挤压类破碎机工作机理和工作性能优化研究
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摘要
挤压类破碎机是散体物料破碎的主要设备,广泛应用在冶金矿山工业、建材工业、筑路工业、化学工业和硅酸盐工业中。然而,国产挤压类破碎机设计比较保守、机器笨重、效率比较低下、能耗高和破碎产品质量与国外产品相比差距还比较大。
自从20世纪中后叶开始,国外研制开发出集层压腔形、高摆频和合理摆动冲程于一身的现代高能挤压类破碎机,这些破碎机集机、电、液技术于一体,实现了远程自动监控、自动清腔、自动过载保护等先进功能,从而极大地提高了破碎机工作性能,改善了破碎产品质量,提高了破碎机厂家和用户的经济效益。
然而国产挤压类破碎机自从20世纪中叶仿制成功以来,未得到大的发展,其技术水平基本停留在国外先进水平的第一代和第二代水平上。因此,为改善国产挤压类破碎机工作性能,提高我国装备制造业技术水平,本文基于先进破碎理论—层压破碎,采用现代优化设计技术,以圆锥破碎机为研究对象,对挤压类破碎机工作机理和工作性能进行了深入研究,建立挤压类破碎机生产率、破碎产品粒度和腔型的多目标规划模型,为研制开发具有完全自主知识产权的新型、高效、节能和环保的现代高能挤压类破碎机奠定理论基础。
围绕如何实现这些目标,本文在上海市科委和某大型破碎机企业合作项目的支持下,将研究课题定位于挤压类破碎机工作机理和工作性能优化研究。全文从破碎机工作机理和工作性能的不同角度展开,在层压破碎理论、挤压类破碎机生产率模型、层压曲线腔型模型、腔形设计方法、破碎产品粒度分布模型和多目标规划模型等方面实现了突破。
本文主要包括下述主要工作和结论:
(1)总结归纳了国内外层压破碎研究成果,探讨了在挤压类破碎机上实现层压破碎的优越性、基本前提和可行性,对挤压类层压破碎机关键使能技术进行了概述。
(2)对破碎机和破碎腔内散体物料的运动特性进行了深入研究,探讨了破碎机和散体物料运动状态对破碎机工作性能的影响,建立挤压类破碎机破碎腔内散体物料运动轨迹模型,提出挤压类破碎机分层破碎特性,为破碎腔进行分层研究和设计奠定基础。
基于破碎机和散体物料运动学和动力学特性,建立挤压类破碎机生产率模型。对影响破碎机生产率的关键结构参数和工作参数进行深入研究,建立生产率与各关键因素关系模型。以改进型国产PYB900圆锥破碎机为研究对象,对破碎机生产率进行了研究,对影响破碎机工作性能的各关键结构参数和工作参数(包括偏心套转速、动锥大小、动锥底角、进动角、排料口摆动行程、闭边排料口尺寸、平行区长度等)进行了定性和定量分析,从而验证了生产率模型的可行性和可靠性。
(3)利用RMT-150B岩石力学试验系统对石灰石散体物料层压破碎过程进行了试验研究,对试验数据进行统计回归分析,得到挤压类破碎机层压破碎过程选择函数模型和破碎函数模型,为对层压破碎产品粒度计算分析提供理论依据。
基于层压破碎原理、总体平衡模型和分层破碎特性,对挤压类破碎机破碎腔内散体物料破碎过程进行了深入研究,结合散体物料破碎矩阵模型,建立挤压类破碎机破碎腔内散体物料层压破碎过程操作模型,揭示了挤压类破碎机层压破碎过程的本质原因,为对破碎产品粒度分布研究和优化奠定基础。
以改进型国产PYB900圆锥破碎机为研究对象,对破碎机破碎产品粒度分布进行了深入研究,建立破碎产品粒度与影响破碎机工作性能的各关键因素关系模型,对各关键因素进行了定性和定量分析。
(4)基于分层破碎特性,结合挤压类破碎腔工作特性,提出适用于挤压类破碎机设计的固定质量原理,并应用于对挤压类破碎机曲线腔形的研究,有效减少或消除了挤压类破碎机破碎腔各破碎层的堵塞和待料。在挤压类破碎机破碎腔研究中,引入工态啮角概念,保证了破碎腔的咬入特性,提高了破碎机工作性能。
基于层压破碎原理、分层破碎特性、固定质量原理和工态啮角要求,建立挤压类破碎机层压曲线腔形模型,提出层压曲线腔形设计新方法。
(5)为研制开发高效挤压类层压破碎机,基于挤压类破碎机工作机理和工作性能研究,建立挤压类破碎机生产率、破碎产品粒度和腔型的多目标规划模型。
结合圆锥破碎机多目标规划问题,对挤压类破碎机多目标规划模型的求解方法进行了深入研究,采用基于K-T方程的系列二次规划算法对多目标规划模型进行求解。此外,还以日本神户制钢有限公司的AUTOFINE36圆锥破碎机为研究对象,利用多目标规划模型进行多目标优化研究,验证了模型的可行性和可靠性。
(6)基于挤压类破碎机工作性能模型和多目标规划模型,研制开发破碎机优化设计软件原型系统,可以对破碎机工作性能参数进行分析和优化。以系列国产圆锥破碎机PYB900、PYB1200、PYB1750和PYB2200等为研究算例,对破碎机进行了多目标优化研究。此外,还对国产PYB900圆锥破碎机的多设计方案进行了多目标规划研究,从而验证了挤压类破碎机工作性能模型和多目标规划模型的可行性和可靠性。
基于多目标规划结果,对国产PYB900圆锥破碎机进行改进设计,与破碎机生产厂家合作,制造相应物理样机一台,通过物理样机实验进一步验证了工作性能模型和多目标规划模型的可行性和可靠性。
基于挤压类破碎机工作机理和工作性能研究,研制开发圆锥破碎机参数优化设计系统,该系统成功应用于上海某破碎机生产厂家,效果良好,得到用户好评。
(7)为完善挤压类破碎机工作机理和工作性能研究,指出了下一步的研究目标、内容和方法。
Compressive crusher is the main equipment of rock material crushing and it is widely used in metallurgy and mining industry, building industry, road construction, chemical engineering and silicate industry. However, domestic compressive crusher is designing conservatively, manipulating inconveniently and heavy, low efficiency, power wasting and poor product quality.
