自保护快速启闭式超高压海产品加工容器关键技术研究
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摘要
超高压技术广泛应用于石油化工、等静压、液体射流等多种现代工业领域。利用超高压技术加工海产品，可以有效进行保鲜灭菌，最大限度地保持其营养成分和原有的色泽、质地、风味，延长海产品货架寿命，为海产品的深加工提供新途径，其发展前景非常广阔。
海产品超高压加工的核心设备是超高压容器。海产品超高压加工容器具有端盖启闭频繁、工作压力特别大、疲劳强度要求高等特点，其安全性至关重要。本文在浙江省科技厅科技兴海重大攻关项目“超高压海产品加工技术研究与设备研制”、“教育部新世纪优秀人才支持计划”和教育部高等学校博士学科点专项科研基金“承压设备强度数值模拟关键技术研究”(资助号：20010335032)的资助下，根据超高压海产品加工工艺和容器的特点，从提高超高压容器的本质安全性出发，对超高压海产品加工容器的一系列关键技术进行了较为深入的研究，主要包括如下内容：
(1)自保护快速启闭超高压容器结构。提出了一种新型结构的钢带错绕自保护齿啮快速启闭式超高压容器，它既有很好的防爆抑爆自保护功能，又有高效的快速启闭特性；提出了一种分体式齿啮快速启闭密封装置，详细分析了其结构特点和快速启闭功能的实现方式。
(2)错绕钢带层对容器的失效保护能力。在研究超高压容器中储存能量的基础上，从钢带层的轴向极限承载能力和钢带层断裂前吸收的最大能量两个方面入手，定量预测了错绕钢带层对超高压容器的失效保护能力，并提出了相应的钢带层设计准则。
(3)预应力套环的设计准则。在分析预应力套环受力特性的基础上，对其进行了详细力学分析，提出了其关键参数的确定方法，建立了预应力套环设计准则。
(4)三角垫密封过程的力学分析。建立了组合自紧密封结构中三角垫的两种简化力学分析模型：等效矩形环模型和线环模型。阐述了三角垫密封过程的的原理和特点，对其密封过程进行了详细力学分析，导出了三角垫和简体内壁之间的接触压力与内压载荷、三角垫材料特性、几何参数等的关系式，提出了在卸载后两者间脱离接触的判据准则，可为三角垫的结构参数设计和选材提供参考。
(5)超高压容器强度数值模拟与关键部件结构优化。分别建立了齿啮快速启闭结构和锯齿螺纹承载结构的整体有限元分析模型，提出了相应的非线性有限元分析方法，并给出了模拟结果的评定方法；对超高压海产品加工容器及端部结构强度进行了数值模拟，并对顶部齿啮结构和底部锯齿螺纹结构进行优化设计，改善啮合齿根应力分布及螺纹载荷分布，提高这两种结构的承载能力和疲劳寿命。
(6)自保护快速启闭式超高压容器的试验研究。进行了超高压海产品加工容器强度试验研究，揭示了超高压齿啮快速启闭结构的受力特性和应力分布规律，验证了三角垫分析模型的合理性以及容器的强度、密封性能、快速启闭效率、有限元分析的精度；通过6台模拟试验容器的爆破试验结果，验证了错绕钢带层对容器筒体的防爆抑爆保护作用，证实了本文所提出的钢带层轴向极限承载能力和钢带失效前极限吸能的计算公式的正确性，按本文提出的能量准则或极限承载能力准则来确定钢带层设计参数，可在确保对容器简体保护能力的前提下，大幅度减少钢带用量。
Ultra High Pressure (UHP) technology is widely applied in various modern industrial fields, such as petrochemical industry, isopressing and liquid jet, etc. The use of UHP for seafood processing, which has been developed extensively, potentionly addresses requirements of modern consumers who prefer minimally processed seafoods. One advantage of UHP technology is that it does not use heat, which causes the sensory and nutritional attributes of seafood products remain virtually unaffected. By this way, quality of seafood products is improved compared to those processed with traditional thermal methods. This technology has a promising future.
