新型辊履支承设计及其检测系统基础研究
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摘要
回转窑、球磨机、筒辊磨等是建材、冶金等行业中生成流程的核心设备,这类低速、重载的大型回转筒体的支承装置近年来主要采用两类:托轮组或滑履组。由于上述的支承方式存在着难于克服的局限,经研究分析因局限引起的故障在生产中时有发生,严重威胁回转窑维护人员的人身安全,或导致生产流程中断,造成重大生产损失。因此,开拓一种全新的支承技术具有重要的现实意义。
作者在深入研究和学习现有的回转体支承装置的结构设计、力学分析、运行监测的基础上,对新型支承系统进行了以下基础性研究工作:
1)借鉴当前的回转体支承技术和辊子输送机的传动技术,科学合理地提出辊履支承技术。
2)在模型的构建上,采用三维CAD软件Pro/E完成了辊履支承的结构设计和几何建模,然后导入到ANSYS中进行修改,以使模型得到合理的简化。
3)应用ANSYS有限元软件对辊履支承进行了静力分析,得出了结构部件的应力应变图,分析了应力应变分布规律。
4)认真分析和研究辊履支承装置的关键物理量对辊履支承运行状况的影响,对各物理量采用相应的检测技术,结合信号分析和处理技术,成功构建了一个基于虚拟仪器技术的辊履检测系统,并进行了其仿真测试及结果分析。
综合以上研究成果,新型辊履支承系统改善了传统的支承方式的缺陷,提高了设备运行的平稳性、可靠性,延长了设备的使用寿命;基于虚拟仪器技术的辊履支承检测系统具有检测方便、运行可靠、界面友好的特点。论文通过对新型辊履支承的基础研究,为后续的设计、改造和应用提供数据参考和奠定理论基础。
Rotary kiln. Ballmill and Horomill are the key equipments in many industrial departments, such as building materials industry, metallurgical industry etc. In recently years, roller and sliding-shoe are used to support this kind of low speed and high load devices, existing different limitations difficult to overcome. The limitations result in kinds of accidents which bring heavy threaten to safeguarders' safety or bring great production loss by breaking off the production. So it is great significant to create a wholly new supporting tenichque.
On the base of the studied mechanics mechanism and structure designs and operating detection of rotary kiln, the paper gives a new design of rolling-shoe bearing ,and the basic researches are as follows:
First, using the experience of the roller bearing technique and roller conveyor driving technique, the paper scientifically and properly proposes roller-bearing technique. Second,the structure design drawing is drawn in Pro/E that is used to draw 3D drawing and then it was channeled to the software of ANSYS to modify to fit software to build the entity model; then the entity model is inputted into ANSYS and is given stress and strain analysis. Third, the paper analyzes the characteristic when roller-bearing bearing static force. Process force analysis of roller-bearing by applying ANSYS and get the results ,then analyzes the law of the stress distribution.Fourth,after the analysis and study of the affection of the key rolling-shoe mechanical quantity on its operations and different dictations of mechanical quantity's requirements and conditions, as well as the signal analysis and processing, a rolling-shoe bearing test system on virtual instrument was built successfully .Then the simulation test and its result analysis was accomplished.
To sum up the theoretical harvest, the new rolling-shoe bearing improves the disadvantages of traditional bearing system, increase the smoothness and the reliability of equipment operation, and lengthen the duration of equipment. The rolling-shoe bearing test system features convenient testing, reliable operation and friendly interface. What's more, the paper provides the data references and establishes theoretical principle for the future study by basic researching of roller-bearing.
