多履带行走装置关键设计技术研究
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摘要
近年来,斗轮挖掘机连续开采工艺成套设备在许多大型褐煤与金属露天矿等工程的应用,显示出效率高、建设周期短,成本低的优越性。斗轮挖掘机的机型也逐渐向高生产能力、大型化方向发展。多履带行走装置担负着大型斗轮挖掘机等重型装备的承重、移动与转向行驶等重要工作,其性能和可靠性直接影响整机的工作安全性和工作效率。开发大型多履带斗轮挖掘机以满足煤炭行业和冶金行业资源开采需求是目前我国矿山机械行业面临的主要任务之一。本文结合产学研合作项目对多履带行走装置的转向行驶理论、主要设计参数确定方法、虚拟样机仿真、多履带行走装置行驶试验以及多履带行走装置设计计算平台开发等关键设计技术进行了研究。
本文在查阅国内外相关文献和与国内外相关企业交流基础上,介绍了多履带行走装置的结构特点、转向方式及转向机构、驱动装置及控制方法,综述了多履带行走装置的理论研究现状和发展趋势。
转向时履带的受力分析是研究多履带行走装置行驶理论的基础。本文对多履带行走装置转向时各条履带的受力进行了研究,考虑了履带的宽度、履带接地面瞬时转动中心的纵向、横向偏移等因素,并分析了各种因素对履带受力的影响。提出了适用于各种多履带行走装置稳态转向分析的数学模型及求解方法。以正三支点六履带行走装置为例,对多履带行走装置非稳态转向特性进行了分析,提出了非稳态转向运动动力学模型及数值求解方法。
基于多履带行走装置行驶理论,提出了通用的多履带行走装置的行驶阻力、转向机构拉力和各条履带驱动功率的计算公式,提出了关键工作部件主要参数的确定方法。基于理想柔性链假设,建立了悬垂履带链的数学模型,推导出离散履带链节的悬垂量计算公式和稳态履带链环的张紧力计算公式。针对影响多履带行走装置行驶安全的脱链问题,提出用于评判脱链风险的指标。
虚拟样机技术是研究多履带行走装置的重要工具,论文基于多体动力学软件RecurDyn建立了多履带行走装置虚拟样机,以三支点六履带行走装置为例进行了典型工况仿真性能试验,对多履带行走装置的工作性能进行预测。
理论分析方法和虚拟样机仿真方法均能够预测多履带行走装置的行驶性能,而理论分析和仿真结果的正确性需通过试验进行验证。本文针对目前国内最大的地面行走机械—应用于元宝山露天煤矿的六履带斗轮挖掘机,进行了直线行驶和转向行驶工况下履带驱动电机功率测试,同时将测试结果和理论计算结果及虚拟样机仿真结果进行了对比,验证了理论计算和虚拟样机仿真结果的正确。
以多履带行驶理论为基础,基于MATLAB/GUI技术,面向多履带行走装置设计工程师开发了多履带行走装置设计计算平台,包括:多履带行走装置转向性能通用计算模块、支重轮辅助设计模块、球铰辅助设计模块和履带转向机构计算等模块,计算多履带行走装置的工作参数和预测其不同工况下的工作性能。
本文对多履带行走装置转向时履带受力、稳态转向特性、非稳态转向特性、虚拟样机仿真及多履带行走装置设计计算平台的开发为多履带走行装置的设计提供了先进的分析方法和软件工具,为我国自主研制和开发多履带行走装置提供了科学的依据。
In recent years, the engineering applications of continuous mining complete set of equipments including bucket wheel excavators, such as in the large lignite and metal open-pit mine, show the advantages of high efficiency, short construction period and low cost. The bucket wheel excavators move toward high production capacity and large-scale direction. The multi-crawler devices are used to carry the huge weight of large bucket wheel excavators, and to drive and steer the entire machine. Their performance and reliability directly influence work efficiency and operational safety of the bucket wheel excavators. Therefore, developing for large multi-crawler bucket wheel excavators is one of the main tasks in mining machinery industry at present. Combining with the project of research cooperation, the key design technologies of multi-crawler devices such as driving theory, determination methods of the main parameters, virtual prototype simulation, driving experiment and design calculation platform development have been studied in this paper.
This paper comprehensively analyzed the structure features, steering method and steering mechanism, driving device and control method of the multi-crawler. Additionally, the theoretical study and the development trend of large-scale crawler are also reviewed.
