翻车机防掉道设计研究
|
摘要
翻车机用于铁路车辆的翻卸工作,在我国煤炭、港口货物卸运系统中有着重要地位。翻车机工作时发生掉道事故导致巨大的经济损失甚至人身伤亡,消除翻车机掉道具有十分重要的意义。本文对翻车机液压系统进行了改进以提高翻车机工作可靠性,并设计了一套螺旋机构安装于翻车机大梁,利用其自锁特性从根本上消除翻车机掉道的风险。
本文在对翻车机液压系统深入分析基础上,确定了翻车机掉道的根本原因是压车缸在工作过程中回缩的行程超过了车轮轮辕台阶的高度。通过对翻车机液压系统进行改进,提高翻车机液压系统工作可靠性。
针对翻车机掉道的风险,设计出一套防掉道机构和相应的液压控制回路。结合翻车机现有结构空间布局,对于防掉道机构的关键部件螺旋副进行了参数设计计算。
运用FMECA对翻车机防掉道系统进行分析,确定系统运行过程中可能发生的各种故障模式,以及每一故障模式的原因和影响。找出系统潜在的薄弱环节是支承螺杆和螺旋套,并通过设计优化提高他们的可靠性。液压泵和液压马达失效也是危害度最高的故障模式,液压系统失效的共因是系统污染,因此对液压系统维护工作尤其重要。
采用有限元的方法对螺旋副进行强度分析,研究螺旋副承受轴向载荷时的应力和应变分布规律、应力集中情况。通过对螺母外圈尺寸和螺旋副的啮合圈数取不同数值进行分析比较,优化了螺旋副结构参数。
Car dumper is widely used to unload bulk materials from trains, leading a significant role on the national transportation system. Derailment accidents while car dumper overturning cargo results in heavy economic damage even person casualty. Thus eliminating car dumper derailment accident is very necessary. Gaining experience from related anti-derailment methods and combining spot investigation, a set of screw pair equipment is designed. The characteristic of screw pair self-lock is applied to eliminate the risk of car dumper derailment.
Based on the analysis of hydraulic system of car dumper, the ultimate cause for car dumper derailment is traced that cargo-pressing hydraulic cylinder recession distance exceeds the step height of cartwheel. Hydraulic system is reconstructed to make car dumper work more reliably and reasonably.
A set of anti-derailment equipment is designed to eliminate the risk of car dumper derailment. Screw pair is the key component in the set of anti-derailment equipment. By investigating installment space and requirement of working parameter of the car dumper, preliminary parameters for screw pair come out, with checking calculation by the method of material mechanics. The dissertation also discussed the principle of adding hydraulic circuit and completed the selection of related hydraulic components.
FMECA is applied to analyze the reliability of anti-derailment system of the car dumper. Various potential failure modes, plus causes and effects of each failure modes, are determined. The weak link of the system is supporting screw rod and nut suit, which reliability should be improved by optimized design. Failure from hydraulic pump and motor were also ascertained as the most critical failure modes. According FMECA analysis, the common causes of hydraulic system components are hydraulic contaminations, which require paying special attentions to hydraulic system maintenances.
Finite element method is applied to analyze the screw pair intensity, research on the distribution regularity of stress and strain and stress concentration when imposing axial load on the screw rod. By analyzing and comparing calculation result from defining series of outer diameter of screw nut and series of meshing cycle numbers of screw pair, parameters of screw pair are optimized.
本文在对翻车机液压系统深入分析基础上,确定了翻车机掉道的根本原因是压车缸在工作过程中回缩的行程超过了车轮轮辕台阶的高度。通过对翻车机液压系统进行改进,提高翻车机液压系统工作可靠性。
针对翻车机掉道的风险,设计出一套防掉道机构和相应的液压控制回路。结合翻车机现有结构空间布局,对于防掉道机构的关键部件螺旋副进行了参数设计计算。
运用FMECA对翻车机防掉道系统进行分析,确定系统运行过程中可能发生的各种故障模式,以及每一故障模式的原因和影响。找出系统潜在的薄弱环节是支承螺杆和螺旋套,并通过设计优化提高他们的可靠性。液压泵和液压马达失效也是危害度最高的故障模式,液压系统失效的共因是系统污染,因此对液压系统维护工作尤其重要。
采用有限元的方法对螺旋副进行强度分析,研究螺旋副承受轴向载荷时的应力和应变分布规律、应力集中情况。通过对螺母外圈尺寸和螺旋副的啮合圈数取不同数值进行分析比较,优化了螺旋副结构参数。
Car dumper is widely used to unload bulk materials from trains, leading a significant role on the national transportation system. Derailment accidents while car dumper overturning cargo results in heavy economic damage even person casualty. Thus eliminating car dumper derailment accident is very necessary. Gaining experience from related anti-derailment methods and combining spot investigation, a set of screw pair equipment is designed. The characteristic of screw pair self-lock is applied to eliminate the risk of car dumper derailment.
