聚酯生产装置高参数齿轮泵的研制
摘要
随着大型聚合物生产装置的迅猛发展，高参数齿轮泵的应用日益广泛。聚合物熔体输送增压用高参数齿轮泵的研究制造是齿轮泵技术发展的一个重要方面。本论文是对国产第一台聚酯生产装置高参数齿轮泵的研制工作的总结，提出了聚合物输送用高参数齿轮泵的设计程序、关键参数的设计计算方法、以及结构设计的关键技术，并对该类型泵制造的关键技术作了总结。本论文的主要工作及结论如下：
1)给出了高参数齿轮泵关键技术参数的计算、选用方法，包括齿轮泵的转排量、齿轮泵的转子型式及其参数、齿轮泵的工作间隙、卸荷槽、齿轮泵的输入扭矩的计算选择方法，并用实验方法检验了关键技术参数选择的合理性。
2)解决了高参数齿轮泵结构设计中的技术难题。本文提供了齿轮泵的壳体，齿轮转子，轴瓦的材料的选择方法，结构设计方法以及需要注意的问题，并提供了在高温高压下密封的解决方法。
3)对高参数齿轮泵制造的关键技术进行研究。指出了齿轮泵关键零部件泵壳、转子、轴瓦的技术要点，包括生产工艺研究，关键工序生产加工方法的研究；对齿轮泵装配的关键技术进行了总结。
4)对高参数齿轮泵样机作了运转试验并对其生产现场运行进行了测试。分析了齿轮泵性能的影响因素以及理论计算结果与实际运行结果的比较。验证了齿轮泵结构设计、材料选用、加工制造、驱动装置设计等技术研究的可行性与合理性。
该齿轮泵装置研制的成功，为高参数齿轮泵产品的系列化打下坚实的基础，为进一步的理论研究提供了样机的实验数据；同时表明我们已经拥有生产聚合物熔体输送增压用高参数齿轮泵的技术，可以实现国产化。对于国内即将投资兴建的新的聚酯生产装置，该齿轮泵可以替代进口产品，除可以降低投入成本外，还可以减小各种维护方面的费用。与国外进口装置相比较，大大降低了生产企业的成本。它带来的直接经济效益显著，并且有着良好的市场前景。
The high parameter gear pump for polymer proceeding is an important branch of gear pump technology, and it is used more and more frequently with the great increase of the polymer equipment. This article is a summary of the study and manufacturing of the first high parameter gear pump in China. It presents the key method of the design procedure, the parameter calculation, the structure design, and the gear pump manufacture. The major conclusions of the article are:
1) It presents the methods of the key parameter selection and calculation of the gear pump, including the volumetric capacity, the gear profile and its parameter, the leakage, and input power. And it demonstrates the rationality of the parameter selection through experiments.
2) It solves the technical problems of the gear pump structure design, such as the method of material selection of the pump housing, gear and bearing, and some aspects that must pay attention to. And it solves the sealing problem under high temperature and high pressure.
3) It conducts study on key techniques for gear pump manufacturing, including the technology for making main parts like the housing, gear, and bearing, and the summary of the assembly.
4) The gear pump is tested both in the manufactory and in the PET equipment. The influencing factors for pump performance have been analyzed. The results are compared with results of testing. It demonstrates the correctness of the structure design, material choosing, and manufacture technology.
The success of the gear pump manufacturing gives testing data for further theoretical study and makes a substantial ground to the series production. It also indicates that this kind of gear pump can be made domestically; accordingly cost will be greatly reduced for domestic users. The market for this product is promising in China.