作者在深入研究和学习现有的回转体支承装置的结构设计、力学分析、运行监测的基础上,对新型支承系统进行了以下基础性研究工作:
1)借鉴当前的回转体支承技术和辊子输送机的传动技术,科学合理地提出辊履支承技术。
2)在模型的构建上,采用三维CAD软件Pro/E完成了辊履支承的结构设计和几何建模,然后导入到ANSYS中进行修改,以使模型得到合理的简化。
3)应用ANSYS有限元软件对辊履支承进行了静力分析,得出了结构部件的应力应变图,分析了应力应变分布规律。
4)认真分析和研究辊履支承装置的关键物理量对辊履支承运行状况的影响,对各物理量采用相应的检测技术,结合信号分析和处理技术,成功构建了一个基于虚拟仪器技术的辊履检测系统,并进行了其仿真测试及结果分析。
综合以上研究成果,新型辊履支承系统改善了传统的支承方式的缺陷,提高了设备运行的平稳性、可靠性,延长了设备的使用寿命;基于虚拟仪器技术的辊履支承检测系统具有检测方便、运行可靠、界面友好的特点。论文通过对新型辊履支承的基础研究,为后续的设计、改造和应用提供数据参考和奠定理论基础。
Rotary kiln. Ballmill and Horomill are the key equipments in many industrial departments, such as building materials industry, metallurgical industry etc. In recently years, roller and sliding-shoe are used to support this kind of low speed and high load devices, existing different limitations difficult to overcome. The limitations result in kinds of accidents which bring heavy threaten to safeguarders' safety or bring great production loss by breaking off the production. So it is great significant to create a wholly new supporting tenichque.
On the base of the studied mechanics mechanism and structure designs and operating detection of rotary kiln, the paper gives a new design of rolling-shoe bearing ,and the basic researches are as follows:
First, using the experience of the roller bearing technique and roller conveyor driving technique, the paper scientifically and properly proposes roller-bearing technique. Second,the structure design drawing is drawn in Pro/E that is used to draw 3D drawing and then it was channeled to the software of ANSYS to modify to fit software to build the entity model; then the entity model is inputted into ANSYS and is given stress and strain analysis. Third, the paper analyzes the characteristic when roller-bearing bearing static force. Process force analysis of roller-bearing by applying ANSYS and get the results ,then analyzes the law of the stress distribution.Fourth,after the analysis and study of the affection of the key rolling-shoe mechanical quantity on its operations and different dictations of mechanical quantity's requirements and conditions, as well as the signal analysis and processing, a rolling-shoe bearing test system on virtual instrument was built successfully .Then the simulation test and its result analysis was accomplished.
To sum up the theoretical harvest, the new rolling-shoe bearing improves the disadvantages of traditional bearing system, increase the smoothness and the reliability of equipment operation, and lengthen the duration of equipment. The rolling-shoe bearing test system features convenient testing, reliable operation and friendly interface. What's more, the paper provides the data references and establishes theoretical principle for the future study by basic researching of roller-bearing.
引文
[1]Blanke H J.Die Systemchmierungvon Zahnkanzantrieben mit Modernen Spruhhaftschmierstoffen[J].ZEMENT-KALK-GIPS,1989,(11):574-581
[2]Walter M G Kiln Alignment:a Perspective[J].Rock Products,1989,(10):42-47
[3]Venen J.Erhohuang der Anagenverfugbakeit durch Optoelekronische Uberprufung der Drehofena-chse[J].ZEENTKALK-GIPS,1989,(11):549-552
[4]张懿.绿色过程工程[J].过程工程学报,2001,(1):10-15
[5]Ramamurti V,Ragantha Sai K.Deformation and Stresses in Kilns[J].ZKG International,1978,31(9):433-435