Based on the analysis of hydraulic system of car dumper, the ultimate cause for car dumper derailment is traced that cargo-pressing hydraulic cylinder recession distance exceeds the step height of cartwheel. Hydraulic system is reconstructed to make car dumper work more reliably and reasonably.
A set of anti-derailment equipment is designed to eliminate the risk of car dumper derailment. Screw pair is the key component in the set of anti-derailment equipment. By investigating installment space and requirement of working parameter of the car dumper, preliminary parameters for screw pair come out, with checking calculation by the method of material mechanics. The dissertation also discussed the principle of adding hydraulic circuit and completed the selection of related hydraulic components.
FMECA is applied to analyze the reliability of anti-derailment system of the car dumper. Various potential failure modes, plus causes and effects of each failure modes, are determined. The weak link of the system is supporting screw rod and nut suit, which reliability should be improved by optimized design. Failure from hydraulic pump and motor were also ascertained as the most critical failure modes. According FMECA analysis, the common causes of hydraulic system components are hydraulic contaminations, which require paying special attentions to hydraulic system maintenances.
Finite element method is applied to analyze the screw pair intensity, research on the distribution regularity of stress and strain and stress concentration when imposing axial load on the screw rod. By analyzing and comparing calculation result from defining series of outer diameter of screw nut and series of meshing cycle numbers of screw pair, parameters of screw pair are optimized.
引文
[1]翻车机卸车系统.大连重工机电动力有限公司. http://www.dhiaaa.com/fcxt.asp/
[2]李胜振.翻车机系统车辆脱轨事故原因分析及防范措施.河北电力技术，2007，26 (2)：46~47
[3]杜勇.翻车机系统研究及优化设计：[工程硕士学位论文].武汉：武汉大学，2004
[4]张文生，戴财生.翻车机卸车系统发展方向的探讨.港工技术，2007 (6)：24~25
[5]王金福,钱亚臣,郭晓勇.翻车机卸车系统的现状及发展.矿山机械，2005(11)：27~28
[6]徐荣华，李世亮，王寿长.重载运输与翻车机的关系.铁道车辆，1993(12)：66~67
[7] Justin Alberty, Johnnie Zibert. Repair technique extends rotary dumper life. Power Engineering. Barrington, 1997, 101 (9): 53
[8]王金福，李继.翻车机卸车系统的改进.起重运输机械，1999 (7)：33
[9]高徐生，江雪.转子式翻车机主要故障的修复.煤矿机械，2001 (4)：47
[10]刘金胜，杨永德.翻车机内车辆脱轨事故的原因及预防.电力安全技术, 2001，3 (1): 22
[11]纪光辉.进口翻车机系统设备掉道问题的改进.湖北电力, 2002，26 (6): 59~60
[12]剧会彬，袁占青，郭玉中.防止翻车机车皮掉道问题的探讨.燃料与化工，1998 (11):295
[13] G.JB451A-2005.可靠性维修性保障性术语.2005
[14] G.JB450A-2004.装备可靠性工作要求.2004