1)给出了高参数齿轮泵关键技术参数的计算、选用方法，包括齿轮泵的转排量、齿轮泵的转子型式及其参数、齿轮泵的工作间隙、卸荷槽、齿轮泵的输入扭矩的计算选择方法，并用实验方法检验了关键技术参数选择的合理性。
2)解决了高参数齿轮泵结构设计中的技术难题。本文提供了齿轮泵的壳体，齿轮转子，轴瓦的材料的选择方法，结构设计方法以及需要注意的问题，并提供了在高温高压下密封的解决方法。
3)对高参数齿轮泵制造的关键技术进行研究。指出了齿轮泵关键零部件泵壳、转子、轴瓦的技术要点，包括生产工艺研究，关键工序生产加工方法的研究；对齿轮泵装配的关键技术进行了总结。
4)对高参数齿轮泵样机作了运转试验并对其生产现场运行进行了测试。分析了齿轮泵性能的影响因素以及理论计算结果与实际运行结果的比较。验证了齿轮泵结构设计、材料选用、加工制造、驱动装置设计等技术研究的可行性与合理性。
该齿轮泵装置研制的成功，为高参数齿轮泵产品的系列化打下坚实的基础，为进一步的理论研究提供了样机的实验数据；同时表明我们已经拥有生产聚合物熔体输送增压用高参数齿轮泵的技术，可以实现国产化。对于国内即将投资兴建的新的聚酯生产装置，该齿轮泵可以替代进口产品，除可以降低投入成本外，还可以减小各种维护方面的费用。与国外进口装置相比较，大大降低了生产企业的成本。它带来的直接经济效益显著，并且有着良好的市场前景。
The high parameter gear pump for polymer proceeding is an important branch of gear pump technology, and it is used more and more frequently with the great increase of the polymer equipment. This article is a summary of the study and manufacturing of the first high parameter gear pump in China. It presents the key method of the design procedure, the parameter calculation, the structure design, and the gear pump manufacture. The major conclusions of the article are:
1) It presents the methods of the key parameter selection and calculation of the gear pump, including the volumetric capacity, the gear profile and its parameter, the leakage, and input power. And it demonstrates the rationality of the parameter selection through experiments.
2) It solves the technical problems of the gear pump structure design, such as the method of material selection of the pump housing, gear and bearing, and some aspects that must pay attention to. And it solves the sealing problem under high temperature and high pressure.
3) It conducts study on key techniques for gear pump manufacturing, including the technology for making main parts like the housing, gear, and bearing, and the summary of the assembly.
4) The gear pump is tested both in the manufactory and in the PET equipment. The influencing factors for pump performance have been analyzed. The results are compared with results of testing. It demonstrates the correctness of the structure design, material choosing, and manufacture technology.
The success of the gear pump manufacturing gives testing data for further theoretical study and makes a substantial ground to the series production. It also indicates that this kind of gear pump can be made domestically; accordingly cost will be greatly reduced for domestic users. The market for this product is promising in China.
引文
[1]机械工程手册编辑委员会．机械工程手册：通用设备卷．北京：机械工业出版社，1997．2-95～99
[2]齿轮手册编委会．齿轮手册．北京：机械工业出版社，1990
[3]陈祝年编著．焊接工程师手册．北京：机械工业出版社，2002．1075～1079
[4]范德明等．工业泵选用手册．北京：化学工业出版社，1998．95，116～137
[5]荆冰彬，张景民．市场需求及其对产品设计的影响．机械设计与研究，1998(1)：15～17
[6]戴干策编著．聚合物加工中的传递现象．北京：中国石化出版社，1999
[7]尤金．齿轮泵．北京：机械工业出版社，1960
[8]唐兵，栾振辉．齿轮泵的发展趋势．流体机械，1999，5：26～28
[9]JAMES M.MCKELVEY. Performance of Gear Pumps in Polymer Processing. POLYMER ENGINGEERING AND SCIENCE, APRIL, 1984,Vol.24, No.6, 398～402
[10]Gregory R W, Harris S L. Gear Pump Handles Tough-to-process Polymer. Proceeding of the institution of Mechanical Engineers, 1964,178(8):207～226
