EBZ135掘进机行星减速器结构优化设计
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摘要
掘进机已广泛应用于桥梁、隧道、地铁和矿井巷道等工程中,在国民经济的发展中起着越来越重要的作用。掘进机技术的发展对提高桥梁、隧道、地铁、矿井巷道等工程的掘进速度和效率具有重要意义。所以,世界各国都在不断引进先进的掘进机技术和设备,并大力研制先进的掘进机。我国对掘进机技术的研制起步较晚,在大量引进国外先进技术、设备的基础上,对先进技术进行消化、吸收,使我国掘进机技术取得了很大提高,特别是悬臂掘进机技术已经跃上了一个新台阶,但仍与国际先进水平有一定差距。
EBZ135掘进机是一种纵轴式悬臂掘进机,主要适用于煤及半煤岩井下巷道的掘进,也适用于工程隧道施工,应用广泛。其截割头的转矩和功率由电动机通过行星减速器传递。行星减速器的传动性能、结构形式直接影响着EBZ135掘进机的截割性能、结构及体积,它是EBZ135掘进机工作机构的重要组成部分,在EBZ135掘进机掘进过程中起着极其重要的作用。
EBZ135掘进机工作机构的预留空间及工作环境,要求行星减速器尽可能简化结构、减小体积、减小齿轮模数、提高机械性能。本文通过对EBZ135掘进机行星减速器结构的分析与计算、对其传动齿轮的安全校核得知:EBZ135掘进机行星减速器安全系数很大,所以其齿轮模数相对较大,有必要对其结构进行优化设计。
本文提出了EBZ135掘进机行星减速器结构优化的总体方案,分配、设计了各级传动的传动比和齿轮的齿数,对其主要构件进行了优化设计与计算。优化后的EBZ135掘进机行星减速器的结构,与原结构相比,齿轮无需变位,齿轮模数由8减小到5.5,径向尺寸减小了5%,减少了传动中冲击,提高了传动的平稳性,降低了噪音,简化了结构,方便制造、安装与维修。
本文应用UG对EBZ135掘进机行星减速器的优化结构进行了实体建模,并对其实体装配模型进行了干涉检查和运动仿真。通过对实体装配模型干涉检查、运动仿真结果进行分析得知:EBZ135掘进机行星减速器优化结构,运转均匀平稳,实现了给定的传动比,能够满足运动学方面的设计要求,各零部件之间运动灵活,没有发生干涉。
本文利用ANSYS对EBZ135掘进机行星减速器优化结构中的各齿轮和行星架等主要构件进行了有限元静力分析。通过有限元静力分析的结果得知:主要构件产生的应力、应变、合变形位移的变化均比较平稳,产生的最大应力、应变、合位移变形均在自身材料的许可范围之内。
综上可知,本文对EBZ135掘进机行星减速器的结构优化设计合理。EBZ135掘进机行星减速器优化结构,能够实现给定的传动比,能够满足强度要求,运行安全可靠,具有较高的实用价值,并为其它行星减速器结构优化设计提供了理论依据。
Roadheader has been widely used in the constructions such as bridges, tunnels, subway and mine roadway etc, and it is more important to the development of the national economy. The technology of the roadheader is more important in enhancing the driving speed and efficiency during the construction of bridges, tunnels, subway and mine roadway etc. As a result, most of companies and research institutes are now improving the technology of the roadheader. The research of the roadheaders in our country is a little later than the developed countries, but the technology of the roadheader specially the boomed roadheader has been achieved the international advanced level.
EBZ135 is a kind of longitudinal axis boomed roadheader, and mainly used to driving the coal and semi-coal rock, and also the tunnel constructions. The torque and power of the cutting head are transmitted by the motor through planetary reducer.The planetary reducer, whose transmission performance and structural determine the cutting performance, structural and size of the roadheader, is an important mechanism of the EBZ135.
According to the reserved space and work environment of the EBZ135, it is necessary to simplify the structure, reduce the size and the gear module, and improve the mechanical properties. The following conclusion is given through the analysis and calculation of the original structure and the security check of the planetary reducer, the planetary reducer of the EBZ135 with high security factor, but the gear module is larger, it is necessary to optimize its structure.
An optimal structure of EBZ135 roadheader planetary reducer is given in this thesis. The main component on the optimal structure are optimized and calculated such as the transmission ratio and the gear teeth. Compared with the original structure, the optimized structure has the following characters: no modified gear, decreasing gear module from 8 to 5.5, reducing radial dimension by 5%, decreasing transmission impact, lower noise, simplifier structure, convenient to manufacture, installation and maintenance.
