装载机传动系载荷谱的测取与应用研究
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摘要
本文结合国家自然科学基金资助项目“轮式工程车辆传动系载荷谱关键技术研究”、国家“863”计划主题项目“大型露天采矿技术与装备”中的“75m3大型露天矿用挖掘机研制”课题以及校企合作项目“某型装载机传动系载荷谱编制方法研究与应用研究”，以某装载机传动系为研究对象，综合运用数理统计、信号分析和处理、结构有限元分析和疲劳设计等理论，基于实测装载机多工况传动系载荷的时间历程，编制了疲劳载荷谱并进行典型零件疲劳寿命预测，形成了较为完善的装载机传动系疲劳载荷谱测试、编制及应用的研究方法，以提高国产装载机的自主研发水平。
在广泛查阅国内外相关文献基础上，综述了载荷谱测试及编制技术研究现状。根据装载机传动系载荷特点，提出了装载机传动系统载荷谱测试方案。经过测试得到五种工况下传动系主要零件的动态转矩和转速数据。提出了装载机传动系实测载荷信号小波分形剔除奇异点的方法，通过与幅值门限法、梯度门限法以及统计平滑方法进行比较，该方法能更有效地剔除奇异点，同时可对信号进行阈值滤波消除信号中的噪声，提高信号处理效率。
根据装载机明显的分段作业特性，提出了划分作业段的方法。给出了度量装载机传动系载荷谱分散性的分位数外推的基本方法，对比分析时域和雨流域频次外推，提出了基于作业段雨流计数结果进行非参数外推重构的“铲-续-铲”谱编制方法，该方法编制的载荷谱比较接近装载机实际使用的载荷情况，反映了装载机进行频繁换挡的循环作业过程；为了便于实施零件疲劳试验，采用损伤等效的方法，编制了轴类零件的8级程序加载谱。利用编制的多工况合成载荷谱，应用应力疲劳分析法对变速箱输出法兰进行了基于有限元的应力寿命预估。
以传动系齿轮类零件的载荷测试为基础，通过研究定轴传动和行星传动中齿轮载荷的计数统计、合成以及外推方法，提出了传动系齿轮类零件的载荷谱编制方法，编制了装载机轮边行星减速器合成作业段载荷谱，运用Romax分析软件，对装载机轮边行星传动齿轮进行了弯曲疲劳寿命预测，预测结果表明轮边减速器齿轮强度满足设计要求。通过敏度分析，研究齿轮输入载荷参数以及齿根圆角参数对寿命的影响。结果表明与行星轮相比，太阳轮损伤对载荷幅值的增大以及齿根圆角参数的恶化比较敏感，损伤增加幅度大。
提出了一种与用户实际使用关联的装载机试验场耐久性试验方法，该方法可再现装载机在实际使用中的载荷和损伤，避免试验的盲目性。为制定有效的耐久性试验计划，通过研究输入数据的收集、压缩、处理以及载荷谱等效等关键技术，分析了与用户关联的试验场试验技术和优化目标，建立了以最小误差和最短时间为目标的多目标优化模型，利用NSGA-II算法，采用基于参考点的多目标优化方法，得到能反映专家偏好的最优解集。该方法可以有效地反映用户实际使用时的载荷情况，能及时发现和改进设备寿命设计中的偏差，指导装载机产品定型或验证试验。
本文测取的载荷谱是装载机传动系抗疲劳设计和疲劳试验加载的重要依据，本文提出的方法可以为其他工程车辆传动系载荷谱测取及疲劳设计提供参考。
This paper is combined with the project supported by the National Natural ScienceFund Project "Study on key technologies of load spectrum for wheeled vehicle powertrain"and the subject "Development of75m3large open-pit mining excavator", branch of theNational "863" Program Project "Large-scale open-pit mining technology and equipment",and the university-enterprise cooperation project "Load spectrum compiling method andapplied research on a type of loader powertrain ". A loader powertrain is taken as theresearch object, and Mathematical statistics, signal analysis and processing, finite elementstructural analysis and fatigue analysis methods are adopted comprehensively. Based on loadtime history of actual measurement for loader powertrain with multiple load cases, thefatigue load spectrum can be compiled and the fatigue life of typical parts can be predicted.Therefore，a comprehensive set of research methods for test, compilation and application ofload spectra can be established so that the level of independent research and development ofdomestic loader would be raised.
On the basis of widely consulting the related literatures of home and abroad, theresearch status of load spectrum testing and its compiling technology are summarized.According to characteristics of loader powertrain load, the load spectrum test scheme isproposed. The dynamic torques and revolving speed data of main powertrain parts in fivekinds of working conditions are obtained. Then, wavelet fractal method is proposed, whicheffectively removing singularity points of the measured load signal in the loader powertrain,compared with Amplitude threshold method, Gradient threshold method and Statisticalsmoothing method, this method can remove singularity more effectively. It can be used forthreshold filtering to eliminate the noise in the signal, and improves the efficiency of signalprocessing.