Since middle and post 20th centuries,the crusher working mechanism and working performance has been deeply studied, and the modern high energy compressive crusher holding interparticle breakage chamber, high rotational speed and rational stroke was researched and designed by foreign crusher manufacturers. Those modern crushers has realized many advanced functions including long distance automotive monitor, clearing chamber and protect of over loading, and so on. Therefore, the working performance and product quality of compressive crusher were greatly improved, which increased the economy benefits of crusher manufacturer and the related users.
Yet, domestic compressive crushers have not been developed since they were imitated successfully, and those technology levels basically rested on the first and second generation of foreign advanced product. Thereby, in order to improve the working performance of domestic compressive crusher and manufacturing technology level of domestic manufacturing industry, this paper was based on interparticle breakage and the modern optimization technology was adopted, the working mechanism and working performance of compressive crusher were deeply studied, and multi-objective planning of productivity, size reduction and chamber was built up, which provide the basis for developing compressive crusher of new style, high efficiency, energy saving, environment protection and independent knowledge property right.
Encircling how to realize these aims, under the support of Shanghai Science and Technology Commission and domestic certain large-scale crusher manufacturer’key research projects, the research task was orientated to“the working mechanism and working performance research on compressive crusher”. The full text was expanded from various points of view of crusher working mechanism and working performance, and several breakthroughs were achieved, including crushing mechanism, compressive crusher productivity model, chamber geometry design methodology model, crushing product grain size distribution model and multi-objective model and so on.
This paper mainly included these research contents and conclusions as follows:
(1) Summarizing the interparticle breakage theory and the related achievements of domestic and foreign countries, discussing the advantages, basic premises and feasibilities of applying interparticle breakage in compressive crushers, the key technology of applying interparticle breakage in compressive crushers was summed up.