In this thesis, the solid modeling and simulation of the optimized structure is created with UG, the interference detection and motion simulation is completed by UG. The results of analysis showed that: the optimized structure of the EBZ135 planetary reducer meets the requirements in kinematic field, and all of the components run smoothly without interference.
The structure static analyzing for all gears and planetary carrier in the optimized structure of the EBZ135 planetary reducer has been completed by the finite-element analysis software-ANSYS. Through the structure static analyzing, the following conclusions are given: the variation of the stress, the strain and the displacement vector sum produced in the main components are all stationary, and the maximum variation of them are all in the permissive extent of the material.
In this thesis, the structural optimization design of EBZ135 planetary reducer is reasonable. The optimized structure of planetary reducer, with high practical value and reliable operation, could meet the transmission ratio and the strength requirements, and also as a theoretical reference of the optimization design of other planetary reducer.
EBZ135掘进机是一种纵轴式悬臂掘进机,主要适用于煤及半煤岩井下巷道的掘进,也适用于工程隧道施工,应用广泛。其截割头的转矩和功率由电动机通过行星减速器传递。行星减速器的传动性能、结构形式直接影响着EBZ135掘进机的截割性能、结构及体积,它是EBZ135掘进机工作机构的重要组成部分,在EBZ135掘进机掘进过程中起着极其重要的作用。
EBZ135掘进机工作机构的预留空间及工作环境,要求行星减速器尽可能简化结构、减小体积、减小齿轮模数、提高机械性能。本文通过对EBZ135掘进机行星减速器结构的分析与计算、对其传动齿轮的安全校核得知:EBZ135掘进机行星减速器安全系数很大,所以其齿轮模数相对较大,有必要对其结构进行优化设计。
本文提出了EBZ135掘进机行星减速器结构优化的总体方案,分配、设计了各级传动的传动比和齿轮的齿数,对其主要构件进行了优化设计与计算。优化后的EBZ135掘进机行星减速器的结构,与原结构相比,齿轮无需变位,齿轮模数由8减小到5.5,径向尺寸减小了5%,减少了传动中冲击,提高了传动的平稳性,降低了噪音,简化了结构,方便制造、安装与维修。
本文应用UG对EBZ135掘进机行星减速器的优化结构进行了实体建模,并对其实体装配模型进行了干涉检查和运动仿真。通过对实体装配模型干涉检查、运动仿真结果进行分析得知:EBZ135掘进机行星减速器优化结构,运转均匀平稳,实现了给定的传动比,能够满足运动学方面的设计要求,各零部件之间运动灵活,没有发生干涉。
本文利用ANSYS对EBZ135掘进机行星减速器优化结构中的各齿轮和行星架等主要构件进行了有限元静力分析。通过有限元静力分析的结果得知:主要构件产生的应力、应变、合变形位移的变化均比较平稳,产生的最大应力、应变、合位移变形均在自身材料的许可范围之内。
综上可知,本文对EBZ135掘进机行星减速器的结构优化设计合理。EBZ135掘进机行星减速器优化结构,能够实现给定的传动比,能够满足强度要求,运行安全可靠,具有较高的实用价值,并为其它行星减速器结构优化设计提供了理论依据。
Roadheader has been widely used in the constructions such as bridges, tunnels, subway and mine roadway etc, and it is more important to the development of the national economy. The technology of the roadheader is more important in enhancing the driving speed and efficiency during the construction of bridges, tunnels, subway and mine roadway etc. As a result, most of companies and research institutes are now improving the technology of the roadheader. The research of the roadheaders in our country is a little later than the developed countries, but the technology of the roadheader specially the boomed roadheader has been achieved the international advanced level.
EBZ135 is a kind of longitudinal axis boomed roadheader, and mainly used to driving the coal and semi-coal rock, and also the tunnel constructions. The torque and power of the cutting head are transmitted by the motor through planetary reducer.The planetary reducer, whose transmission performance and structural determine the cutting performance, structural and size of the roadheader, is an important mechanism of the EBZ135.
According to the reserved space and work environment of the EBZ135, it is necessary to simplify the structure, reduce the size and the gear module, and improve the mechanical properties. The following conclusion is given through the analysis and calculation of the original structure and the security check of the planetary reducer, the planetary reducer of the EBZ135 with high security factor, but the gear module is larger, it is necessary to optimize its structure.
An optimal structure of EBZ135 roadheader planetary reducer is given in this thesis. The main component on the optimal structure are optimized and calculated such as the transmission ratio and the gear teeth. Compared with the original structure, the optimized structure has the following characters: no modified gear, decreasing gear module from 8 to 5.5, reducing radial dimension by 5%, decreasing transmission impact, lower noise, simplifier structure, convenient to manufacture, installation and maintenance.
