexible coupling virtual prototype technology, the design problems of key parts such as the serious deformation and large stress on haulage unit’s shell, the out-of-tolerance of coaxial errors of haulage unit’s planetary part II, etc have been found. According to simulation results, improvement measures and optimization scheme are proposed. This method provides a new way to design and research the large mining equipment which are working in complex environment. It also has enormous significance and wide application prospects.
以某煤机公司设计的MG300/700-WD型电机牵引采煤机为工程对象,应用MATLAB建立了采煤机受力的数学模型,并应用三维实体建模软件Pro/E为采煤机建立实体模型,在ANSYS中生成关键零件的模态中性文件,应用相应的接口技术导入到ADAMS,最终在ADAMS中形成采煤机刚-柔耦合模型。解决了采煤机在截割过程中负载输入的实现,以及添加约束、边界条件等关键技术。同时,提出了保证仿真精度、提高仿真速度、缩短仿真时间的具体措施,从而大大提高了Pro/E、MATLAB、ADAMS和ANSYS四款软件协同仿真的可操作性;基于虚拟样机技术的刚-柔耦合采煤机仿真分析,发现了采煤机关键零件设计上存在的诸如行走壳体应力过大、变形剧烈以及行走部二级行星部分动态同轴度超差等问题。依据仿真结果提出了改进措施及优化方案,为大型复杂环境下工作的采煤装备的设计与研究提供了一种新的方法和手段,具有巨大的意义和广阔的应用前景。
Shearer is one of the main equipment in coal mining process, which includes cutting units, travel units, haulage units and other related equipment. The underground working environment is very serious, so the loads on the shearer’s parts are very complex. It is difficult to fully understand the dynamic characteristics during the process of coal mining by using traditional methods. But virtual prototyping technology provides a new approach to study.
Taking a coal company designed MG300/700-WD electrical traction shearer as project object, force mathematical model has been built by MATLAB, and solid model of the shearer has been built by three-dimensional solid modeling software Pro/E,modal neutral files of the key parts have been generated by ANSYS and imported to ADAMS by using corresponding modal interface technology. At last rigid-flexible coupled model has been formed in ADAMS. Key technologies like loads input, adding constraints and boundary conditions during the cutting process have been solved. At the same time, specific measures about ensuring simulation accuracy, improving simulation speed and shortening the simulation time have proposed. Thus co-simulation’s operability about Pro/E, MATLAB, ADAMS and ANSYS has been greatly improved. Based on simulation analysis of the rigid-flexible coupling virtual prototype technology, the design problems of key parts such as the serious deformation and large stress on haulage unit’s shell, the out-of-tolerance of coaxial errors of haulage unit’s planetary part II, etc have been found. According to simulation results, improvement measures and optimization scheme are proposed. This method provides a new way to design and research the large mining equipment which are working in complex environment. It also has enormous significance and wide application prospects.
引文
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[13]田振林,张传伟,李建华.综采工作面技术装备的发展动态[J].煤炭技术,2006(10):1-3.
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[19]陈云.大功率矿用行星减速器优化设计及三维特征建模的研究[D].辽宁工程技术大学图书馆,2006:25-39.
[20]温建民,于广滨,左晓英.Pro/E野火中文版残品设计应用范例[M].北京:清华大学出版社,2006:263-270.
[21] G.Gary Wang. Definition and Review of virtual Prototyping[J]. Journal of computing and Information Science in Engineering. 2002(2):232-236.
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[23]赵丽娟,李世旭,刘杰.基于Pro/E与ADAMS协同仿真中的图形数据交换[J].机械与电子,2006,总第170期(12):78-80.
[24]杜中华,狄长春,王兴贵. Pro/E与ADAMS建立的虚拟样机结构尺寸优化[J].机电工程技术,2002,31(4):31-32.
[25]石博强.ADAMS基础与工程范例教程[M].北京:中国铁道出版社,2007:163-170.
[26]范成建,熊光明,周明飞.虚拟样机软件MSC.ADAMS应用与提高[M].北京:机械工业出版社,2006:29-75.
[27]赵丽娟,董萌萌.含硫化铁结核薄煤层采煤机工作机构载荷问题研究[J].煤炭学报,2009,34(6):840-844.
[28]于润伟.MATLAB基础及应用[M].北京:机械工业出版社,2003:39-60.
[29]韦树宝.基于虚拟样机技术的龙门起重机动力学仿真研究[D].太原:武汉理工大学图书馆,2006
[30]孙恒,陈作模,葛文杰.机械原理[M].北京:高等教育出版社,2006:214-224.
[31]王振乾.滚筒式采煤机行走机构运动学分析及强度研究[D].上海:煤炭科学研究总院机械设计及理论,2007.
