120km/h机械冷板冷藏车车体钢结构研究
|
摘要
随着国民经济的发展和易腐货物运量的不断增加，为满足铁路货运提速的需要，将具有诸多优点的冷板蓄冷技术应用于铁路载运工具，开发研制120km／h机械冷板冷藏车成为现实需求。作为这种新型冷藏车的承载结构，其车体钢结构是研制该产品的关键所在。
主要的研究工作包括：按照总体方案进行结构设计，车体采用整体承载式全钢焊接结构，板材选用耐候钢，外形轮廓符合车辆限界；运用有限元分析方法，建立车体钢结构计算模型，进行了强度与刚度计算，验证了结构设计符合车辆强度规范；通过工艺技术准备和制作的工艺装备，确保了两辆样车钢结构的试制质量，实物检测数据基本符合该车的技术要求；进行了车体静强度试验，试验数据表明，样车钢结构强度和刚度均满足车辆强度规范要求；经过运用考验，样车钢结构的技术状态保持良好。
分析了车体钢结构腐蚀对其强度的影响，提出了三种分析方法，估算了这种新型冷藏车在运用过程中，不同腐蚀年数的钢结构强度、刚度状况，定量分析了随着年数增加腐蚀对强度、刚度的影响程度和变化趋势。
对这种车体钢结构进行了进一步的优化探讨，提出了基于灵敏度分析的钢结构轻量化方法和原则。对车体钢结构多个设计变量的应力灵敏度、位移灵敏度和质量灵敏度进行了计算，这样可以准确把握各设计变量对车体钢结构强度、刚度和质量的影响程度。通过对其车体钢结构进行结构优化、灵敏度分析和参数优化，为车体承载结构轻量化提供了一种科学的分析计算方法。
实践证明，研制的这种新型冷藏车的车体钢结构，符合该车的技术性能指标和参数的要求，可以满足120km／h运行速度的铁路快捷冷藏运输的需要，达到了研发的预期目标。通过试验和运用考验，证明了这种新型冷藏车冷藏效果好，运行速度快，装载容积大，有运用灵活、经济、可靠、节能、环保等特点，具有很好的经济效益和社会效益。
With the development of national economy and the increasing perishable cargoes, and to meet the needs of railway speed increasing, it is urgent to develop 120km/h mechanical cool plate refrigerator cars, which apply the cool plate to railway vehicles. As the load-bearing structure, the development of the car-body steel structure is one of the main tasks.
The main tasks of development and methods utilized include: the structure is designed in accordance with the overall scheme. The car body is with integral-load-bearing whole-steel welding structure, weather-resistatant steel is selected as the plate material. The profile of car meets the needs of the car delimitation. Using the finite element analysis method, a calculation model for the car-body steel structure is built, the strength and rigidity of the cars are calculated, and the structure design is verified to satisfy the car strength criterion. The manufacturing quality of the model cars is ensured by technical preparation and equipment. The data from the test on the model car basically meets the technical requirement. The static strength test is carried on the model cars, and the resulting data indicates that the strength and rigidity of model car steel structure meet the criterion. The technical performances of the model cars remain good after the application test.
Effect of corrosion on the strength of the car-body steel structure is also analyzed, and three analysis methods are put forward. The strength and rigidity of the steel structure after different years of corrosion are estimated and predicted. The extent and tendency of effect of corrosion on the strength and rigidity are analyzed with increasing years of application of cars.
Optimization design on the above car-body steel structure is discussed. A weight lightening method and principle of steel structure is put forward based on sensitivity analysis. The stress sensitivity, displacement sensitivity, and mass sensitivity of several variables of car-body steel structure are calculated to precisely control the effect of each variable on the strength, rigidity and mass of car-body steel structure. A scientific analysis and calculation method is provided for weight lightening of the car-body load-bearing structure via structure optimization, sensitivity analysis and parameters optimization of the car-body steel structure.
