捣固装置及其电液激振技术的研究
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摘要
捣固车是广泛应用于新建铁路和铁路大修中的养路机械。捣固装置是捣固车的核心部件,它是利用加压、冲击或振动的原理使得轨枕底部的道碴重新排列,紧固密实,并使枕下支撑力量均衡的一种专用机械装置。论文在综合分析了国内外捣固装置及其激振技术的研究现状与进展的基础上,结合工程实际,指出现存捣固装置的激振技术在频率和振幅的连续可调等方面存在的问题,提出了应用于捣固装置的电液激振技术。电液激振器在一定频率内能增大输出推力、实现高振幅以及解决液压缸振动时的偏置撞缸,其关键技术是通过步进电机带动阀芯旋转、液流高频换向使得液压缸运动换向,以实现激振频率和振幅的控制。研制出阀芯旋转式四通高速换向阀和自动限位的微行程双作用激振液压缸所组成的电液激振器,克服在高频换向难以实现大流量的缺陷,满足了捣固装置不同工况的需求。论文的主要研究工作如下：
1.结合新捣固装置的工作原理,主要对激振部分和下捣固臂进行数学建模分析。根据现有捣固装置的技术参数,以及捣固臂机构受力分析,完成了机械结构建模和设计,确定了装置中主要结构尺寸及电液激振器工作性能参数。利用虚拟样机技术及仿真软件平台Pro／E,建立新型捣固装置的虚拟样机,并进行运动学仿真。
2.通过分别建立电液激振器和转阀的数学模型,对电液激振器和转阀的特性进行了分析研究。针对捣固装置激振性能的要求,确定了电液激振器的结构原理及主要参数,并基于所需的振动波形进行了阀口分析求解。研究了不同参数(阀芯转速、阀口轴向面积导通宽度、阻尼和供油压力)对电液激振器动态性能的影响。
3.通过对转阀阀芯的受力情况进行分析,研究了阀芯旋转式四通高速换向阀阀芯的液动力矩和粘性摩擦力矩的生成机理和计算方法。探讨了结构参数(阀芯外径,阀芯和阀套的径向间隙,阀口轴向长度,阻尼比和转动惯量)对阀芯旋转式四通高速换向阀工作特性的影响。基于不同矩形阀口的阀芯结构,在考虑阀口压降对阀口过流面积影响的基础上,进一步分别对无环形槽阀芯和有环形槽阀芯建立对应的阀口过流面积模型以及其负载平均流量模型,对应用于捣固装置电液激振器的振动波形进行了具体数值分析。
4.研制出应用于捣固装置的电液激振试验系统,通过流量计、ICP加速度传感器和压力传感器测取激振缸在20-60Hz频率范围内的工作流量、运动参数值和激振力,对理论结果进行验证。
Tamping machine is a kind of special engineering equipment which is used for railway construction. Tamping device being used to compact ballast is the key part of tamping machine, with which two main tamping processes, clamping and vibrating, could be carried out Clamping squeezes the stones to flow under the sleeper and vibrating compresses ballast The development of tamping device is briefly introduced, and then the current status of tamping device and the exciting technology are discussed in detail. Combining with project practice, the problems concerning excitation technology of tamping device, control of electro-hydraulic vibration in high frequency and adjustable amplitude are analyzed, and the new electro-hydraulic excitation for tamping device is proposed. The novel electro-hydraulic exciter can increase the export force, realize high amplitude during certain frequency range and solve the problem of bias impact to the cylinder. Its key technology is realizing the control of excitation frequency and amplitude through the rotation valve spool which is driven by step motor and the hydraulic cylinder changing direction lead by the high frequent oil flow direction. This work developed a novel electro-hydraulic exciter comprising of high speed rotation valve with four-way commutation and auto-limitation micro-displacement double-rod cylinder. It can overcome the limitation of flow quantity under the condition of high frequent changing direction to meet the needs of different operating work of the tamping unit The main research works are as follows.
1. Based on working principle of tamping device, mathematical models of the exciting part and tamping arm were built According to the technical parameters of the existing tamping unit and the mechanism analysis of tamping arm, the new tamping unit mechanical design and structure modeling were completed. Then, the size of the device's main structure and the work performance parameters of electro-hydraulic exciter were determined. Taking advantage of virtual prototyping technology and simulation software platform Pro/E, a virtual prototype of the new tamping unit was created and kinematics simulation was carried out
2. The mathematical model of the electro-hydraulic exciter and rotary valve were built in order to study the characteristics of electro-hydraulic exciter and rotary valve respectively. According to the exciting performance requirements of tamping unit, the main structure principles and parameters of the electro-hydraulic exciter were determined, the valve port based on the required vibration waveform was solved. The different parameters (spool speed, the width of the valve port in axial direction, damping and oil pressure) working on the dynamic performance of the electro-hydraulic exciter were studied.
3. Through stress analysis of the rotary valve spool, the formation mechanism and calculation methods of hydrodynamic torque and viscous friction torque were studied. The impact of structural parameters (the Spool diameter, spool and radial sleeve clearance, the axial length of the valve port, damping ratio and rotational inertia) on the operating characteristics of high speed rotation valve was discussed. Based on different types of rectangular valve port structures, and considering the valve port flow area change caused by the pressure drop, the corresponding valve port flow area model and the average load flow model to spool with ring groove and without ring groove were built separately. Numerical calculation and analysis for vibration waveform of the new electro-hydraulic exciter were conducted.