[6]沈久瑜,马丽丹,吴晚云等.超静定、等强度构件群体偏载失效的力学分析[J].北方工业大学学报,1996.9,8(3):24-33
[7]Bowen,A E.Causes and Effects of Kiln Tire Problems[J].IEEE Transactions of Industry Application,1985,IA-21(2):344-355
[8]Li Xuejun,Zhu Pingyu,Liu Deshun,et al.Diagnosis Method for Supporting Wheel Crack Shaft of Large-scale Rotary Kiln with Multi-Supporting based on Vibration[J].Progress in Safety Science and Technology,Beijing:Science Press,2002,Vol.3,488-491
[9]孟琳,肖友刚.大型多支承回转窑机械运行状态检测技术的发展及应用[J].轻金属,2002,(12):12-15
周勇武.滑履轴承磨及其新型传动装置的介绍[J].水泥装备,1996,(6):33-36
[10]董金利,兰广林.管磨机大型化的出路——滑履磨[J].机械装备,2003,(5):44-47
[11]周贤,刘义伦,赵先琼等.回转窑托轮接触应力分布研究[J].有色金属,2002.8,54(3):55-58
[12]王夏华,翟人雄,曾俊.对回转窑托轮铀承瓦的探讨[J].中国建材装备,1996,(3):24-25
[13]张谨谋.改性尼龙瓦在回转窑托轮轴上的应用[J].水泥,1994,(7):9-11
[14]李永军,廖顺泰.石墨镶嵌瓦在回转窑托轮轴承上的应用[J].水泥,2000,(9):24
[15]魏希朝,董进奎.HF-托轮油在回转窑上的应用[J].合成润滑材料,2003,30:48-49
[16]江旭昌.回转窑托轮的调整(二)[J].新世纪水泥导报,1999,5(2):36-40
[17]Duda W H.International Process Engineering in the Cement Industry 2th Edition Wiesbaden[R].Berlin,1977
[18]Berthier Y,et al.Fretting Fatigue and Fretting Wear[J].Tribalogy International,1989,22
[19]何漫江,李兵,刘义伦等.大型回转窑支撑系统的有限元数值模拟[J].湘潭大学自然科学学报,2004.3,26(1):86-88
[20]Schumacher M,Theisen W.Hexadur:High Wear Resistant Rollers for High Pressure Roller Presses[J].World Cement,1998,29(3):35-41
[21]赵金山.ZA27合金在大型同转窑承托装置上的应用[J].特种铸造和有色合金,2002,(2):34-35
[22]Walter M G.Hot Kiln Alignment System[P].US Patent Number.5.148.238
[23]Li Jiansen.Study of Forces Applied to Spring Plates of Rotary Kiln[R].Proceedings of the 5th International Symposium on the Cement and Concrete,2002
[24]Giencke,Donald P.Guide to Rotary Kiln Alignment and Maintenance[M],Pit & Quarry,1978,70(11):68-75
[25]Krystowczyk B.Alignment of Rotary Klins and Correction of Roller Setting During Operation[J].ZKG
[26]International,1983,36(5):288-292
[27]Walter M G.Kiln Alignment Analysis an Overview of the Direct Method.IEEE Cement Industry Technical Conference,2000 IEEE-IAS/PCA Cement Industry,Salt Lake City,2000,379-393
[28]Zhangyun,Application of the Hand-instrument of Measurement of Tire Gap and Diameter in Cement Rotary Kiln[J].Journal of Wuhan University of Technology-Material Science Edition,2001.6,16(2):58-62
[29]江旭昌.回转窑托轮的调整(五)[J].新世纪水泥导报,1999,5(6):29-32
[30]Zhangyun,Increasing Plant Availability by Mechanical Checking of the Cement Rotary Kiln Axis[J].Journal of Wuhan University of Technology-Material Science Edition,2001.9,16(3):76-78
[31]陈建江等.对磨机滑履支承的计算及其优化设计[J].中国建材装备,2002,(6):9-12
[32]叶青等.实用专利公告(2478682)滑履磨[J].2002.2.27
[33]申占民.滑履轴承润滑装置的改进[J].水泥技术,2003,(2):23-24
[34]Huang Zhichu et al.Vibration Analysis and Experimental Study of GHM Horomill in Operation[J].The 5th International Symposium on Cement and Concrete,2002,173-177
[35]中国建筑材料工业协会[N].国家“九五”重点科技攻关计划项目“水泥厂料层间挤压粉磨新技术与装备研究开发”项目验收资料,2001.12
[36]魏延刚.空心圆柱滚子与滚道接触应力及位移分析[J].轴承,2003,(5):1-5
[37]张立民.轮轨接触应力与钢轨波磨分析[J].西南交通大学学报,2003,(1):34-37
[38]文小炎,史良蟾.辊子输送机的概况与分析,汽车工程,1996,133(4):1-4
[39]PTC.Pro/E模块全集介绍[J].http://www.rj518.com/article/87/Article867_1.hun.20(0-10-11 12:21:14
[40]刘国庆,杨庆东.ANSYS工程应用教程(机械篇)[M].北京:中国铁道出版社,2003:1
[41]张朝晖.ANSYS8.0结构分析及实例解析[M].北京:机械工业出版社,2005:79-80
[42]施文康,余晓芬.检测技术第2版[M].机械工业出版社,2005.