It is proved that the car-body steel structure of the new refrigerator cars meet the technical parameters requirements, it can meet the needs of railway refrigeration transport at the speed of 120km/h, and also the development aims are achieved. Experiments and application tests prove that the new refrigerator cars with good refrigeration effect, higher speed, and large volume. And the cars are flexible for usage, economical, reliable, energy-saving, and environmentally friendly, so it will create excellent economic benefit and social benefit.
主要的研究工作包括：按照总体方案进行结构设计，车体采用整体承载式全钢焊接结构，板材选用耐候钢，外形轮廓符合车辆限界；运用有限元分析方法，建立车体钢结构计算模型，进行了强度与刚度计算，验证了结构设计符合车辆强度规范；通过工艺技术准备和制作的工艺装备，确保了两辆样车钢结构的试制质量，实物检测数据基本符合该车的技术要求；进行了车体静强度试验，试验数据表明，样车钢结构强度和刚度均满足车辆强度规范要求；经过运用考验，样车钢结构的技术状态保持良好。
分析了车体钢结构腐蚀对其强度的影响，提出了三种分析方法，估算了这种新型冷藏车在运用过程中，不同腐蚀年数的钢结构强度、刚度状况，定量分析了随着年数增加腐蚀对强度、刚度的影响程度和变化趋势。
对这种车体钢结构进行了进一步的优化探讨，提出了基于灵敏度分析的钢结构轻量化方法和原则。对车体钢结构多个设计变量的应力灵敏度、位移灵敏度和质量灵敏度进行了计算，这样可以准确把握各设计变量对车体钢结构强度、刚度和质量的影响程度。通过对其车体钢结构进行结构优化、灵敏度分析和参数优化，为车体承载结构轻量化提供了一种科学的分析计算方法。
实践证明，研制的这种新型冷藏车的车体钢结构，符合该车的技术性能指标和参数的要求，可以满足120km／h运行速度的铁路快捷冷藏运输的需要，达到了研发的预期目标。通过试验和运用考验，证明了这种新型冷藏车冷藏效果好，运行速度快，装载容积大，有运用灵活、经济、可靠、节能、环保等特点，具有很好的经济效益和社会效益。
With the development of national economy and the increasing perishable cargoes, and to meet the needs of railway speed increasing, it is urgent to develop 120km/h mechanical cool plate refrigerator cars, which apply the cool plate to railway vehicles. As the load-bearing structure, the development of the car-body steel structure is one of the main tasks.
The main tasks of development and methods utilized include: the structure is designed in accordance with the overall scheme. The car body is with integral-load-bearing whole-steel welding structure, weather-resistatant steel is selected as the plate material. The profile of car meets the needs of the car delimitation. Using the finite element analysis method, a calculation model for the car-body steel structure is built, the strength and rigidity of the cars are calculated, and the structure design is verified to satisfy the car strength criterion. The manufacturing quality of the model cars is ensured by technical preparation and equipment. The data from the test on the model car basically meets the technical requirement. The static strength test is carried on the model cars, and the resulting data indicates that the strength and rigidity of model car steel structure meet the criterion. The technical performances of the model cars remain good after the application test.
Effect of corrosion on the strength of the car-body steel structure is also analyzed, and three analysis methods are put forward. The strength and rigidity of the steel structure after different years of corrosion are estimated and predicted. The extent and tendency of effect of corrosion on the strength and rigidity are analyzed with increasing years of application of cars.
Optimization design on the above car-body steel structure is discussed. A weight lightening method and principle of steel structure is put forward based on sensitivity analysis. The stress sensitivity, displacement sensitivity, and mass sensitivity of several variables of car-body steel structure are calculated to precisely control the effect of each variable on the strength, rigidity and mass of car-body steel structure. A scientific analysis and calculation method is provided for weight lightening of the car-body load-bearing structure via structure optimization, sensitivity analysis and parameters optimization of the car-body steel structure.