Stress analysis of crawler during steering is the basis of studying the theory of multi-crawler device. In this paper, the stress of various crawlers when multi-crawler device on steering has been studied, considering factors like crawler width, longitudinal and lateral deviations of the rotation center in the instant of the crawler contacts to the ground. And the influence of various factors on crawler stress has been analyzed. Mathematical model and the solution method of steady steering analysis suitable for all kinds of multi-crawler devices have been putted forward. Taking three-crawler device as an example, the non-steady steering property has been analyzed, and the dynamic model and the numerical solution method of non-steady steering movement have been proposed.
Based on the steering theory of multi-crawler, the commonly used calculation formulas of turning resistance, theoretical turning radius, sweep turning radius and the turning radius of each of the tracks on multi- crawler vehicles are provided. The main calculation methods of the critical parts are also proposed. Using the classical Newtonian mechanics, the mathematical equations of hanging chains for the ideal flexible chain have been deduced, based on which the calculation formula of the discrete track-chain is studied. And then, the calculation formula of the tension force of the steady track chain is deduced. According to the issues on disconnection of the chain that will affect the safety of the vehicle, four quantifiable indicators for judging the risk of disconnection have been put forward.
A digital prototype of multi-crawler device is established and virtual tests on the performance of the three-point-six-track under multiple operating conditions were simulated. Both of the numerical simulation method and the virtual prototype simulation method can be employed to forecast the driving performance of the multi-crawler. The accuracy of simulation results should be verified by experiments, and according to the largest six-track bucket wheel excavator operated in Yuanbaoshan mine of China, the driving parameters were tested. The test results and virtual prototype simulation were compared to verify whether the numerical simulation and virtual prototype simulation results are reasonable or not.
This paper explored the design and computation platform of the multi-crawler. It includes the following contents concretely: (1) Based on Solidworks (3D modeling software) and MATLAB, the digital design platform of the three-point multi-crawler was researched and developed; (2) Based on MATLAB/GUI, the design and computation platform of three-point-six-track was established. Finally, the calculation module of steering was verified by the lateral force, power and turning speed. And also the interplay relationship among pressure and force of supporting wheels, the ball hinge force and other design parameters were analyzed comprehensively.
In short, this thesis obtained the important progress for the large-scale multi-crawler research in the force imposed on the crawler device when steering, steering performance analysis in steady and nonsteady cases, virtual prototyping simulation and development of the design platform. It not only provided the advanced analysis methods and software, but also provided the scientific basis of independent research and development of a large-scale crawler device for our country. So it achieved significant the theoretical value and the practical application.
本文在查阅国内外相关文献和与国内外相关企业交流基础上,介绍了多履带行走装置的结构特点、转向方式及转向机构、驱动装置及控制方法,综述了多履带行走装置的理论研究现状和发展趋势。
转向时履带的受力分析是研究多履带行走装置行驶理论的基础。本文对多履带行走装置转向时各条履带的受力进行了研究,考虑了履带的宽度、履带接地面瞬时转动中心的纵向、横向偏移等因素,并分析了各种因素对履带受力的影响。提出了适用于各种多履带行走装置稳态转向分析的数学模型及求解方法。以正三支点六履带行走装置为例,对多履带行走装置非稳态转向特性进行了分析,提出了非稳态转向运动动力学模型及数值求解方法。
基于多履带行走装置行驶理论,提出了通用的多履带行走装置的行驶阻力、转向机构拉力和各条履带驱动功率的计算公式,提出了关键工作部件主要参数的确定方法。基于理想柔性链假设,建立了悬垂履带链的数学模型,推导出离散履带链节的悬垂量计算公式和稳态履带链环的张紧力计算公式。针对影响多履带行走装置行驶安全的脱链问题,提出用于评判脱链风险的指标。
虚拟样机技术是研究多履带行走装置的重要工具,论文基于多体动力学软件RecurDyn建立了多履带行走装置虚拟样机,以三支点六履带行走装置为例进行了典型工况仿真性能试验,对多履带行走装置的工作性能进行预测。
理论分析方法和虚拟样机仿真方法均能够预测多履带行走装置的行驶性能,而理论分析和仿真结果的正确性需通过试验进行验证。本文针对目前国内最大的地面行走机械—应用于元宝山露天煤矿的六履带斗轮挖掘机,进行了直线行驶和转向行驶工况下履带驱动电机功率测试,同时将测试结果和理论计算结果及虚拟样机仿真结果进行了对比,验证了理论计算和虚拟样机仿真结果的正确。
以多履带行驶理论为基础,基于MATLAB/GUI技术,面向多履带行走装置设计工程师开发了多履带行走装置设计计算平台,包括:多履带行走装置转向性能通用计算模块、支重轮辅助设计模块、球铰辅助设计模块和履带转向机构计算等模块,计算多履带行走装置的工作参数和预测其不同工况下的工作性能。
本文对多履带行走装置转向时履带受力、稳态转向特性、非稳态转向特性、虚拟样机仿真及多履带行走装置设计计算平台的开发为多履带走行装置的设计提供了先进的分析方法和软件工具,为我国自主研制和开发多履带行走装置提供了科学的依据。