According to the obvious segmented working characteristics of loader, the manner ofdividing operation section is presented. It gives a basic method of quantile extrapolation thatmeasures load spectra dispersion from loader powertrain, compared with time domain andrain-flow frequency extrapolation, the “shovel-continuation-shovel” spectrum compilationmethod is put foreword based on nonparametric extrapolation reconstruction of operationsection rain-flow. The load spectrum from above method is the nearest to the load from loader’s practical use. Moreover, above method reflects the cycle-working process when theloader shifts frequently. In order to facilitate the implementation of fatigue test, this papercompiles the shaft of the8grade program load spectrum which used by the method ofequivalent damage. Compiling multiple conditions synthetic load spectrum, stress fatiguelife of the gearbox output flange is estimated with the stress fatigue analysis method basedon finite element method.
Based upon the load tests on the transmission gear parts, a load spectrum compilationmethod of transmission agent gears is proposed by counting processing, composition andextrapolation of gear load count in fixed-axis transmission and planetary gear one. Bycompiling the load spectrum of the wheel-side reducer for loader during the period ofsynthetic operation, using Romax, we can predict the flexible fatigue life on the wheel-sideplanetary transmission gear for loader. The prediction results show that gear strength of thereducer meets the design requirement. Through the sensitivity analysis, the influence of theinput load parameters for gear and the tooth root filler parameters on fatigue life is studied.The conclusion shows that the damage of sun gear on the increase of load amplitude and thedeterioration of tooth root filler parameters is more sensitive compared with the planetarywheel. In addition, the damage of the sun gear tooth has the larger increase magnitudes.
A durability test method of loader proving ground is proposed, the load and damagemechanism of the loader in practical use is reproduced by this way and the blindness of testis avoided. By discussing collection, compression and processing of the input data,equivalent load spectrum and other key technologies to make effective plan of durability test,the experimental technique and the optimization objectives associated with proving groundare analyzed. The multi-objective optimization problem aim at minimum error and minimumtest time is established, and feasible solution set to meet the requirement is obtained withNSGA-II algorithm, with a multi-objective optimization method based on the referencepoints, the preference of experts can be reflected from Pareto optimal solution set. Thismethod can effectively reflect the load condition of an actual usage and deviation, and cantimely discover and improve the deviation of equipment life design. A valuable reference isprovided for the loader’s product-forming and verification test.
In the paper the measured load spectrum is important data for structure fatigue resistantdesign and fatigue test loads of the loader. The proposed method in this paper gives areference for other engineering vehicle in load spectra measurement and fatigue design.
在广泛查阅国内外相关文献基础上，综述了载荷谱测试及编制技术研究现状。根据装载机传动系载荷特点，提出了装载机传动系统载荷谱测试方案。经过测试得到五种工况下传动系主要零件的动态转矩和转速数据。提出了装载机传动系实测载荷信号小波分形剔除奇异点的方法，通过与幅值门限法、梯度门限法以及统计平滑方法进行比较，该方法能更有效地剔除奇异点，同时可对信号进行阈值滤波消除信号中的噪声，提高信号处理效率。
根据装载机明显的分段作业特性，提出了划分作业段的方法。给出了度量装载机传动系载荷谱分散性的分位数外推的基本方法，对比分析时域和雨流域频次外推，提出了基于作业段雨流计数结果进行非参数外推重构的“铲-续-铲”谱编制方法，该方法编制的载荷谱比较接近装载机实际使用的载荷情况，反映了装载机进行频繁换挡的循环作业过程；为了便于实施零件疲劳试验，采用损伤等效的方法，编制了轴类零件的8级程序加载谱。利用编制的多工况合成载荷谱，应用应力疲劳分析法对变速箱输出法兰进行了基于有限元的应力寿命预估。
以传动系齿轮类零件的载荷测试为基础，通过研究定轴传动和行星传动中齿轮载荷的计数统计、合成以及外推方法，提出了传动系齿轮类零件的载荷谱编制方法，编制了装载机轮边行星减速器合成作业段载荷谱，运用Romax分析软件，对装载机轮边行星传动齿轮进行了弯曲疲劳寿命预测，预测结果表明轮边减速器齿轮强度满足设计要求。通过敏度分析，研究齿轮输入载荷参数以及齿根圆角参数对寿命的影响。结果表明与行星轮相比，太阳轮损伤对载荷幅值的增大以及齿根圆角参数的恶化比较敏感，损伤增加幅度大。
提出了一种与用户实际使用关联的装载机试验场耐久性试验方法，该方法可再现装载机在实际使用中的载荷和损伤，避免试验的盲目性。为制定有效的耐久性试验计划，通过研究输入数据的收集、压缩、处理以及载荷谱等效等关键技术，分析了与用户关联的试验场试验技术和优化目标，建立了以最小误差和最短时间为目标的多目标优化模型，利用NSGA-II算法，采用基于参考点的多目标优化方法，得到能反映专家偏好的最优解集。该方法可以有效地反映用户实际使用时的载荷情况，能及时发现和改进设备寿命设计中的偏差，指导装载机产品定型或验证试验。
本文测取的载荷谱是装载机传动系抗疲劳设计和疲劳试验加载的重要依据，本文提出的方法可以为其他工程车辆传动系载荷谱测取及疲劳设计提供参考。