(2) Based on kinematic and dynamic characters of crusher and rock material, the motion track model of rock material in chamber was built up, and the crushing zones’characters were also studied, which provided the basis for designing and researching the chamber by the method of crushing zones.
The motive characters of compressive crushers and rock material in the chamber were deeply studied and the influences between motive states of crusher and rock material and crusher working performance also were discussed. Based on motive character of crusher and rock material, the productivity model of compressive crusher was achieved. Beside, the key structure and working parameters of crusher also deeply researched, and the relationship model between productivity and various key factors was built up. The improved domestic PYB900 cone crusher was considered as research object, the productivity of crusher was studied, and the key structure and working parameters (main shaft rotational speed, cone diameter, base angle of cone, eccentricity, stroke, Close Sided Setting and the length of parallel strip) affecting crusher performance were quantitatively and qualitatively researched, which verified the reliability and feasibility of productivity calculation model.
(3) Using the RMT-150B rock mechanic test system to study the interparticle breakage of chamber geometry in compressive crushers, those test data were regressed, and the Selection function and Breakage function were got, which provided the basis for calculate and simulate the size reduction of compressive crushers.
Based on advanced breakage theory—interparticle breakage, population balance model and crushing zones’characters, the interparticle breakage process of rock material in chamber of compressive crusher was deeply studied. Combined with the matrix model of rock material breakage, the operating model of rock material interparticle breakage process in chamber of compressive crusher was built up, which opened out the essential causes of interparticle breakage of compressive crushers and also provided the basis for simulating and optimizing product grain size distribution.
The improved domestic PYB900 cone crusher was regarded as research object, the crushing product grain size distribution was deeply studied, and the relationship model between product grain size distribution and the key working and structure parameters was accomplished, and the key factors were also quantitatively and qualitatively studied.
(4) Based on the characters of crushing zones, combined with the working character of compressive chamber, the fixed mass theory was put forward, and it was used to study the curved chamber geometry of compressive crushers, and the stroking and awaiting characters of compressive crusher lessened or got rid of. Moreover, the concept of working nip angle was introduced into chamber geometry research, which guaranteed the nipping requirement and improved the machine’s working performance.
Based on interparticle breakage, crushing zones’characters, the fixed mass theory and working nip angle demand, the interparticle curved chamber geometry was built up and the new method of interpartcle curved chamber geometry was put forward.
(5) Based on working mechanism and working performance research of compressive crusher, the multi-objective planning of crusher productivity, product grain size distribution and chamber geometry was built up, which provided the basis for developing new style and high efficiency modern compressive crusher.
Combined with multi-objective planning of cone crusher, the solving methodology of multi-objective planning of compressive crusher was deeply studied, and the serial quadratic programming based on K-T equation was adopted to solve this multi-objective problem. Besides, the AUTOFINE36 cone crusher was considered as research object, the multi-objective planning was used to optimize this kind of cone crusher, which verified the feasibility and reliability of those models.
(6) Based on compressive crusher working performance models and multi-planning model, the cone crusher optimization system was developed. This system could optimize and analyze the working performance and design parameters of cone crusher. The serial domestic cone crusher PYB900, PYB1200, PYB1750 and PYB2200 was used to as research examples, the related multi-objective planning of those cone crushers were researched. Besides, the multi-design programs of domestic PYB900 cone crusher were optimized, which further verified the feasibility and reliability of working performance models and multi-objective planning models.
Based on multi-objective planning results, the domestic PYB900 cone crusher was improved, cooperating with crusher manufacturer, a physical prototype was manufactured. Through the related physical prototype full scale test further verified the feasibility and reliability of working performance models and multi-objective models.
Based on working mechanism and working performance research, the parameters’optimization system was developed and successfully applied in the related crusher manufacturer. This optimization system has got many compliments for its good effect.
(7) The future research works, including research aims, contents, and methods, are put forward to outlook.