[43]强锡富.传感器.机械工业出版社[M].2004
[44]王伟.基于相关测速法的热轧材速度测量[J].兰州理工大学学报,2004,30(6):79-80
[45]朱云辉.基于压力互相关和虚拟仪器的流速测量研究[D].武汉理工大学,200
[46][美]David McCombs著,杨定新,汪东,宋新译.PC数据采集—使用C++测理物理量[M].中国电力出版社,2004
[47]侯国屏,王绅,叶齐鑫主编.LabVIEW7.1编程与虚拟仪器设计[M].清华大学出版社,2004
[48]雷振山主编.LabVIEW7 Express实用技术教程[M].中国铁道出版社,2005
[49]邓焱,王磊主编.LabVIEW7.1测试技术与仪器应用[M].机械工业出版社,2005
[50]杨乐平,李海涛,赵勇,磊安滢编著.LabVIEW高级程序设计[M].清华大学出版社,2003
[51]By Nasser Kehtarnavaz,Namjin Kim.Digitai Signal Processing System-Level Design Using LabVIEW[M].Newnes,2005
[52]ByL.Clark.LabVIEW Digital Signal Processing and Digital Communications[M].McGraw-Hill,2005
[2]Walter M G Kiln Alignment:a Perspective[J].Rock Products,1989,(10):42-47
[3]Venen J.Erhohuang der Anagenverfugbakeit durch Optoelekronische Uberprufung der Drehofena-chse[J].ZEENTKALK-GIPS,1989,(11):549-552
[4]张懿.绿色过程工程[J].过程工程学报,2001,(1):10-15
[5]Ramamurti V,Ragantha Sai K.Deformation and Stresses in Kilns[J].ZKG International,1978,31(9):433-435
[6]沈久瑜,马丽丹,吴晚云等.超静定、等强度构件群体偏载失效的力学分析[J].北方工业大学学报,1996.9,8(3):24-33
[7]Bowen,A E.Causes and Effects of Kiln Tire Problems[J].IEEE Transactions of Industry Application,1985,IA-21(2):344-355
[8]Li Xuejun,Zhu Pingyu,Liu Deshun,et al.Diagnosis Method for Supporting Wheel Crack Shaft of Large-scale Rotary Kiln with Multi-Supporting based on Vibration[J].Progress in Safety Science and Technology,Beijing:Science Press,2002,Vol.3,488-491
[9]孟琳,肖友刚.大型多支承回转窑机械运行状态检测技术的发展及应用[J].轻金属,2002,(12):12-15
周勇武.滑履轴承磨及其新型传动装置的介绍[J].水泥装备,1996,(6):33-36
[10]董金利,兰广林.管磨机大型化的出路——滑履磨[J].机械装备,2003,(5):44-47
[11]周贤,刘义伦,赵先琼等.回转窑托轮接触应力分布研究[J].有色金属,2002.8,54(3):55-58
[12]王夏华,翟人雄,曾俊.对回转窑托轮铀承瓦的探讨[J].中国建材装备,1996,(3):24-25
[13]张谨谋.改性尼龙瓦在回转窑托轮轴上的应用[J].水泥,1994,(7):9-11
[14]李永军,廖顺泰.石墨镶嵌瓦在回转窑托轮轴承上的应用[J].水泥,2000,(9):24
[15]魏希朝,董进奎.HF-托轮油在回转窑上的应用[J].合成润滑材料,2003,30:48-49
[16]江旭昌.回转窑托轮的调整(二)[J].新世纪水泥导报,1999,5(2):36-40
[17]Duda W H.International Process Engineering in the Cement Industry 2th Edition Wiesbaden[R].Berlin,1977
[18]Berthier Y,et al.Fretting Fatigue and Fretting Wear[J].Tribalogy International,1989,22
[19]何漫江,李兵,刘义伦等.大型回转窑支撑系统的有限元数值模拟[J].湘潭大学自然科学学报,2004.3,26(1):86-88
[20]Schumacher M,Theisen W.Hexadur:High Wear Resistant Rollers for High Pressure Roller Presses[J].World Cement,1998,29(3):35-41
[21]赵金山.ZA27合金在大型同转窑承托装置上的应用[J].特种铸造和有色合金,2002,(2):34-35
[22]Walter M G.Hot Kiln Alignment System[P].US Patent Number.5.148.238