[15] Puneet Kukkal, John B. Bowles, Ronad D Donell.DataBase Degign for Failure Mode and Effects Analysis. PROCEEDINGS Annual Reliability And Maintainability Symposium, 1993: 232~238
[16] Gabor Kocza, Andre Bossche. Application of the integrated reliability analysis system (IRAS). Reliability Engineering and System Safety, 1999 (64): 99~107
[17] Burton H.Lee. Using bayes belief networks in industrial FMEA modeling and analysis. Proceedings Annual and Maintainablity Symposium, 2001: 7~15
[18] G.Q.Huang, M. Nie, K.L. Mak. Web-based failure mode and efeect analysis (FMEA). Computers&Industrial Engineering 1999 (37): 170~180
[19]陈勇飞. FMEA简介.机械工程师，2002 , 1: 31~35
[20]孙有朝，樊慰勋.故障模式影响的模糊综合评判.机械传动，1997 (12): 12~15
[21]康锐，石荣德. FMECA技术及其应用.北京：国防工业出版社，2006：15~36
[22] Steven Kementa. Advanced Failure Modes and Effects Analysis: A Mothod for Predicting and Evaluating Failures in Products and Processes. Stanford University Doctor Paper, 2000
[23] Joseph T Pizzo. Probabilistic FMECA.Proceedings Annual and Maintainablity Symposium, 1994: 390~395
[24]天津大学材料力学教研室电测组编著.电阻应变仪测试技术.北京：科学出版社，1980: 23~27
[25]张如一.应变电测与传感器.北京：清华大学出版社，1999: 45~47
[26]马惠南.电阻应变计法测定载荷.黑龙江水利科技，2003 (1): 73
[27]袁桂芳.高强度螺栓的应力测试阴.起重运输机械，2004 (5): 53~54
[28]邹宇峰，舒世明.一种拉扭构件荷载的电测法.企业技术开发，2008，28 (1): 5
[29] Yan Chengai.The Research of a New Coating Material in the Photoelastic Coating. ICAEM, TIANJIN CHINA, 1988.
[30]戴积林.平面和曲面栅状光贴片的研制—聚碳酸酯PC光贴片的系列研究之二.第八届全国实验力学学术会议论文集，1995.
[31]严承蔼.光贴片法中新型贴片材料的研究.中国科学技术文库, 1998.
[32]任春红.光弹性实验中研究应力集中的两个问题.河南机电高等专科学校学报，2004，12 (2): 18
[33]严承蔼.光弹性贴片法及工程应用.测控技术，2001，(207)：46
[34] OgiH, Hirao Mand Fukuoka H. Aeoustoelastic stress measurement on railroad rails using electromagnetic transducer. Nippon Kikai Gakkai Ronbunshu , 1994, 60(571): 881~887
[35] Yamasak T, Ikeda M, Fukuoka H. Stress dependence of anhysteretic permeability and itsapplication to nondestructive residual stress measurement. Nippon Kakai Gakkai Ronbunshu, 1994, 60(571):777~783.
[36] JiaoFJ. Zhang WJ.YuanZK.Measurement of welding residual stresses by aeoustoelastic technique. HanjieXuebao, 1993, 14(2): 98~103
[37] SatoH. Nlshino H，Cho H. Estlmation of elastiec constants from surface acoustic wave velocity by inverse analyslsis，using the downhill simplex method . Japanese Journal ofApplied physics (part l:Regular papers & short Notes & Review papers)，1998，37(5B): 3116~3119
[38]福冈秀和，户田裕己.音弹性残留应力解析.材料，1986, 35 (396): 961~971
[39]王璋奇等.螺栓应力测量的超声波法综述.电力情报，1994 (3): 21~25
[40]刘镇涛.用超声波技术测量螺栓轴向紧固应力田.测试技术学报，11 (l) 1997:32~37
[41] Sopwith D.G.. The distribution of load in screw thread. Inst. Mech. Eng. Appl. Mech. Proc. 159: 373~383.
[42]И·A·比尔格尔.机械零件强度手册.北京：机械工业出版社，1987.