自从20世纪中后叶开始,国外研制开发出集层压腔形、高摆频和合理摆动冲程于一身的现代高能挤压类破碎机,这些破碎机集机、电、液技术于一体,实现了远程自动监控、自动清腔、自动过载保护等先进功能,从而极大地提高了破碎机工作性能,改善了破碎产品质量,提高了破碎机厂家和用户的经济效益。
然而国产挤压类破碎机自从20世纪中叶仿制成功以来,未得到大的发展,其技术水平基本停留在国外先进水平的第一代和第二代水平上。因此,为改善国产挤压类破碎机工作性能,提高我国装备制造业技术水平,本文基于先进破碎理论—层压破碎,采用现代优化设计技术,以圆锥破碎机为研究对象,对挤压类破碎机工作机理和工作性能进行了深入研究,建立挤压类破碎机生产率、破碎产品粒度和腔型的多目标规划模型,为研制开发具有完全自主知识产权的新型、高效、节能和环保的现代高能挤压类破碎机奠定理论基础。
围绕如何实现这些目标,本文在上海市科委和某大型破碎机企业合作项目的支持下,将研究课题定位于挤压类破碎机工作机理和工作性能优化研究。全文从破碎机工作机理和工作性能的不同角度展开,在层压破碎理论、挤压类破碎机生产率模型、层压曲线腔型模型、腔形设计方法、破碎产品粒度分布模型和多目标规划模型等方面实现了突破。
本文主要包括下述主要工作和结论:
(1)总结归纳了国内外层压破碎研究成果,探讨了在挤压类破碎机上实现层压破碎的优越性、基本前提和可行性,对挤压类层压破碎机关键使能技术进行了概述。
(2)对破碎机和破碎腔内散体物料的运动特性进行了深入研究,探讨了破碎机和散体物料运动状态对破碎机工作性能的影响,建立挤压类破碎机破碎腔内散体物料运动轨迹模型,提出挤压类破碎机分层破碎特性,为破碎腔进行分层研究和设计奠定基础。
基于破碎机和散体物料运动学和动力学特性,建立挤压类破碎机生产率模型。对影响破碎机生产率的关键结构参数和工作参数进行深入研究,建立生产率与各关键因素关系模型。以改进型国产PYB900圆锥破碎机为研究对象,对破碎机生产率进行了研究,对影响破碎机工作性能的各关键结构参数和工作参数(包括偏心套转速、动锥大小、动锥底角、进动角、排料口摆动行程、闭边排料口尺寸、平行区长度等)进行了定性和定量分析,从而验证了生产率模型的可行性和可靠性。
(3)利用RMT-150B岩石力学试验系统对石灰石散体物料层压破碎过程进行了试验研究,对试验数据进行统计回归分析,得到挤压类破碎机层压破碎过程选择函数模型和破碎函数模型,为对层压破碎产品粒度计算分析提供理论依据。
基于层压破碎原理、总体平衡模型和分层破碎特性,对挤压类破碎机破碎腔内散体物料破碎过程进行了深入研究,结合散体物料破碎矩阵模型,建立挤压类破碎机破碎腔内散体物料层压破碎过程操作模型,揭示了挤压类破碎机层压破碎过程的本质原因,为对破碎产品粒度分布研究和优化奠定基础。
以改进型国产PYB900圆锥破碎机为研究对象,对破碎机破碎产品粒度分布进行了深入研究,建立破碎产品粒度与影响破碎机工作性能的各关键因素关系模型,对各关键因素进行了定性和定量分析。
(4)基于分层破碎特性,结合挤压类破碎腔工作特性,提出适用于挤压类破碎机设计的固定质量原理,并应用于对挤压类破碎机曲线腔形的研究,有效减少或消除了挤压类破碎机破碎腔各破碎层的堵塞和待料。在挤压类破碎机破碎腔研究中,引入工态啮角概念,保证了破碎腔的咬入特性,提高了破碎机工作性能。
基于层压破碎原理、分层破碎特性、固定质量原理和工态啮角要求,建立挤压类破碎机层压曲线腔形模型,提出层压曲线腔形设计新方法。
(5)为研制开发高效挤压类层压破碎机,基于挤压类破碎机工作机理和工作性能研究,建立挤压类破碎机生产率、破碎产品粒度和腔型的多目标规划模型。
结合圆锥破碎机多目标规划问题,对挤压类破碎机多目标规划模型的求解方法进行了深入研究,采用基于K-T方程的系列二次规划算法对多目标规划模型进行求解。此外,还以日本神户制钢有限公司的AUTOFINE36圆锥破碎机为研究对象,利用多目标规划模型进行多目标优化研究,验证了模型的可行性和可靠性。
(6)基于挤压类破碎机工作性能模型和多目标规划模型,研制开发破碎机优化设计软件原型系统,可以对破碎机工作性能参数进行分析和优化。以系列国产圆锥破碎机PYB900、PYB1200、PYB1750和PYB2200等为研究算例,对破碎机进行了多目标优化研究。此外,还对国产PYB900圆锥破碎机的多设计方案进行了多目标规划研究,从而验证了挤压类破碎机工作性能模型和多目标规划模型的可行性和可靠性。
基于多目标规划结果,对国产PYB900圆锥破碎机进行改进设计,与破碎机生产厂家合作,制造相应物理样机一台,通过物理样机实验进一步验证了工作性能模型和多目标规划模型的可行性和可靠性。
基于挤压类破碎机工作机理和工作性能研究,研制开发圆锥破碎机参数优化设计系统,该系统成功应用于上海某破碎机生产厂家,效果良好,得到用户好评。
(7)为完善挤压类破碎机工作机理和工作性能研究,指出了下一步的研究目标、内容和方法。
Compressive crusher is the main equipment of rock material crushing and it is widely used in metallurgy and mining industry, building industry, road construction, chemical engineering and silicate industry. However, domestic compressive crusher is designing conservatively, manipulating inconveniently and heavy, low efficiency, power wasting and poor product quality.