It is proved that the car-body steel structure of the new refrigerator cars meet the technical parameters requirements, it can meet the needs of railway refrigeration transport at the speed of 120km/h, and also the development aims are achieved. Experiments and application tests prove that the new refrigerator cars with good refrigeration effect, higher speed, and large volume. And the cars are flexible for usage, economical, reliable, energy-saving, and environmentally friendly, so it will create excellent economic benefit and social benefit.
引文
[1] Xie Ruhe, Hu Siji. Research on the Problem of Weight-Loss of Perishable Goods in Refrigerated Transportation, the 20th International Congress of Refrigeration, Sydney, Australia, 1999
[2] Billiard, F. New Developments in the Food Cold Chain Worldwide, in: 20th International Congress of Refrigeration. ⅡR/ⅡF, Sydney, Australia, 1999
[3] Cleland, A.C., Market-pull factor for refrigerated Transport services. Frio Calor Aire acond.,ES., 2000.03, n.313; 34～39
[4] Commere, B., Hautier, J.P. Transport: how to master the cold chain. Froid, FR., 2001.12; vol.91; n.1019; 55～58
[5] Gene Cope, et al. Development of Railway Refrigerator Cars in the United States. 1997 Car & Locomotive Cyclopedia,193～200
[6] 谢如鹤．机械冷板冷藏车运用模式的研究．长沙：中南大学，2002．3～5．
[7] 孙桂初，刘东岭．铁路冷藏运输．北京：中国铁道出版社，1996．75～96
[8] 中华人民共和国铁道部．GB146．1-83．标准轨距铁路机车车辆限界．北京：中国铁道出版社，1983．
[9] 西南交通大学．车辆构造．北京：中国铁道出版社，1984．6～7
[10] Zienkiewica O.C. The Finite Element Method. New York, McGraw-Hill, 1997
[11] Chandrupatla T, Belegundu A. Introduction to Finite Elements in engineering. Prentice Hall, 1991
[12] Swanson Analysistems, Inc. ANSYS Manual:Introduction to ANSYS, Vol. Ⅰ, 2004
[13] 陈世和．车辆钢结构腐蚀与防护．北京：中国铁道出版社，1994．197～198
[14] 博弈创作室．ANSYS 9.0经典产品高级分析技术与实例详解．北京：中国水利水电出版社，2005．236～237
[15] 成建民，姚金山，尤文娅．车辆设计参考手册．北京：中国铁道出版社，1988．1～44
[16] 严隽耄，成建民．车辆工程．第二版．北京：中国铁道出版社，2003．475～476
[17] Segrlind L. Applied Finite Element Analysis. New York, John Wiley and Sons, 1984
[18] D.H.Norrie, G.Devries. An Introduction to Finite Element Analysis. Academic press, 1978
[19] ANSYS, Inc. ANSYS Structural Analysis Guide Release 5.4. Third Edition. SAP, IP Inc., 1997
[20] 中华人民共和国铁道部．TB／T1335—1996．铁道车辆强度设计及试验鉴定规范．北京：铁道部标准计量研究所，1999
[21] Swanson Analysistems, Inc. ANSYS User's Manual:Procedures, Vol. Ⅰ, 2004