This paper is combined with the project supported by the National Natural ScienceFund Project "Study on key technologies of load spectrum for wheeled vehicle powertrain"and the subject "Development of75m3large open-pit mining excavator", branch of theNational "863" Program Project "Large-scale open-pit mining technology and equipment",and the university-enterprise cooperation project "Load spectrum compiling method andapplied research on a type of loader powertrain ". A loader powertrain is taken as theresearch object, and Mathematical statistics, signal analysis and processing, finite elementstructural analysis and fatigue analysis methods are adopted comprehensively. Based on loadtime history of actual measurement for loader powertrain with multiple load cases, thefatigue load spectrum can be compiled and the fatigue life of typical parts can be predicted.Therefore，a comprehensive set of research methods for test, compilation and application ofload spectra can be established so that the level of independent research and development ofdomestic loader would be raised.
On the basis of widely consulting the related literatures of home and abroad, theresearch status of load spectrum testing and its compiling technology are summarized.According to characteristics of loader powertrain load, the load spectrum test scheme isproposed. The dynamic torques and revolving speed data of main powertrain parts in fivekinds of working conditions are obtained. Then, wavelet fractal method is proposed, whicheffectively removing singularity points of the measured load signal in the loader powertrain,compared with Amplitude threshold method, Gradient threshold method and Statisticalsmoothing method, this method can remove singularity more effectively. It can be used forthreshold filtering to eliminate the noise in the signal, and improves the efficiency of signalprocessing.
According to the obvious segmented working characteristics of loader, the manner ofdividing operation section is presented. It gives a basic method of quantile extrapolation thatmeasures load spectra dispersion from loader powertrain, compared with time domain andrain-flow frequency extrapolation, the “shovel-continuation-shovel” spectrum compilationmethod is put foreword based on nonparametric extrapolation reconstruction of operationsection rain-flow. The load spectrum from above method is the nearest to the load from loader’s practical use. Moreover, above method reflects the cycle-working process when theloader shifts frequently. In order to facilitate the implementation of fatigue test, this papercompiles the shaft of the8grade program load spectrum which used by the method ofequivalent damage. Compiling multiple conditions synthetic load spectrum, stress fatiguelife of the gearbox output flange is estimated with the stress fatigue analysis method basedon finite element method.
Based upon the load tests on the transmission gear parts, a load spectrum compilationmethod of transmission agent gears is proposed by counting processing, composition andextrapolation of gear load count in fixed-axis transmission and planetary gear one. Bycompiling the load spectrum of the wheel-side reducer for loader during the period ofsynthetic operation, using Romax, we can predict the flexible fatigue life on the wheel-sideplanetary transmission gear for loader. The prediction results show that gear strength of thereducer meets the design requirement. Through the sensitivity analysis, the influence of theinput load parameters for gear and the tooth root filler parameters on fatigue life is studied.The conclusion shows that the damage of sun gear on the increase of load amplitude and thedeterioration of tooth root filler parameters is more sensitive compared with the planetarywheel. In addition, the damage of the sun gear tooth has the larger increase magnitudes.
A durability test method of loader proving ground is proposed, the load and damagemechanism of the loader in practical use is reproduced by this way and the blindness of testis avoided. By discussing collection, compression and processing of the input data,equivalent load spectrum and other key technologies to make effective plan of durability test,the experimental technique and the optimization objectives associated with proving groundare analyzed. The multi-objective optimization problem aim at minimum error and minimumtest time is established, and feasible solution set to meet the requirement is obtained withNSGA-II algorithm, with a multi-objective optimization method based on the referencepoints, the preference of experts can be reflected from Pareto optimal solution set. Thismethod can effectively reflect the load condition of an actual usage and deviation, and cantimely discover and improve the deviation of equipment life design. A valuable reference isprovided for the loader’s product-forming and verification test.
In the paper the measured load spectrum is important data for structure fatigue resistantdesign and fatigue test loads of the loader. The proposed method in this paper gives areference for other engineering vehicle in load spectra measurement and fatigue design.
引文
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