[43] Yamamoto，A.，1980. Theory and Computation of Thread conneetion. Youkendo，Tokyo: 35~54
[44]李黎明. ANSYS有限元分析实用教程.北京：清华大学出版社，2005：10
[45] Jien-Jongehen，Yan-Shin Shih.A Study of the Helical Effect on the Threaded Connection by Three Dimensional Finite Element Analysis. Nuclear Engineering and Design l91(1999): 109~116
[46] Satoshi Izumi. Three-dimensional Finite Element Analysis of Tightening and Loosening Mechanism of threaded Fastener. Engineering Failure Analysis 12(2005): 604~615
[47]黄志东，任继文，卢怀亮等.滑动螺旋传动中螺牙应力和工作压力的研究.锻压技术,2004 (2)：57~58
[48]张尔文.重载传动螺旋副受力分析与承载能力研究：［硕士学位论文］广州：广东工业大学，2007
[49]山本晃.螺纹联接的理论与计算.郭可谦译.上海:上海科学技术出版, 1984: 15~28
[50] Lehnloff，T.F.，Wiistehuff，WE.，Non-linear Effeets on the Stress and Deformations of Bolt Joint. Mechanical Design 118(1996): 54~58
[51]周先辉.高效重载钢背衬碳织物/环氧树脂复合材料螺旋副研究：［博士学位论文］广州：广东工业大学，2008
[52]小飒工作室编.最新经典ANSYS及workbench教程.北京:电子工业出版社, 2004
[53]周先辉，孙友松，张尔文.基于有限元方法的传动螺纹螺牙轴向载荷分布规律分析.机械设计与制造，2008 (1)：17~18
[2]李胜振.翻车机系统车辆脱轨事故原因分析及防范措施.河北电力技术，2007，26 (2)：46~47
[3]杜勇.翻车机系统研究及优化设计：[工程硕士学位论文].武汉：武汉大学，2004
[4]张文生，戴财生.翻车机卸车系统发展方向的探讨.港工技术，2007 (6)：24~25
[5]王金福,钱亚臣,郭晓勇.翻车机卸车系统的现状及发展.矿山机械，2005(11)：27~28
[6]徐荣华，李世亮，王寿长.重载运输与翻车机的关系.铁道车辆，1993(12)：66~67
[7] Justin Alberty, Johnnie Zibert. Repair technique extends rotary dumper life. Power Engineering. Barrington, 1997, 101 (9): 53
[8]王金福，李继.翻车机卸车系统的改进.起重运输机械，1999 (7)：33
[9]高徐生，江雪.转子式翻车机主要故障的修复.煤矿机械，2001 (4)：47
[10]刘金胜，杨永德.翻车机内车辆脱轨事故的原因及预防.电力安全技术, 2001，3 (1): 22
[11]纪光辉.进口翻车机系统设备掉道问题的改进.湖北电力, 2002，26 (6): 59~60
[12]剧会彬，袁占青，郭玉中.防止翻车机车皮掉道问题的探讨.燃料与化工，1998 (11):295
[13] G.JB451A-2005.可靠性维修性保障性术语.2005
[14] G.JB450A-2004.装备可靠性工作要求.2004
[15] Puneet Kukkal, John B. Bowles, Ronad D Donell.DataBase Degign for Failure Mode and Effects Analysis. PROCEEDINGS Annual Reliability And Maintainability Symposium, 1993: 232~238
[16] Gabor Kocza, Andre Bossche. Application of the integrated reliability analysis system (IRAS). Reliability Engineering and System Safety, 1999 (64): 99~107
[17] Burton H.Lee. Using bayes belief networks in industrial FMEA modeling and analysis. Proceedings Annual and Maintainablity Symposium, 2001: 7~15
[18] G.Q.Huang, M. Nie, K.L. Mak. Web-based failure mode and efeect analysis (FMEA). Computers&Industrial Engineering 1999 (37): 170~180
[19]陈勇飞. FMEA简介.机械工程师，2002 , 1: 31~35
[20]孙有朝，樊慰勋.故障模式影响的模糊综合评判.机械传动，1997 (12): 12~15
[21]康锐，石荣德. FMECA技术及其应用.北京：国防工业出版社，2006：15~36
[22] Steven Kementa. Advanced Failure Modes and Effects Analysis: A Mothod for Predicting and Evaluating Failures in Products and Processes. Stanford University Doctor Paper, 2000
[23] Joseph T Pizzo. Probabilistic FMECA.Proceedings Annual and Maintainablity Symposium, 1994: 390~395
[24]天津大学材料力学教研室电测组编著.电阻应变仪测试技术.北京：科学出版社，1980: 23~27
[25]张如一.应变电测与传感器.北京：清华大学出版社，1999: 45~47
[26]马惠南.电阻应变计法测定载荷.黑龙江水利科技，2003 (1): 73
[27]袁桂芳.高强度螺栓的应力测试阴.起重运输机械，2004 (5): 53~54
[28]邹宇峰，舒世明.一种拉扭构件荷载的电测法.企业技术开发，2008，28 (1): 5
[29] Yan Chengai.The Research of a New Coating Material in the Photoelastic Coating. ICAEM, TIANJIN CHINA, 1988.