Since middle and post 20th centuries,the crusher working mechanism and working performance has been deeply studied, and the modern high energy compressive crusher holding interparticle breakage chamber, high rotational speed and rational stroke was researched and designed by foreign crusher manufacturers. Those modern crushers has realized many advanced functions including long distance automotive monitor, clearing chamber and protect of over loading, and so on. Therefore, the working performance and product quality of compressive crusher were greatly improved, which increased the economy benefits of crusher manufacturer and the related users.
Yet, domestic compressive crushers have not been developed since they were imitated successfully, and those technology levels basically rested on the first and second generation of foreign advanced product. Thereby, in order to improve the working performance of domestic compressive crusher and manufacturing technology level of domestic manufacturing industry, this paper was based on interparticle breakage and the modern optimization technology was adopted, the working mechanism and working performance of compressive crusher were deeply studied, and multi-objective planning of productivity, size reduction and chamber was built up, which provide the basis for developing compressive crusher of new style, high efficiency, energy saving, environment protection and independent knowledge property right.
Encircling how to realize these aims, under the support of Shanghai Science and Technology Commission and domestic certain large-scale crusher manufacturer’key research projects, the research task was orientated to“the working mechanism and working performance research on compressive crusher”. The full text was expanded from various points of view of crusher working mechanism and working performance, and several breakthroughs were achieved, including crushing mechanism, compressive crusher productivity model, chamber geometry design methodology model, crushing product grain size distribution model and multi-objective model and so on.
This paper mainly included these research contents and conclusions as follows:
(1) Summarizing the interparticle breakage theory and the related achievements of domestic and foreign countries, discussing the advantages, basic premises and feasibilities of applying interparticle breakage in compressive crushers, the key technology of applying interparticle breakage in compressive crushers was summed up.
(2) Based on kinematic and dynamic characters of crusher and rock material, the motion track model of rock material in chamber was built up, and the crushing zones’characters were also studied, which provided the basis for designing and researching the chamber by the method of crushing zones.
