SL6装船机卷扬系统平台力学行为及减振研究
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摘要
大型港口散料装船机,在能源、电力、冶金、港口等行业特别是一些大宗散料集散中心的高速、稳定、集效、滚动式发展中,发挥着重要作用。随着经济全球化进程的加快,新的设计理念使装船机的装载能力不断提高,设备结构越来越庞大。因此设备的稳定性、钢结构的动强度与刚度、整机的振动特性等也越来越受到人们的重视。目前国内外对于装船机的力学特性分析主要集中在静力结构与静强度方面,而对人们所关注的动力学问题涉及很少,因此对装船机的动态力学行为研究具有重要的理论意义和工程价值。
本文以神华黄骅港务公司与燕山大学签订的《神华黄骅港二期工程SL6装船机卷扬机构平台振动问题研究》项目为依托,针对黄骅港SL6装船机在俯仰臂高速升降时卷扬系统平台的异常振动问题,从动力学角度进行了现场实测和理论研究,提出并实施了平台减振加固改造方案。方案实施后,平台振幅显著降低,装船机作业率提高,经济效益增加。
由于装船机设备庞大,振源分散,难以确定主要振源。为全面地分析卷扬系统平台振动的振源,采用集中质量法,针对卷扬机主传动系统建立扭振非线性数学模型,引入卷筒齿轮综合啮合刚度非线性,并对俯仰臂不同升降速度下卷筒负载进行建模求解,使扭振数学模型与实际结构相吻合。采用变步长Runge-Kutta方法对该非线性系统进行动力学响应求解,得到了扭振系统的固有振动特性和响应,通过频谱分析得到非线性扭振系统的响应特征。
建立了SL6装船机整机以及卷扬机平台有限元模型,通过对装船机整机在伸缩臂处于不同位置下进行模态仿真,得到了装船机和卷扬系统平台的模态。通过对卷扬系统平台进行谐响应分析和应力位移分析,得到了不同工况下平台的频响特征和应力状态。
为了确定卷扬系统平台产生振动的根本原因,对平台动态应变和卷扬系统齿轮轴动态扭矩进行了现场测试,采用现代数据处理技术对测试信号进行时域和频域分析,找到平台振动和卷扬系统扭振的频率成分,得到了平台在实际工况下的力学状态,理论分析结果与测试结果相吻合,验证了仿真模型正确性。
在理论分析和现场测试的基础上,结合现场实际提出合理可行的卷扬系统平台的减振方案,并将其付诸实践,有效提高了平台结构刚度。为了评估减振方案的有效性,建立了减振改造后的卷扬系统平台有限元模型,并对其进行了强度校核,通过模态分析和谐响应分析得到了改造后振动模态和不同激励下的响应水平;对平台动态特性进行了对比测试,获得了不同工况下平台的动态应力水平和振动响应水平。通过改造前后仿真和测试结果的对比,验证了卷扬系统平台的减振方案的合理性和有效性。
本文针对黄骅港SL6装船机卷扬系统平台振动问题提出的研究方法和减振方案,为类似结构装船机振动问题的解决开拓了新思路,具有重要的学术研究意义和工程参考价值。
Large port bulk shiploaders play an important role in industries such as energy, power, metallurgy, port, etc. especially in the rapid, stable, efficient and cumulative development of some balk cargo collection and distribution center. With the acceleration of economic globalization, new design concepts made the delivered payload capability of shiploaders updating continually, and the structure of the equipment getting larger and larger. Then the stability of equipment, dynamic strength and rigidity of steel structure and vibration performance of the complete appliance has been given more and more attention. Currently, the researches of mechanical properties for shiploaders have mainly concentrated on the aspects of static structure and strength, the study of concerned dynamics behavior for shiploaders are rare in literature. Therefore the researches of dynamic mechanical behavior for shiploaders have important theoretical and engineering significance.
Based on the project "Research of boom luffing winch platform vibration for SL6 shiploader in Shenhua Huanghua Port phase II", aiming at the abnormal vibration of boom luffing winch platform of SL6 shiploader in Shenhua Huanghua Port Company, in this dissertation, the spot testing and theoretical researches have been completed, the vibration reduction and reconstruction scheme of platform has been proposed and put into effect. With the reconstructed scheme, the amplitude of vibration has been reduced evidently, and the economic benefit has been increased.