[22] Swanson Analysistems, Inc. ANSYS User's Manual:Commands, Vol. Ⅱ, 2004
[23] 李浩月，周田朋，刘相新．ANSYS工程计算应用教程．北京：中国铁道出版社，2003．35～95
[24] 傅永华．有限元分析基础．武汉：武汉大学出版社．2003．96～97
[25] 上海铁道学院．车辆强度计算理论．北京：中国铁道出版社，1986．162～163
[26] Swanson Analysistems, Inc. ANSYS User's Manual:Elements, Vol. Ⅲ, 2004
[27] 杨岳，罗意平．CAD／CAM原理与实践．北京：中国铁道出版社，2002．148～149
[28] 叶先磊，史亚杰．ANSYS工程分析软件应用实例．北京：清华大学出版社，2003．76～89
[29] 周晓峰．B15K型代用棚车车体钢结构强度、刚度计算报告．北京：铁道部科学研究院机车车辆研究所．2005
[30] 龚曙光．ANSYS基础应用及范例解析．北京：机械工业出版社，2003．306～308
[31] 刘鸿文．材料力学．第二版(上册)．北京：高等教育出版社，1982．308～309
[32] 刘美衡．冷板车侧墙、车顶钢结构制造工艺．广厂科技．2001年总第11期．13～21
[33] 王元良．焊接及焊接结构．北京：中国铁道出版社，1996．57～58
[34] 周晓峰．B15K型代用棚车车体静强度试验研究报告．北京：铁道部科学研究院机车车辆研究所．2005
[35] 王福天．车辆动力学．北京：中国铁道出版社，1985．11～19
[36] 中华人民共和国铁道部．GB5599-85．铁道车辆动力学性能评定及试验鉴定规范．北京：中国铁道出版社，1985
[37] 张炘宇，蒋六保．结构力学．北京：中国铁道出版社，1986．59～60
[38] 陈邦文，刘力．铁道车辆用09CuPTiXt耐候钢性能研究．铁道车辆，1987，(3)：12～17
[39] 吴瑞银，郭泰清．铁道车辆用10CrNiCuP耐候冷扎钢板的研制．铁道车辆，1987，(3)：18～21
[40] R.L.Fox. Optimization Methods for Engineering Design. Addison-Wesleg Publishing, 1972
[41] R.C.Johson. Mechanical Design Synthesis with Optimization Applications New-York.1971
[42] 刘华．轻量化通用敞车设计．铁道车辆，2004，(3)：21～23
[43] 张景阳，李佩瑜，唐志侬．机冷车车体夹层结构的设计和制造(上)．铁道车辆，1995，(9)：26～29
[44] 成建民．有限单元法及其在车辆强度计算的应用．北京：中国铁道出版社，1998
[45] 陈秀宁．机械优化设计．杭州：浙江大学出版社，1991．13～14
[46] 李玉家，赵洪伦．基于频率约束的高速客车车体承载结构优化．铁道车辆，2000，(1)：9～11
[47] Heinrich Husken, et al. Structural Design and Test of the Portland's Low-floor LRV. Railway Gazette International,1996, No.10:659-662
[2] Billiard, F. New Developments in the Food Cold Chain Worldwide, in: 20th International Congress of Refrigeration. ⅡR/ⅡF, Sydney, Australia, 1999
[3] Cleland, A.C., Market-pull factor for refrigerated Transport services. Frio Calor Aire acond.,ES., 2000.03, n.313; 34～39
[4] Commere, B., Hautier, J.P. Transport: how to master the cold chain. Froid, FR., 2001.12; vol.91; n.1019; 55～58
[5] Gene Cope, et al. Development of Railway Refrigerator Cars in the United States. 1997 Car & Locomotive Cyclopedia,193～200
[6] 谢如鹤．机械冷板冷藏车运用模式的研究．长沙：中南大学，2002．3～5．
[7] 孙桂初，刘东岭．铁路冷藏运输．北京：中国铁道出版社，1996．75～96
[8] 中华人民共和国铁道部．GB146．1-83．标准轨距铁路机车车辆限界．北京：中国铁道出版社，1983．
[9] 西南交通大学．车辆构造．北京：中国铁道出版社，1984．6～7
[10] Zienkiewica O.C. The Finite Element Method. New York, McGraw-Hill, 1997