[32]纪玉祥.基于虚拟样机技术的采煤机动力学仿真[D].太原:太原理工大学机械设计及理论,2006.
[33]刘钦鹏.柔性空间展开机构动力学建模研究[J].机械设计,2006,23(3):1-3.
[34]鸿嘉振.刚柔耦合系统动力学研究进展[J].动力学与控制学报,2004,62(2):1-4.
[35]孙玉国.刚柔耦合动力系统固有振动特性研究[J].振动、测试与诊断,2003,23(1):48-50.
[36]洪清泉,程颖.一种齿轮副模型及其在多体动力学仿真中的应用[J].兵工学报,2003.24(4):509-512.
[37]朱才朝,秦大同,李润方等.内齿行星齿轮传动动态特性的研究[J].重庆大学学报(自然科学版),1997,20(5):26-32.
[38]王春光.行星齿轮传动动态特性的研究[J].哈尔滨船舶锅炉轮机研究所,2005.3
[39]阎绍泽.含间隙铰的机械多体系统动力学模型[J].振动工程学报,2003,16(3):290-293.
[40]陆佑方.柔性多体动力学[M].北京:高等教育出版社,1996:120-121.
[41]蒋元广,左正兴.多领域协同仿真分析的集成方法研究[J].轻型汽车技术,2006,204(8):8-14.
[42]何涛,杨竞,金鑫.ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程[M].北京:机械工业出版社,2007:101-110.
[43]梁浩,余跃庆,张成新.基于ADAMS及ANSYS的柔性机器人动力学仿真系统[J].机械科学与技术,2002,21(6):892-895.
[44]邢俊文.MSC.ADAMS/Flex与AutoFlex培训教程[M].北京:科学出版社,2006:57-78.
[45]赫雄.ADAMS动力学仿真算法及参数设置分析[J].传动技术,2005,19(3): 27-30.
[46]于殿勇,钱玉进.基于ADAMS动力学仿真参数设置的研究[J].计算机仿真,2006,23(9): 103-107.
[47]戴洪光.基于ADAMS平台的柔性体仿真理论的若干研究[D].合肥:合肥工业大学图书馆,2008.
[48] Gill-Jeong Cheon, Robert G. Parker. Influence of Manufacturing Errors on the Dynamic Characteristics of Planetary Gear Systems [J]. KSME International Journal, 2004, 18(4):606-621.
[49] JWeickert, BM terHaarRomeny, M A Viergever. Efficient and Reliable Schemes for Nonlinear Diffusion Filtering[J]. IEEE Transactions on Image Processing, 1998,7(3): 398-410.
[50]王国强,张进平,马若丁.虚拟样机技术机器在ADAMS上的实践[M].西安:西北工业大学出版社,2002:134-164.
[51]赵丽娟,马永志.基于多体动力学的采煤机截割部可靠性研究[J].煤炭学报,2009,34(9): 1271-1275.
[2]蔡有章.采煤机司机(初级、中级、高级)[M].北京:煤炭工业出版社,2005:12-19.
[3]邵俊杰.采煤机数值化建模与关键零部件有限元分析[D].西安:西安科技大学图书馆,2009.
[4] K Abdul Ghani,V Jayabalan,M Sugumar. Impact of Advanced Manufacturing Technology on Organizational Structure. Journal of High Technology Management Research,2002(13):157-175
[5] Packer R J. The role of modeling in system design and acceptance[J]. Padar System Modeling (Ref. No.1998/459). 1998(5):1-6.
[6] Bo Hu Li, Xingren Wang, Kedi Huang, etc. Further Research on Synthetic Simulation Environment[J]. IEEE Colloquium on Published, 2000,12(5):285-290.
[7] Hou,BL,Wang,JN. Evaluation of dynamic performance of mageneto. Theological damper by virtual prototype technology [J].International Journal of Modern Physics. B,Condensed Matter Physics, Statistical Physics,Applied Physics,2005.
[8]赵丽娟,刘杰.复杂机电系统的建模与仿真研究[M].沈阳:辽宁大学出版社,2007:1-8
[9]李薇.虚拟样机技术的研究和实现[D].南京:南京理工大学图书馆,2002.
[10]马涛.基于虚拟样机技术的矿用掘进机行走减速器仿真研究[D].太原:太原理工大学图书馆,2008.
[11]席俊杰.虚拟样机技术的发展及应用[J].制造业自动化,2006,11(11)19-22.
[12]刘楷安.采煤机截割部虚拟样机及其动态特性仿真研究[D].太原:太原理工大学图书馆,2005.
[13]田振林,张传伟,李建华.综采工作面技术装备的发展动态[J].煤炭技术,2006(10):1-3.
[14]李贵轩,李晓豁.采煤机械设计[M].沈阳:辽宁大学出版社,1994:15-20.