The motive characters of compressive crushers and rock material in the chamber were deeply studied and the influences between motive states of crusher and rock material and crusher working performance also were discussed. Based on motive character of crusher and rock material, the productivity model of compressive crusher was achieved. Beside, the key structure and working parameters of crusher also deeply researched, and the relationship model between productivity and various key factors was built up. The improved domestic PYB900 cone crusher was considered as research object, the productivity of crusher was studied, and the key structure and working parameters (main shaft rotational speed, cone diameter, base angle of cone, eccentricity, stroke, Close Sided Setting and the length of parallel strip) affecting crusher performance were quantitatively and qualitatively researched, which verified the reliability and feasibility of productivity calculation model.
(3) Using the RMT-150B rock mechanic test system to study the interparticle breakage of chamber geometry in compressive crushers, those test data were regressed, and the Selection function and Breakage function were got, which provided the basis for calculate and simulate the size reduction of compressive crushers.
Based on advanced breakage theory—interparticle breakage, population balance model and crushing zones’characters, the interparticle breakage process of rock material in chamber of compressive crusher was deeply studied. Combined with the matrix model of rock material breakage, the operating model of rock material interparticle breakage process in chamber of compressive crusher was built up, which opened out the essential causes of interparticle breakage of compressive crushers and also provided the basis for simulating and optimizing product grain size distribution.
The improved domestic PYB900 cone crusher was regarded as research object, the crushing product grain size distribution was deeply studied, and the relationship model between product grain size distribution and the key working and structure parameters was accomplished, and the key factors were also quantitatively and qualitatively studied.
(4) Based on the characters of crushing zones, combined with the working character of compressive chamber, the fixed mass theory was put forward, and it was used to study the curved chamber geometry of compressive crushers, and the stroking and awaiting characters of compressive crusher lessened or got rid of. Moreover, the concept of working nip angle was introduced into chamber geometry research, which guaranteed the nipping requirement and improved the machine’s working performance.
Based on interparticle breakage, crushing zones’characters, the fixed mass theory and working nip angle demand, the interparticle curved chamber geometry was built up and the new method of interpartcle curved chamber geometry was put forward.
(5) Based on working mechanism and working performance research of compressive crusher, the multi-objective planning of crusher productivity, product grain size distribution and chamber geometry was built up, which provided the basis for developing new style and high efficiency modern compressive crusher.
Combined with multi-objective planning of cone crusher, the solving methodology of multi-objective planning of compressive crusher was deeply studied, and the serial quadratic programming based on K-T equation was adopted to solve this multi-objective problem. Besides, the AUTOFINE36 cone crusher was considered as research object, the multi-objective planning was used to optimize this kind of cone crusher, which verified the feasibility and reliability of those models.
(6) Based on compressive crusher working performance models and multi-planning model, the cone crusher optimization system was developed. This system could optimize and analyze the working performance and design parameters of cone crusher. The serial domestic cone crusher PYB900, PYB1200, PYB1750 and PYB2200 was used to as research examples, the related multi-objective planning of those cone crushers were researched. Besides, the multi-design programs of domestic PYB900 cone crusher were optimized, which further verified the feasibility and reliability of working performance models and multi-objective planning models.
Based on multi-objective planning results, the domestic PYB900 cone crusher was improved, cooperating with crusher manufacturer, a physical prototype was manufactured. Through the related physical prototype full scale test further verified the feasibility and reliability of working performance models and multi-objective models.
Based on working mechanism and working performance research, the parameters’optimization system was developed and successfully applied in the related crusher manufacturer. This optimization system has got many compliments for its good effect.
(7) The future research works, including research aims, contents, and methods, are put forward to outlook.
引文
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【16】 C.A. Tang, H.Y. Liu, W.C. Zhu, T.H. Yang, W.H. Li, L. Song, P.Lin. Numerical Approach to Particle Breakage under different Loading Conditions[J]. Powder Technology, 2004, 143-144:130-143.
【17】 C.A. Tang, X.H. Xu, S.Q. Kou, P.-A. Lindqvist, H.Y. Liu. Numerical Investigation of Particle Breakage as Applied to Mechanical Crushing-Part I: Single-Particle Breakage[J]. International Journal of Rock Mechanics & Mining Sciences, 2001, 38:1147-1162.
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