Ultra High Pressure Vessel (UHPV) is one of core equipments of UHP technology. UHPV employed in seafood process particularly specializes in quick-actuating end closure, ultra high working pressure and long fatigue life, and its safety is of great importance. Financed jointly by Fundamental Project of Zhejiang Science & Technology Bureau, the Excellent Talent of New Century of Education Ministry and the Specialized Research Fund for the Doctoral Program of Higher Education (No. 20010335032), a series of research has been carried out on some key technologies of UHPV:
(1) UHPV Structure with self-shielding and quick-actuating device. Based on some advantages of flat steel ribbon-wound pressure vessel and requirements of essential safety and quick-actuating on UHPV, a novel structure of UHPV was put forward, which can shield vessel with protective Flat Steel Ribbons (FSR) and achieve quick-actuating with meshing gear. A new type of Tooth-Locked Quick-Actuating (TLQA) end closure was also put forth, in which detachable seal plug and end head were employed.
(2) Shielding capability of helically winding FSR layer. Based on energy deposited in UHPV, the formula of ultimate load-bearing capability as well as energy
absorbed before fracture of FSR were derived. The shielding function and capability of FSR to vessel was analyzed quantificationally in detail, and 2 design criterions on FSR were put forward.
(3) Design criterion on Prestressed Collar (PC). The force state and protective function of PC were analyzed in detail, and a method was given to determine some key parameters on prestressed collar, and a design criterion on PC was also achived.
(4) Mechanical analysis on sealing process of delta-ring. According to force state features of delta-ring, two simplified mechanical model, that is, rectangular ring model and line model, were proposed. Based on elastic-plastic theory and principle of sealing process of delta-ring, the contact pressure between delta-ring and vessel shell, as well as the stress and the strain of delta-ring are analyzed, and the formulation of the residual contact pressure vs. the working pressure, the material properties and geometric parameters were obtained. The formulation can be applied to the delta back-up ring, but also to the carriers of in dual "O" ring seal.
(5) Numerical simulation on strength of UHPV and structural optimization on its key components. A 3-D FE whole model was established to simulate peak stress in TLQA end closure of UHPV, and a 2-D FE whole axisymmetric model was also established to simulate buttress thread end closure. Optimized structures of this two kind end closure of UHPV were achieved, and fatigue life of vessel was extended.
(6) Experiment on the self-shielding and quick-actuating UHPV. An experiment was carried out to investigate the strengths of seafood UHPV, and the sealing properties and quick-actuating efficiency were verified. Burst experimental results of 6 model vessels proved that the derived formulations on ultimate load-bearing capability and energy absorption of FSR layer are reasonable.
海产品超高压加工的核心设备是超高压容器。海产品超高压加工容器具有端盖启闭频繁、工作压力特别大、疲劳强度要求高等特点，其安全性至关重要。本文在浙江省科技厅科技兴海重大攻关项目“超高压海产品加工技术研究与设备研制”、“教育部新世纪优秀人才支持计划”和教育部高等学校博士学科点专项科研基金“承压设备强度数值模拟关键技术研究”(资助号：20010335032)的资助下，根据超高压海产品加工工艺和容器的特点，从提高超高压容器的本质安全性出发，对超高压海产品加工容器的一系列关键技术进行了较为深入的研究，主要包括如下内容：
(1)自保护快速启闭超高压容器结构。提出了一种新型结构的钢带错绕自保护齿啮快速启闭式超高压容器，它既有很好的防爆抑爆自保护功能，又有高效的快速启闭特性；提出了一种分体式齿啮快速启闭密封装置，详细分析了其结构特点和快速启闭功能的实现方式。
(2)错绕钢带层对容器的失效保护能力。在研究超高压容器中储存能量的基础上，从钢带层的轴向极限承载能力和钢带层断裂前吸收的最大能量两个方面入手，定量预测了错绕钢带层对超高压容器的失效保护能力，并提出了相应的钢带层设计准则。
(3)预应力套环的设计准则。在分析预应力套环受力特性的基础上，对其进行了详细力学分析，提出了其关键参数的确定方法，建立了预应力套环设计准则。
(4)三角垫密封过程的力学分析。建立了组合自紧密封结构中三角垫的两种简化力学分析模型：等效矩形环模型和线环模型。阐述了三角垫密封过程的的原理和特点，对其密封过程进行了详细力学分析，导出了三角垫和简体内壁之间的接触压力与内压载荷、三角垫材料特性、几何参数等的关系式，提出了在卸载后两者间脱离接触的判据准则，可为三角垫的结构参数设计和选材提供参考。
(5)超高压容器强度数值模拟与关键部件结构优化。分别建立了齿啮快速启闭结构和锯齿螺纹承载结构的整体有限元分析模型，提出了相应的非线性有限元分析方法，并给出了模拟结果的评定方法；对超高压海产品加工容器及端部结构强度进行了数值模拟，并对顶部齿啮结构和底部锯齿螺纹结构进行优化设计，改善啮合齿根应力分布及螺纹载荷分布，提高这两种结构的承载能力和疲劳寿命。