[23]Li Jiansen.Study of Forces Applied to Spring Plates of Rotary Kiln[R].Proceedings of the 5th International Symposium on the Cement and Concrete,2002
[24]Giencke,Donald P.Guide to Rotary Kiln Alignment and Maintenance[M],Pit & Quarry,1978,70(11):68-75
[25]Krystowczyk B.Alignment of Rotary Klins and Correction of Roller Setting During Operation[J].ZKG
[26]International,1983,36(5):288-292
[27]Walter M G.Kiln Alignment Analysis an Overview of the Direct Method.IEEE Cement Industry Technical Conference,2000 IEEE-IAS/PCA Cement Industry,Salt Lake City,2000,379-393
[28]Zhangyun,Application of the Hand-instrument of Measurement of Tire Gap and Diameter in Cement Rotary Kiln[J].Journal of Wuhan University of Technology-Material Science Edition,2001.6,16(2):58-62
[29]江旭昌.回转窑托轮的调整(五)[J].新世纪水泥导报,1999,5(6):29-32
[30]Zhangyun,Increasing Plant Availability by Mechanical Checking of the Cement Rotary Kiln Axis[J].Journal of Wuhan University of Technology-Material Science Edition,2001.9,16(3):76-78
[31]陈建江等.对磨机滑履支承的计算及其优化设计[J].中国建材装备,2002,(6):9-12
[32]叶青等.实用专利公告(2478682)滑履磨[J].2002.2.27
[33]申占民.滑履轴承润滑装置的改进[J].水泥技术,2003,(2):23-24
[34]Huang Zhichu et al.Vibration Analysis and Experimental Study of GHM Horomill in Operation[J].The 5th International Symposium on Cement and Concrete,2002,173-177
[35]中国建筑材料工业协会[N].国家“九五”重点科技攻关计划项目“水泥厂料层间挤压粉磨新技术与装备研究开发”项目验收资料,2001.12
[36]魏延刚.空心圆柱滚子与滚道接触应力及位移分析[J].轴承,2003,(5):1-5
[37]张立民.轮轨接触应力与钢轨波磨分析[J].西南交通大学学报,2003,(1):34-37
[38]文小炎,史良蟾.辊子输送机的概况与分析,汽车工程,1996,133(4):1-4
[39]PTC.Pro/E模块全集介绍[J].http://www.rj518.com/article/87/Article867_1.hun.20(0-10-11 12:21:14
[40]刘国庆,杨庆东.ANSYS工程应用教程(机械篇)[M].北京:中国铁道出版社,2003:1
[41]张朝晖.ANSYS8.0结构分析及实例解析[M].北京:机械工业出版社,2005:79-80
[42]施文康,余晓芬.检测技术第2版[M].机械工业出版社,2005.
[43]强锡富.传感器.机械工业出版社[M].2004
[44]王伟.基于相关测速法的热轧材速度测量[J].兰州理工大学学报,2004,30(6):79-80
[45]朱云辉.基于压力互相关和虚拟仪器的流速测量研究[D].武汉理工大学,200
[46][美]David McCombs著,杨定新,汪东,宋新译.PC数据采集—使用C++测理物理量[M].中国电力出版社,2004
[47]侯国屏,王绅,叶齐鑫主编.LabVIEW7.1编程与虚拟仪器设计[M].清华大学出版社,2004
[48]雷振山主编.LabVIEW7 Express实用技术教程[M].中国铁道出版社,2005
[49]邓焱,王磊主编.LabVIEW7.1测试技术与仪器应用[M].机械工业出版社,2005
[50]杨乐平,李海涛,赵勇,磊安滢编著.LabVIEW高级程序设计[M].清华大学出版社,2003
[51]By Nasser Kehtarnavaz,Namjin Kim.Digitai Signal Processing System-Level Design Using LabVIEW[M].Newnes,2005
[52]ByL.Clark.LabVIEW Digital Signal Processing and Digital Communications[M].McGraw-Hill,2005