[11]Harris S L. Comparison of an External Gear Pump Wear Model with Test Data. Proceeding of the institution of Mechanical Engineers, 1958, 172: 87～112
[12]胡开文．齿轮泵工作原理的探讨．农业机械学报，2000(3)：67～70
[13]吴限，高红旗．齿轮泵流量调节方式之新设想．机械工程师，1996，增刊：58～60
[14]吴大任．齿轮啮合原理．北京：机械工业出版社,1985
[15]闵德云．齿轮泵的优化设计．机械设计与制造，1990，4：5～9
[16]甘学辉．聚合物齿轮泵特性理论研究及数值模拟：[博士学位论文]．郑州：郑州机械研究所，2002
[17]陈佩琳．改善齿轮泵性能的研究：[硕士学位论文]．西安：西安交通大学，1987
[18]刘志和．大流量齿轮泵的降噪研究：[硕士学位论文]．西安：西安交通大学，1984
[19]王海兰．外啮合齿轮泵的内泄漏与油液污染磨损研究：[硕士学位论文]．吉林：吉林工业大学，1999
[20]马昌 等．泵的流量脉动率对比测试．哈尔滨理工大学学报，1999，(1) ：53～59
[21]徐灏编著．密封．北京：冶金工业出版社，1993．81～109
[22]Gan Xuehui,Wu Xiaoling. Virtual Manufacture Technology and Implementation in Worshop,Proceeding of the First International conference on Mechanical Engineering (IMCE 2000). China Machine Press, November20～22,2000 Shanghai ,China
[23]甘学辉，吴晓铃，侯东海．液压齿轮泵的性能研究．机械设计与制造，2001，Vol．145，No．3：69～71
[24]甘学辉，吴晓铃，侯东海．斜齿轮泵间隙最优化设计．机械设计，2002，Vol．19，No．4：30～33
[25]甘学辉，吴晓铃，侯东海．全齿廓啮合斜齿齿轮泵流量脉动特性．石油化工与设备，2002，No．5
[26]甘学辉，吴晓铃，郑英豪．外啮合斜齿轮泵困油特性分析．机械传动，2001，Vol．25，No．4：8～10
[27]甘学辉，吴晓铃，向平．斜齿轮泵有侧隙啮合困油特性分析．机械传动，2002，Vol．6，No．6：14～16
[28]侯东海等．少齿差摆线齿轮泵啮合原理及几何参数选择．机械传动，1995，(3)：24～27
[29]Chen C K, Yang S C. Geometric modeling for cylindrical and helical Gear Pumps with circular are teeth. PI MECH ENG C J MEG ,2000, 214(4): 599～607
[30]Bartilla T. Gear pumps inner extrusion applications. Kunststoffe-German Plastics, Oct 1992 ,V82,No.10:28～30
[31]Fenton, R. G. Optimum Design of Gear Pumps. American Society of Mechanical Engineering, Apr 1975: 21～24
[32]K.Duke. Improving Gear Pump Relief Groove Design. Proc Natl Conf Fluid Power, 1976(30)
[33]Smith, Dan,Stalling, Tony. Specifying a Total Gear Pump System. Plastic Engineering, Feb1994,V50 N2: 19～23
[34]Fielding D,Foster K. Sources of Press Pulsation from A Gear Pump. Inst of Mech Eng, 1977
[35]Denis R Unruia. Outlet Pressure Ripple Measurement of Positive Displacement Hydraulic Pump. Natl Conf On Fluid Power, 1975
[36]P K King.A Ripple Free Gear Pump Using Conational Leakage. SAE 801006
[37]Akira,Ishibashi. Studies On Volumetric Efficiency And Theoretical Deli every of Gear Pump. Bulletin of the JSME, 1970:13～59
[38]D E Browns. Methods for Characterizing the Fluid bore Noise Generated by Displacement Pumps. 1985
[39]Conditions for Minimum Tooth Tip Losses In External Gear Pumps. 6th Intl Fluid Power Symposium. April 1981,8～10
[40]戴干策，陈敏恒．化工流体力学．北京：化学工业出版社，1988
[41]戴干策，任得呈，范自晖．传递现象导论．北京：化学工业出版社，1996
[42]戴干策，任得呈，范自晖．化学工程基础．北京：中国石化出版社，1991
[43]Pearson J RA. Mechanical principles of Polymer melt Processing. Pergamon Press, 1966
[44]Isayev A L. Modeling of Polymer Processing. Hanser Publishers, 1991
[45]Keith T, O'Brien. Computer Modeling for Extrusion and Other Continuous Process Applications. Hanser Publishers, 1992
[2]齿轮手册编委会．齿轮手册．北京：机械工业出版社，1990
[3]陈祝年编著．焊接工程师手册．北京：机械工业出版社，2002．1075～1079
[4]范德明等．工业泵选用手册．北京：化学工业出版社，1998．95，116～137
[5]荆冰彬，张景民．市场需求及其对产品设计的影响．机械设计与研究，1998(1)：15～17
[6]戴干策编著．聚合物加工中的传递现象．北京：中国石化出版社，1999
[7]尤金．齿轮泵．北京：机械工业出版社，1960
[8]唐兵，栾振辉．齿轮泵的发展趋势．流体机械，1999，5：26～28