In recent years, the engineering applications of continuous mining complete set of equipments including bucket wheel excavators, such as in the large lignite and metal open-pit mine, show the advantages of high efficiency, short construction period and low cost. The bucket wheel excavators move toward high production capacity and large-scale direction. The multi-crawler devices are used to carry the huge weight of large bucket wheel excavators, and to drive and steer the entire machine. Their performance and reliability directly influence work efficiency and operational safety of the bucket wheel excavators. Therefore, developing for large multi-crawler bucket wheel excavators is one of the main tasks in mining machinery industry at present. Combining with the project of research cooperation, the key design technologies of multi-crawler devices such as driving theory, determination methods of the main parameters, virtual prototype simulation, driving experiment and design calculation platform development have been studied in this paper.
This paper comprehensively analyzed the structure features, steering method and steering mechanism, driving device and control method of the multi-crawler. Additionally, the theoretical study and the development trend of large-scale crawler are also reviewed.
Stress analysis of crawler during steering is the basis of studying the theory of multi-crawler device. In this paper, the stress of various crawlers when multi-crawler device on steering has been studied, considering factors like crawler width, longitudinal and lateral deviations of the rotation center in the instant of the crawler contacts to the ground. And the influence of various factors on crawler stress has been analyzed. Mathematical model and the solution method of steady steering analysis suitable for all kinds of multi-crawler devices have been putted forward. Taking three-crawler device as an example, the non-steady steering property has been analyzed, and the dynamic model and the numerical solution method of non-steady steering movement have been proposed.
Based on the steering theory of multi-crawler, the commonly used calculation formulas of turning resistance, theoretical turning radius, sweep turning radius and the turning radius of each of the tracks on multi- crawler vehicles are provided. The main calculation methods of the critical parts are also proposed. Using the classical Newtonian mechanics, the mathematical equations of hanging chains for the ideal flexible chain have been deduced, based on which the calculation formula of the discrete track-chain is studied. And then, the calculation formula of the tension force of the steady track chain is deduced. According to the issues on disconnection of the chain that will affect the safety of the vehicle, four quantifiable indicators for judging the risk of disconnection have been put forward.
A digital prototype of multi-crawler device is established and virtual tests on the performance of the three-point-six-track under multiple operating conditions were simulated. Both of the numerical simulation method and the virtual prototype simulation method can be employed to forecast the driving performance of the multi-crawler. The accuracy of simulation results should be verified by experiments, and according to the largest six-track bucket wheel excavator operated in Yuanbaoshan mine of China, the driving parameters were tested. The test results and virtual prototype simulation were compared to verify whether the numerical simulation and virtual prototype simulation results are reasonable or not.
This paper explored the design and computation platform of the multi-crawler. It includes the following contents concretely: (1) Based on Solidworks (3D modeling software) and MATLAB, the digital design platform of the three-point multi-crawler was researched and developed; (2) Based on MATLAB/GUI, the design and computation platform of three-point-six-track was established. Finally, the calculation module of steering was verified by the lateral force, power and turning speed. And also the interplay relationship among pressure and force of supporting wheels, the ball hinge force and other design parameters were analyzed comprehensively.
In short, this thesis obtained the important progress for the large-scale multi-crawler research in the force imposed on the crawler device when steering, steering performance analysis in steady and nonsteady cases, virtual prototyping simulation and development of the design platform. It not only provided the advanced analysis methods and software, but also provided the scientific basis of independent research and development of a large-scale crawler device for our country. So it achieved significant the theoretical value and the practical application.
引文
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