Due to large size and dispersive vibration source, the principal vibration source is hard to be fixed. For deciding the principal vibration source of the platform, lumped parameter method was used to establish the nonlinear mathematical model for boom luffing winch system, which considered the nonlinear of winch gear meshing stiffness, and the winch loads under varied velocities of boom luffing have been built model and resolved, which makes the torsional vibration model being consistent with the practical situation. Using variable-step Runge-Kutta method the dynamic response of the nonlinear system has solved, the nature vibration characteristics and responses have been obtained, then to nonlinear response characteristics of torsional vibration system by the spectrum analysis.
By establishing FEM models of SL6 shiploader and boom luffing winch platform, the modalities of shiploader and the platform at different boom luffing locations have been calculated. With harmonic response analysis applied to the platform, frequency response characteristics and stress states under different conditions has been obtained. Simulation results and spot testing results confirm each other, which provided a theoretical basis for vibration reduction reconstruction for platform.
In order to determine the basic reasons of platform vibration, the dynamic strains of platform and dynamic torques of the gear shaft in boom luffing winch system has been obtained on spot testing, with the modern data technology the signals analysis in time domain and frequency domain have been completed, then the frequency components of platform vibration and torsional vibration of boom luffing winch system have been obtained, the mechanical state of platform in the actual operating conditions have been acquired. The theoretical analysis results accord with that of testing, which proved the simulation model.
Based on the spot testing and theoretical analysis, with the consideration of the practical situation, the reasonable and practical vibration reduction scheme has been proposed and put into effect, which enhanced the rigidity of the platform effectively. To assess the effectively of vibration reduction scheme, the reconstruction platform FEM model has been established, and then the strength has been checked. Through modal analysis and harmonic analysis the modalities and the different responses to the level of excitation have been acquired. The contrastive spot testing has been executed, and then the dynamic stress and vibration response results under different conditions have been obtained. By comparing the simulation results and testing results, the rationality and effectiveness of the scheme has been affirmed.
In this dissertation, the research methods and solution scheme for the vibration of Huanghua port SL6 shiploader boom luffing winch platform offer a new paradigm for solving vibration problem of similar type of shiploader, and have significance of academic research and engineering reference value.
本文以神华黄骅港务公司与燕山大学签订的《神华黄骅港二期工程SL6装船机卷扬机构平台振动问题研究》项目为依托,针对黄骅港SL6装船机在俯仰臂高速升降时卷扬系统平台的异常振动问题,从动力学角度进行了现场实测和理论研究,提出并实施了平台减振加固改造方案。方案实施后,平台振幅显著降低,装船机作业率提高,经济效益增加。
由于装船机设备庞大,振源分散,难以确定主要振源。为全面地分析卷扬系统平台振动的振源,采用集中质量法,针对卷扬机主传动系统建立扭振非线性数学模型,引入卷筒齿轮综合啮合刚度非线性,并对俯仰臂不同升降速度下卷筒负载进行建模求解,使扭振数学模型与实际结构相吻合。采用变步长Runge-Kutta方法对该非线性系统进行动力学响应求解,得到了扭振系统的固有振动特性和响应,通过频谱分析得到非线性扭振系统的响应特征。
建立了SL6装船机整机以及卷扬机平台有限元模型,通过对装船机整机在伸缩臂处于不同位置下进行模态仿真,得到了装船机和卷扬系统平台的模态。通过对卷扬系统平台进行谐响应分析和应力位移分析,得到了不同工况下平台的频响特征和应力状态。
为了确定卷扬系统平台产生振动的根本原因,对平台动态应变和卷扬系统齿轮轴动态扭矩进行了现场测试,采用现代数据处理技术对测试信号进行时域和频域分析,找到平台振动和卷扬系统扭振的频率成分,得到了平台在实际工况下的力学状态,理论分析结果与测试结果相吻合,验证了仿真模型正确性。
在理论分析和现场测试的基础上,结合现场实际提出合理可行的卷扬系统平台的减振方案,并将其付诸实践,有效提高了平台结构刚度。为了评估减振方案的有效性,建立了减振改造后的卷扬系统平台有限元模型,并对其进行了强度校核,通过模态分析和谐响应分析得到了改造后振动模态和不同激励下的响应水平;对平台动态特性进行了对比测试,获得了不同工况下平台的动态应力水平和振动响应水平。通过改造前后仿真和测试结果的对比,验证了卷扬系统平台的减振方案的合理性和有效性。
本文针对黄骅港SL6装船机卷扬系统平台振动问题提出的研究方法和减振方案,为类似结构装船机振动问题的解决开拓了新思路,具有重要的学术研究意义和工程参考价值。