[15]胡仁喜,张心俊,吴高阳.Pro/ENGINEER Wildfire 3.0中文版机械设计高级应用实例[M].北京:机械工业出版社,2007:1-16.
[16]李建广,夏平均.虚拟装配技术研究现状及其发展[J].航空制造技术,2010(3):34-38.
[17]张林煊,童秉枢.并行工程中的装配仿真系统及其关键技术研究[J].计算机辅助设计与图形学学报,1999(2):163-167.
[18]林清安.Pro/ENGINEER野火3.0中文版动态机构设计与仿真[M].北京:电子工业出版社,2007:25-33.
[19]陈云.大功率矿用行星减速器优化设计及三维特征建模的研究[D].辽宁工程技术大学图书馆,2006:25-39.
[20]温建民,于广滨,左晓英.Pro/E野火中文版残品设计应用范例[M].北京:清华大学出版社,2006:263-270.
[21] G.Gary Wang. Definition and Review of virtual Prototyping[J]. Journal of computing and Information Science in Engineering. 2002(2):232-236.
[22]王振乾,汪崇建,周常飞.基于ADAMS的采煤机行走运动学分析[J],煤矿机电, 2007(1).
[23]赵丽娟,李世旭,刘杰.基于Pro/E与ADAMS协同仿真中的图形数据交换[J].机械与电子,2006,总第170期(12):78-80.
[24]杜中华,狄长春,王兴贵. Pro/E与ADAMS建立的虚拟样机结构尺寸优化[J].机电工程技术,2002,31(4):31-32.
[25]石博强.ADAMS基础与工程范例教程[M].北京:中国铁道出版社,2007:163-170.
[26]范成建,熊光明,周明飞.虚拟样机软件MSC.ADAMS应用与提高[M].北京:机械工业出版社,2006:29-75.
[27]赵丽娟,董萌萌.含硫化铁结核薄煤层采煤机工作机构载荷问题研究[J].煤炭学报,2009,34(6):840-844.
[28]于润伟.MATLAB基础及应用[M].北京:机械工业出版社,2003:39-60.
[29]韦树宝.基于虚拟样机技术的龙门起重机动力学仿真研究[D].太原:武汉理工大学图书馆,2006
[30]孙恒,陈作模,葛文杰.机械原理[M].北京:高等教育出版社,2006:214-224.
[31]王振乾.滚筒式采煤机行走机构运动学分析及强度研究[D].上海:煤炭科学研究总院机械设计及理论,2007.
[32]纪玉祥.基于虚拟样机技术的采煤机动力学仿真[D].太原:太原理工大学机械设计及理论,2006.
[33]刘钦鹏.柔性空间展开机构动力学建模研究[J].机械设计,2006,23(3):1-3.
[34]鸿嘉振.刚柔耦合系统动力学研究进展[J].动力学与控制学报,2004,62(2):1-4.
[35]孙玉国.刚柔耦合动力系统固有振动特性研究[J].振动、测试与诊断,2003,23(1):48-50.
[36]洪清泉,程颖.一种齿轮副模型及其在多体动力学仿真中的应用[J].兵工学报,2003.24(4):509-512.
[37]朱才朝,秦大同,李润方等.内齿行星齿轮传动动态特性的研究[J].重庆大学学报(自然科学版),1997,20(5):26-32.
[38]王春光.行星齿轮传动动态特性的研究[J].哈尔滨船舶锅炉轮机研究所,2005.3
[39]阎绍泽.含间隙铰的机械多体系统动力学模型[J].振动工程学报,2003,16(3):290-293.
[40]陆佑方.柔性多体动力学[M].北京:高等教育出版社,1996:120-121.
[41]蒋元广,左正兴.多领域协同仿真分析的集成方法研究[J].轻型汽车技术,2006,204(8):8-14.
[42]何涛,杨竞,金鑫.ANSYS10.0/LS-DYNA非线性有限元分析实例指导教程[M].北京:机械工业出版社,2007:101-110.
[43]梁浩,余跃庆,张成新.基于ADAMS及ANSYS的柔性机器人动力学仿真系统[J].机械科学与技术,2002,21(6):892-895.
[44]邢俊文.MSC.ADAMS/Flex与AutoFlex培训教程[M].北京:科学出版社,2006:57-78.
[45]赫雄.ADAMS动力学仿真算法及参数设置分析[J].传动技术,2005,19(3): 27-30.
[46]于殿勇,钱玉进.基于ADAMS动力学仿真参数设置的研究[J].计算机仿真,2006,23(9): 103-107.
[47]戴洪光.基于ADAMS平台的柔性体仿真理论的若干研究[D].合肥:合肥工业大学图书馆,2008.
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