(6)自保护快速启闭式超高压容器的试验研究。进行了超高压海产品加工容器强度试验研究，揭示了超高压齿啮快速启闭结构的受力特性和应力分布规律，验证了三角垫分析模型的合理性以及容器的强度、密封性能、快速启闭效率、有限元分析的精度；通过6台模拟试验容器的爆破试验结果，验证了错绕钢带层对容器筒体的防爆抑爆保护作用，证实了本文所提出的钢带层轴向极限承载能力和钢带失效前极限吸能的计算公式的正确性，按本文提出的能量准则或极限承载能力准则来确定钢带层设计参数，可在确保对容器简体保护能力的前提下，大幅度减少钢带用量。
Ultra High Pressure (UHP) technology is widely applied in various modern industrial fields, such as petrochemical industry, isopressing and liquid jet, etc. The use of UHP for seafood processing, which has been developed extensively, potentionly addresses requirements of modern consumers who prefer minimally processed seafoods. One advantage of UHP technology is that it does not use heat, which causes the sensory and nutritional attributes of seafood products remain virtually unaffected. By this way, quality of seafood products is improved compared to those processed with traditional thermal methods. This technology has a promising future.
Ultra High Pressure Vessel (UHPV) is one of core equipments of UHP technology. UHPV employed in seafood process particularly specializes in quick-actuating end closure, ultra high working pressure and long fatigue life, and its safety is of great importance. Financed jointly by Fundamental Project of Zhejiang Science & Technology Bureau, the Excellent Talent of New Century of Education Ministry and the Specialized Research Fund for the Doctoral Program of Higher Education (No. 20010335032), a series of research has been carried out on some key technologies of UHPV:
(1) UHPV Structure with self-shielding and quick-actuating device. Based on some advantages of flat steel ribbon-wound pressure vessel and requirements of essential safety and quick-actuating on UHPV, a novel structure of UHPV was put forward, which can shield vessel with protective Flat Steel Ribbons (FSR) and achieve quick-actuating with meshing gear. A new type of Tooth-Locked Quick-Actuating (TLQA) end closure was also put forth, in which detachable seal plug and end head were employed.
(2) Shielding capability of helically winding FSR layer. Based on energy deposited in UHPV, the formula of ultimate load-bearing capability as well as energy
absorbed before fracture of FSR were derived. The shielding function and capability of FSR to vessel was analyzed quantificationally in detail, and 2 design criterions on FSR were put forward.
(3) Design criterion on Prestressed Collar (PC). The force state and protective function of PC were analyzed in detail, and a method was given to determine some key parameters on prestressed collar, and a design criterion on PC was also achived.
(4) Mechanical analysis on sealing process of delta-ring. According to force state features of delta-ring, two simplified mechanical model, that is, rectangular ring model and line model, were proposed. Based on elastic-plastic theory and principle of sealing process of delta-ring, the contact pressure between delta-ring and vessel shell, as well as the stress and the strain of delta-ring are analyzed, and the formulation of the residual contact pressure vs. the working pressure, the material properties and geometric parameters were obtained. The formulation can be applied to the delta back-up ring, but also to the carriers of in dual "O" ring seal.
(5) Numerical simulation on strength of UHPV and structural optimization on its key components. A 3-D FE whole model was established to simulate peak stress in TLQA end closure of UHPV, and a 2-D FE whole axisymmetric model was also established to simulate buttress thread end closure. Optimized structures of this two kind end closure of UHPV were achieved, and fatigue life of vessel was extended.
(6) Experiment on the self-shielding and quick-actuating UHPV. An experiment was carried out to investigate the strengths of seafood UHPV, and the sealing properties and quick-actuating efficiency were verified. Burst experimental results of 6 model vessels proved that the derived formulations on ultimate load-bearing capability and energy absorption of FSR layer are reasonable.
引文
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