[30]戴积林.平面和曲面栅状光贴片的研制—聚碳酸酯PC光贴片的系列研究之二.第八届全国实验力学学术会议论文集，1995.
[31]严承蔼.光贴片法中新型贴片材料的研究.中国科学技术文库, 1998.
[32]任春红.光弹性实验中研究应力集中的两个问题.河南机电高等专科学校学报，2004，12 (2): 18
[33]严承蔼.光弹性贴片法及工程应用.测控技术，2001，(207)：46
[34] OgiH, Hirao Mand Fukuoka H. Aeoustoelastic stress measurement on railroad rails using electromagnetic transducer. Nippon Kikai Gakkai Ronbunshu , 1994, 60(571): 881~887
[35] Yamasak T, Ikeda M, Fukuoka H. Stress dependence of anhysteretic permeability and itsapplication to nondestructive residual stress measurement. Nippon Kakai Gakkai Ronbunshu, 1994, 60(571):777~783.
[36] JiaoFJ. Zhang WJ.YuanZK.Measurement of welding residual stresses by aeoustoelastic technique. HanjieXuebao, 1993, 14(2): 98~103
[37] SatoH. Nlshino H，Cho H. Estlmation of elastiec constants from surface acoustic wave velocity by inverse analyslsis，using the downhill simplex method . Japanese Journal ofApplied physics (part l:Regular papers & short Notes & Review papers)，1998，37(5B): 3116~3119
[38]福冈秀和，户田裕己.音弹性残留应力解析.材料，1986, 35 (396): 961~971
[39]王璋奇等.螺栓应力测量的超声波法综述.电力情报，1994 (3): 21~25
[40]刘镇涛.用超声波技术测量螺栓轴向紧固应力田.测试技术学报，11 (l) 1997:32~37
[41] Sopwith D.G.. The distribution of load in screw thread. Inst. Mech. Eng. Appl. Mech. Proc. 159: 373~383.
[42]И·A·比尔格尔.机械零件强度手册.北京：机械工业出版社，1987.
[43] Yamamoto，A.，1980. Theory and Computation of Thread conneetion. Youkendo，Tokyo: 35~54
[44]李黎明. ANSYS有限元分析实用教程.北京：清华大学出版社，2005：10
[45] Jien-Jongehen，Yan-Shin Shih.A Study of the Helical Effect on the Threaded Connection by Three Dimensional Finite Element Analysis. Nuclear Engineering and Design l91(1999): 109~116
[46] Satoshi Izumi. Three-dimensional Finite Element Analysis of Tightening and Loosening Mechanism of threaded Fastener. Engineering Failure Analysis 12(2005): 604~615
[47]黄志东，任继文，卢怀亮等.滑动螺旋传动中螺牙应力和工作压力的研究.锻压技术,2004 (2)：57~58
[48]张尔文.重载传动螺旋副受力分析与承载能力研究：［硕士学位论文］广州：广东工业大学，2007
[49]山本晃.螺纹联接的理论与计算.郭可谦译.上海:上海科学技术出版, 1984: 15~28
[50] Lehnloff，T.F.，Wiistehuff，WE.，Non-linear Effeets on the Stress and Deformations of Bolt Joint. Mechanical Design 118(1996): 54~58
[51]周先辉.高效重载钢背衬碳织物/环氧树脂复合材料螺旋副研究：［博士学位论文］广州：广东工业大学，2008
[52]小飒工作室编.最新经典ANSYS及workbench教程.北京:电子工业出版社, 2004
[53]周先辉，孙友松，张尔文.基于有限元方法的传动螺纹螺牙轴向载荷分布规律分析.机械设计与制造，2008 (1)：17~18