Large port bulk shiploaders play an important role in industries such as energy, power, metallurgy, port, etc. especially in the rapid, stable, efficient and cumulative development of some balk cargo collection and distribution center. With the acceleration of economic globalization, new design concepts made the delivered payload capability of shiploaders updating continually, and the structure of the equipment getting larger and larger. Then the stability of equipment, dynamic strength and rigidity of steel structure and vibration performance of the complete appliance has been given more and more attention. Currently, the researches of mechanical properties for shiploaders have mainly concentrated on the aspects of static structure and strength, the study of concerned dynamics behavior for shiploaders are rare in literature. Therefore the researches of dynamic mechanical behavior for shiploaders have important theoretical and engineering significance.
Based on the project "Research of boom luffing winch platform vibration for SL6 shiploader in Shenhua Huanghua Port phase II", aiming at the abnormal vibration of boom luffing winch platform of SL6 shiploader in Shenhua Huanghua Port Company, in this dissertation, the spot testing and theoretical researches have been completed, the vibration reduction and reconstruction scheme of platform has been proposed and put into effect. With the reconstructed scheme, the amplitude of vibration has been reduced evidently, and the economic benefit has been increased.
Due to large size and dispersive vibration source, the principal vibration source is hard to be fixed. For deciding the principal vibration source of the platform, lumped parameter method was used to establish the nonlinear mathematical model for boom luffing winch system, which considered the nonlinear of winch gear meshing stiffness, and the winch loads under varied velocities of boom luffing have been built model and resolved, which makes the torsional vibration model being consistent with the practical situation. Using variable-step Runge-Kutta method the dynamic response of the nonlinear system has solved, the nature vibration characteristics and responses have been obtained, then to nonlinear response characteristics of torsional vibration system by the spectrum analysis.
By establishing FEM models of SL6 shiploader and boom luffing winch platform, the modalities of shiploader and the platform at different boom luffing locations have been calculated. With harmonic response analysis applied to the platform, frequency response characteristics and stress states under different conditions has been obtained. Simulation results and spot testing results confirm each other, which provided a theoretical basis for vibration reduction reconstruction for platform.
In order to determine the basic reasons of platform vibration, the dynamic strains of platform and dynamic torques of the gear shaft in boom luffing winch system has been obtained on spot testing, with the modern data technology the signals analysis in time domain and frequency domain have been completed, then the frequency components of platform vibration and torsional vibration of boom luffing winch system have been obtained, the mechanical state of platform in the actual operating conditions have been acquired. The theoretical analysis results accord with that of testing, which proved the simulation model.
Based on the spot testing and theoretical analysis, with the consideration of the practical situation, the reasonable and practical vibration reduction scheme has been proposed and put into effect, which enhanced the rigidity of the platform effectively. To assess the effectively of vibration reduction scheme, the reconstruction platform FEM model has been established, and then the strength has been checked. Through modal analysis and harmonic analysis the modalities and the different responses to the level of excitation have been acquired. The contrastive spot testing has been executed, and then the dynamic stress and vibration response results under different conditions have been obtained. By comparing the simulation results and testing results, the rationality and effectiveness of the scheme has been affirmed.
In this dissertation, the research methods and solution scheme for the vibration of Huanghua port SL6 shiploader boom luffing winch platform offer a new paradigm for solving vibration problem of similar type of shiploader, and have significance of academic research and engineering reference value.
引文
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