4. Electro-hydraulic vibration test system used in tamping unit was established. The work flow, motion parameter values and exciting force of vibration cylinder within the range of20to60Hz are measured through flow meter, ICP acceleration and pressure sensors to verify the theoretical research.
1.结合新捣固装置的工作原理,主要对激振部分和下捣固臂进行数学建模分析。根据现有捣固装置的技术参数,以及捣固臂机构受力分析,完成了机械结构建模和设计,确定了装置中主要结构尺寸及电液激振器工作性能参数。利用虚拟样机技术及仿真软件平台Pro／E,建立新型捣固装置的虚拟样机,并进行运动学仿真。
2.通过分别建立电液激振器和转阀的数学模型,对电液激振器和转阀的特性进行了分析研究。针对捣固装置激振性能的要求,确定了电液激振器的结构原理及主要参数,并基于所需的振动波形进行了阀口分析求解。研究了不同参数(阀芯转速、阀口轴向面积导通宽度、阻尼和供油压力)对电液激振器动态性能的影响。
3.通过对转阀阀芯的受力情况进行分析,研究了阀芯旋转式四通高速换向阀阀芯的液动力矩和粘性摩擦力矩的生成机理和计算方法。探讨了结构参数(阀芯外径,阀芯和阀套的径向间隙,阀口轴向长度,阻尼比和转动惯量)对阀芯旋转式四通高速换向阀工作特性的影响。基于不同矩形阀口的阀芯结构,在考虑阀口压降对阀口过流面积影响的基础上,进一步分别对无环形槽阀芯和有环形槽阀芯建立对应的阀口过流面积模型以及其负载平均流量模型,对应用于捣固装置电液激振器的振动波形进行了具体数值分析。
4.研制出应用于捣固装置的电液激振试验系统,通过流量计、ICP加速度传感器和压力传感器测取激振缸在20-60Hz频率范围内的工作流量、运动参数值和激振力,对理论结果进行验证。
Tamping machine is a kind of special engineering equipment which is used for railway construction. Tamping device being used to compact ballast is the key part of tamping machine, with which two main tamping processes, clamping and vibrating, could be carried out Clamping squeezes the stones to flow under the sleeper and vibrating compresses ballast The development of tamping device is briefly introduced, and then the current status of tamping device and the exciting technology are discussed in detail. Combining with project practice, the problems concerning excitation technology of tamping device, control of electro-hydraulic vibration in high frequency and adjustable amplitude are analyzed, and the new electro-hydraulic excitation for tamping device is proposed. The novel electro-hydraulic exciter can increase the export force, realize high amplitude during certain frequency range and solve the problem of bias impact to the cylinder. Its key technology is realizing the control of excitation frequency and amplitude through the rotation valve spool which is driven by step motor and the hydraulic cylinder changing direction lead by the high frequent oil flow direction. This work developed a novel electro-hydraulic exciter comprising of high speed rotation valve with four-way commutation and auto-limitation micro-displacement double-rod cylinder. It can overcome the limitation of flow quantity under the condition of high frequent changing direction to meet the needs of different operating work of the tamping unit The main research works are as follows.
1. Based on working principle of tamping device, mathematical models of the exciting part and tamping arm were built According to the technical parameters of the existing tamping unit and the mechanism analysis of tamping arm, the new tamping unit mechanical design and structure modeling were completed. Then, the size of the device's main structure and the work performance parameters of electro-hydraulic exciter were determined. Taking advantage of virtual prototyping technology and simulation software platform Pro/E, a virtual prototype of the new tamping unit was created and kinematics simulation was carried out
2. The mathematical model of the electro-hydraulic exciter and rotary valve were built in order to study the characteristics of electro-hydraulic exciter and rotary valve respectively. According to the exciting performance requirements of tamping unit, the main structure principles and parameters of the electro-hydraulic exciter were determined, the valve port based on the required vibration waveform was solved. The different parameters (spool speed, the width of the valve port in axial direction, damping and oil pressure) working on the dynamic performance of the electro-hydraulic exciter were studied.
3. Through stress analysis of the rotary valve spool, the formation mechanism and calculation methods of hydrodynamic torque and viscous friction torque were studied. The impact of structural parameters (the Spool diameter, spool and radial sleeve clearance, the axial length of the valve port, damping ratio and rotational inertia) on the operating characteristics of high speed rotation valve was discussed. Based on different types of rectangular valve port structures, and considering the valve port flow area change caused by the pressure drop, the corresponding valve port flow area model and the average load flow model to spool with ring groove and without ring groove were built separately. Numerical calculation and analysis for vibration waveform of the new electro-hydraulic exciter were conducted.
4. Electro-hydraulic vibration test system used in tamping unit was established. The work flow, motion parameter values and exciting force of vibration cylinder within the range of20to60Hz are measured through flow meter, ICP acceleration and pressure sensors to verify the theoretical research.
引文
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