[11] Chandrupatla T, Belegundu A. Introduction to Finite Elements in engineering. Prentice Hall, 1991
[12] Swanson Analysistems, Inc. ANSYS Manual:Introduction to ANSYS, Vol. Ⅰ, 2004
[13] 陈世和．车辆钢结构腐蚀与防护．北京：中国铁道出版社，1994．197～198
[14] 博弈创作室．ANSYS 9.0经典产品高级分析技术与实例详解．北京：中国水利水电出版社，2005．236～237
[15] 成建民，姚金山，尤文娅．车辆设计参考手册．北京：中国铁道出版社，1988．1～44
[16] 严隽耄，成建民．车辆工程．第二版．北京：中国铁道出版社，2003．475～476
[17] Segrlind L. Applied Finite Element Analysis. New York, John Wiley and Sons, 1984
[18] D.H.Norrie, G.Devries. An Introduction to Finite Element Analysis. Academic press, 1978
[19] ANSYS, Inc. ANSYS Structural Analysis Guide Release 5.4. Third Edition. SAP, IP Inc., 1997
[20] 中华人民共和国铁道部．TB／T1335—1996．铁道车辆强度设计及试验鉴定规范．北京：铁道部标准计量研究所，1999
[21] Swanson Analysistems, Inc. ANSYS User's Manual:Procedures, Vol. Ⅰ, 2004
[22] Swanson Analysistems, Inc. ANSYS User's Manual:Commands, Vol. Ⅱ, 2004
[23] 李浩月，周田朋，刘相新．ANSYS工程计算应用教程．北京：中国铁道出版社，2003．35～95
[24] 傅永华．有限元分析基础．武汉：武汉大学出版社．2003．96～97
[25] 上海铁道学院．车辆强度计算理论．北京：中国铁道出版社，1986．162～163
[26] Swanson Analysistems, Inc. ANSYS User's Manual:Elements, Vol. Ⅲ, 2004
[27] 杨岳，罗意平．CAD／CAM原理与实践．北京：中国铁道出版社，2002．148～149
[28] 叶先磊，史亚杰．ANSYS工程分析软件应用实例．北京：清华大学出版社，2003．76～89
[29] 周晓峰．B15K型代用棚车车体钢结构强度、刚度计算报告．北京：铁道部科学研究院机车车辆研究所．2005
[30] 龚曙光．ANSYS基础应用及范例解析．北京：机械工业出版社，2003．306～308
[31] 刘鸿文．材料力学．第二版(上册)．北京：高等教育出版社，1982．308～309
[32] 刘美衡．冷板车侧墙、车顶钢结构制造工艺．广厂科技．2001年总第11期．13～21
[33] 王元良．焊接及焊接结构．北京：中国铁道出版社，1996．57～58
[34] 周晓峰．B15K型代用棚车车体静强度试验研究报告．北京：铁道部科学研究院机车车辆研究所．2005
[35] 王福天．车辆动力学．北京：中国铁道出版社，1985．11～19
[36] 中华人民共和国铁道部．GB5599-85．铁道车辆动力学性能评定及试验鉴定规范．北京：中国铁道出版社，1985
[37] 张炘宇，蒋六保．结构力学．北京：中国铁道出版社，1986．59～60
[38] 陈邦文，刘力．铁道车辆用09CuPTiXt耐候钢性能研究．铁道车辆，1987，(3)：12～17
[39] 吴瑞银，郭泰清．铁道车辆用10CrNiCuP耐候冷扎钢板的研制．铁道车辆，1987，(3)：18～21
[40] R.L.Fox. Optimization Methods for Engineering Design. Addison-Wesleg Publishing, 1972
[41] R.C.Johson. Mechanical Design Synthesis with Optimization Applications New-York.1971
[42] 刘华．轻量化通用敞车设计．铁道车辆，2004，(3)：21～23
[43] 张景阳，李佩瑜，唐志侬．机冷车车体夹层结构的设计和制造(上)．铁道车辆，1995，(9)：26～29
[44] 成建民．有限单元法及其在车辆强度计算的应用．北京：中国铁道出版社，1998
[45] 陈秀宁．机械优化设计．杭州：浙江大学出版社，1991．13～14
[46] 李玉家，赵洪伦．基于频率约束的高速客车车体承载结构优化．铁道车辆，2000，(1)：9～11
[47] Heinrich Husken, et al. Structural Design and Test of the Portland's Low-floor LRV. Railway Gazette International,1996, No.10:659-662