[9]JAMES M.MCKELVEY. Performance of Gear Pumps in Polymer Processing. POLYMER ENGINGEERING AND SCIENCE, APRIL, 1984,Vol.24, No.6, 398～402
[10]Gregory R W, Harris S L. Gear Pump Handles Tough-to-process Polymer. Proceeding of the institution of Mechanical Engineers, 1964,178(8):207～226
[11]Harris S L. Comparison of an External Gear Pump Wear Model with Test Data. Proceeding of the institution of Mechanical Engineers, 1958, 172: 87～112
[12]胡开文．齿轮泵工作原理的探讨．农业机械学报，2000(3)：67～70
[13]吴限，高红旗．齿轮泵流量调节方式之新设想．机械工程师，1996，增刊：58～60
[14]吴大任．齿轮啮合原理．北京：机械工业出版社,1985
[15]闵德云．齿轮泵的优化设计．机械设计与制造，1990，4：5～9
[16]甘学辉．聚合物齿轮泵特性理论研究及数值模拟：[博士学位论文]．郑州：郑州机械研究所，2002
[17]陈佩琳．改善齿轮泵性能的研究：[硕士学位论文]．西安：西安交通大学，1987
[18]刘志和．大流量齿轮泵的降噪研究：[硕士学位论文]．西安：西安交通大学，1984
[19]王海兰．外啮合齿轮泵的内泄漏与油液污染磨损研究：[硕士学位论文]．吉林：吉林工业大学，1999
[20]马昌 等．泵的流量脉动率对比测试．哈尔滨理工大学学报，1999，(1) ：53～59
[21]徐灏编著．密封．北京：冶金工业出版社，1993．81～109
[22]Gan Xuehui,Wu Xiaoling. Virtual Manufacture Technology and Implementation in Worshop,Proceeding of the First International conference on Mechanical Engineering (IMCE 2000). China Machine Press, November20～22,2000 Shanghai ,China
[23]甘学辉，吴晓铃，侯东海．液压齿轮泵的性能研究．机械设计与制造，2001，Vol．145，No．3：69～71
[24]甘学辉，吴晓铃，侯东海．斜齿轮泵间隙最优化设计．机械设计，2002，Vol．19，No．4：30～33
[25]甘学辉，吴晓铃，侯东海．全齿廓啮合斜齿齿轮泵流量脉动特性．石油化工与设备，2002，No．5
[26]甘学辉，吴晓铃，郑英豪．外啮合斜齿轮泵困油特性分析．机械传动，2001，Vol．25，No．4：8～10
[27]甘学辉，吴晓铃，向平．斜齿轮泵有侧隙啮合困油特性分析．机械传动，2002，Vol．6，No．6：14～16
[28]侯东海等．少齿差摆线齿轮泵啮合原理及几何参数选择．机械传动，1995，(3)：24～27
[29]Chen C K, Yang S C. Geometric modeling for cylindrical and helical Gear Pumps with circular are teeth. PI MECH ENG C J MEG ,2000, 214(4): 599～607
[30]Bartilla T. Gear pumps inner extrusion applications. Kunststoffe-German Plastics, Oct 1992 ,V82,No.10:28～30
[31]Fenton, R. G. Optimum Design of Gear Pumps. American Society of Mechanical Engineering, Apr 1975: 21～24
[32]K.Duke. Improving Gear Pump Relief Groove Design. Proc Natl Conf Fluid Power, 1976(30)
[33]Smith, Dan,Stalling, Tony. Specifying a Total Gear Pump System. Plastic Engineering, Feb1994,V50 N2: 19～23
[34]Fielding D,Foster K. Sources of Press Pulsation from A Gear Pump. Inst of Mech Eng, 1977
[35]Denis R Unruia. Outlet Pressure Ripple Measurement of Positive Displacement Hydraulic Pump. Natl Conf On Fluid Power, 1975
[36]P K King.A Ripple Free Gear Pump Using Conational Leakage. SAE 801006
[37]Akira,Ishibashi. Studies On Volumetric Efficiency And Theoretical Deli every of Gear Pump. Bulletin of the JSME, 1970:13～59
[38]D E Browns. Methods for Characterizing the Fluid bore Noise Generated by Displacement Pumps. 1985
[39]Conditions for Minimum Tooth Tip Losses In External Gear Pumps. 6th Intl Fluid Power Symposium. April 1981,8～10
[40]戴干策，陈敏恒．化工流体力学．北京：化学工业出版社，1988
[41]戴干策，任得呈，范自晖．传递现象导论．北京：化学工业出版社，1996
[42]戴干策，任得呈，范自晖．化学工程基础．北京：中国石化出版社，1991
[43]Pearson J RA. Mechanical principles of Polymer melt Processing. Pergamon Press, 1966
[44]Isayev A L. Modeling of Polymer Processing. Hanser Publishers, 1991
[45]Keith T, O'Brien. Computer Modeling for Extrusion and Other Continuous Process Applications. Hanser Publishers, 1992
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