In this thesis, the solid modeling and simulation of the optimized structure is created with UG, the interference detection and motion simulation is completed by UG. The results of analysis showed that: the optimized structure of the EBZ135 planetary reducer meets the requirements in kinematic field, and all of the components run smoothly without interference.
The structure static analyzing for all gears and planetary carrier in the optimized structure of the EBZ135 planetary reducer has been completed by the finite-element analysis software-ANSYS. Through the structure static analyzing, the following conclusions are given: the variation of the stress, the strain and the displacement vector sum produced in the main components are all stationary, and the maximum variation of them are all in the permissive extent of the material.
In this thesis, the structural optimization design of EBZ135 planetary reducer is reasonable. The optimized structure of planetary reducer, with high practical value and reliable operation, could meet the transmission ratio and the strength requirements, and also as a theoretical reference of the optimization design of other planetary reducer.
引文
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[21]郭丹丹.纵轴式掘进机仿形切割理论研究[D].辽宁:辽宁工程技术大学,2007.
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[2]张照煌.全断面岩石掘进机盘形滚刀寿命管理理论及技术研究[D].北京:华北电力大学,2008.
[3]丛铁军.巷道掘进机[M].北京:煤炭工业出版社,1982:1-344.
[4]煤炭科学研究院太原分院.国外掘进机[M].北京:煤炭工业出版社,1986:1-6.
[5]邢印成,王凤林,郭滨.掘进机的发展[J].煤炭技术,2005,24(5).
[6]王喜胜,姜希琴,王学成.我国悬臂式掘进机新技术的应用与发展[C].中国煤炭学会2007短壁机械化开采专业委员会学术研讨会论文集.太原:中国煤炭学会,2007:83-90.
[7]马跃.谈我国悬臂式掘进机的发展及趋势[J].煤,2006,15(2):29-32.
[8]高春花.悬臂式掘进机开发设计方向的探讨[J].煤矿机械,2009,30(3):28-29.
[9]毛君,吴常田,谢苗.浅谈悬臂掘进机的发展及趋势[J].中国工程机械学报,2007,5(2):240-242.
[10]饶振纲.行星齿轮传动设计[M].北京:化学工业出版社,2003:1-274.
[11]张国瑞,张展.行星传动技术[M].上海:上海交通大学出版社,1989:1-85
[12] He Yibin, Chen Dingfang, etc.The virtual design and assembly of a multilevel planetary reducer[C]. 2008 3rd International Conference on Pervasive Computing and Application(s ICPCA08),Alexandria:Inst. of Elec. and Elec. Eng. Computer Society,2008,2: 802-806.
[13]张立君,周志祥.大功率行星齿轮减速器填补国内空白[N].中国建材报,2002-09-10.
[14]崔怀纲,刘和平.我国第一台大功率行星齿轮减速器通过鉴定[N].现代物流报,2006-3-21.
[15] A.Boniface. Tunnel Boring Machine performance in basalts of the Lesotho Formation[J]. Tunnelling and Underground Space Technology, 2000, 15(1):49-54.
[16] S. Yagiz, C. Gokceoglu, E. Sezer, etc.. Application of two non-linear prediction tools to the estimation of tunnel boring machine performance[J].Engineering Applications of Artificial Intelligence,2009 , 22(4-5):808-814.
[17]方志淮.EBH-120型掘进机关键零部件的优化设计[D].合肥:安徽理工大学,2005.
[18]陈同宝,钱沛云,陶峥.我国悬臂式巷道掘进机技术的现状与发展[J].煤矿机电,2000,(5):58-62.
[19]任葆瑞,刘建平.煤巷快速掘进设备的使用与发展[J].煤矿机电,2003,(5):52-54.
[20]刘雪.纵轴式掘进机工作稳定性的研究[D].辽宁:辽宁工程技术大学,2007.
[21]郭丹丹.纵轴式掘进机仿形切割理论研究[D].辽宁:辽宁工程技术大学,2007.
[22]汪胜陆.孟国营等.悬臂掘进机的发展状况及趋势[J].煤矿机械,2007,28(6): 1-3.
[23] T. Morimoto, M. Hori. Performance characteristics of a tunnel boring machine from the geomechanical viewpoint[J]. International Journal of Rock Mechanics and Mining Science & Geomechanics Abstracts,1986, 23(1):55-66.
[24]陶泽光.齿轮传动系统齿轮模数的选择对噪音的影响[J].昆明:昆明工学院学报,1989,14(2):45-50.
[25]振文纬,吴克坚.机械原理[M].北京:高等教育出版社,1997.
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