电梯导轨弯曲变形校直理论模型、仿真与实验研究
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摘要
电梯导轨质量的好坏将直接影响到电梯运行的平稳性与安全性。尤其是随着高层建筑的急剧增加,高速电梯的需求量越来越大,对导轨的平直度要求也越来越高。弯曲校直是保证电梯导轨平直度的不可或缺的工序,但目前还停留在粗放式凭经验校直的阶段,极大地影响了导轨的加工精度及效率。同时,由于对导轨校直的弹塑性变形机理、校直模型与控制方法等方面研究的缺失,致使发展电梯导轨的数字化、自动化校直尚有差距。为此,本文通过理论建模、有限元仿真及实验的方法,对电梯导轨的弯曲变形校直理论与方法进行了系统的研究,为进一步研发电梯导轨自动校直机奠定基础。全文共有七章：
第1章从电梯导轨加工工艺流程出发,对电梯导轨加工技术现状进行了调研分析,阐述了电梯导轨弯曲变形的产生原因以及目前的变形预防措施的局限性,从而引出导轨弯曲变形校直的必要性,综述了电梯导轨弯曲变形校直的研究现状。
第2章为探索导轨的弯曲变形特征,得出校直压力头、支撑点的位置及初始弯曲曲率等校直特征参数,研制了电梯导轨全自动弯曲变形测量系统。实现了对导轨的全长自动测量,从而得出导轨的弯曲变形量,提出基于导轨弯曲测量数据构建其弯曲变形特征曲线及表达式的方法,对导轨的弯曲变形特征进行了统计分析,进而给出导轨的弯曲校直判定准则以及校直压头、支点的位置确定方法,给出导轨弯曲变形的初始弯曲曲率的计算公式。围绕导轨何处、何种弯曲、弯曲量为多少、是否需要校直等问题提出了解决方案,为导轨弯曲校直理论模型的研究打下了基础。
第3章针对电梯导轨的弯曲变形既有水平的侧弯变形,又有垂直方向的翘曲变形,为复杂的二维弯曲变形,两种变形模式的校直理论方程有着根本性的区别。为此,本章在利用弹塑性力学分析了弯曲变形校直过程中的材料模型、应力-应变关系、基本曲率关系及曲率弯矩关系的基础上,考虑到导轨具有无轨腰、有轨腰这两种结构形式,分别建立了它们的侧弯变形校直模型,给出各自的校直理论方程,并进一步得出其校直控制参数即校直行程的计算表达式,利用该表达式可直接计算初始弯曲挠度对应的校直行程,为侧弯变形校直实施带来方便；最后进行了模型的实例应用,并对模型的误差来进行了分析。
第4章由于电梯导轨翘曲方向为非对称截面,且截面尺寸有突变,其弯曲变形校直相对其侧弯变形而言尤为复杂。为此,本章在分析带轨腰导轨翘曲截面特性及翘曲变形校直的特点的基础上,利用弹塑性力学分析了翘曲校直过程中的应力-应变关系,推导了其四种不同弯曲程度下的校直弯矩方程及校直一定初始翘曲的校直曲率方程,给出反弯曲率比与初始曲率比间的关系。为便于翘曲变形校直实践,进一步给出校直控制参数的表达式,有效的结合了翘曲校直模型与翘曲校直实践。并进行了模型的实例应用,验证了导轨翘曲校直模型的可行性,并对翘曲校直模型的误差进行了分析。最后给出了无轨腰导轨三种不同情况下的翘曲校直理论方程。
第5章针对电梯导轨弯曲校直问题,利用ANSYS有限元软件分别建立了其侧弯与翘曲校直的有限元仿真模型,通过比较模型与仿真两种方式得到的导轨的侧弯、翘曲校直载荷与校直行程参数,验证了导轨侧弯、翘曲校直模型的可行性；并基于导轨弯曲校直仿真数据,进一步提出导轨侧弯、翘曲校直修正模型,即基于仿真数据的行程-挠度模型,给出该修正模型的表达式,通过修正模型可直接根据初始侧弯、翘曲挠度得出对应的校直行程,校直行程的计算速度与精度相对导轨侧弯、翘曲校直理论模型有所提高。
第6章针对导轨的侧弯、翘曲变形校直问题,进行了大量的实验研究。在校直理论模型的有限元仿真验证后,进一步利用导轨校直实验数据验证了导轨侧弯、翘曲校直理论模型的可行性,对校直理论模型、有限元、实验三种方式下获得的导轨侧弯、翘曲校直控制参数进行了对比分析,进而提出基于校直实验数据的导轨侧弯、翘曲校直行程预测模型,给出模型表达式。
第7章给出了本学位论文的研究结论,展望了本领域的进一步研究方向。
As a component-oriented, the guide rail straightness directly influences the stability and security of an elevator, especially on a high-speed elevator. With the rapid increase of high-rise buildings, the demand and the quality requirements for high-speed, high precision elevators are increasing. In order to improve the guide rail straightness, bend straightening is essential for processing operations. At present, bending straightening of elevator guide rail basically remains at a lower level, which mainly depends on workers'experiences, this state reduces the machining accuracy and efficiency of elevator guide rail greatly. So, the development of automatic straightener for elevator guide rail become an urgent issues, but the automation and digital straightening still lacks systematic theory support. This dissertation by coalescing the theoretical modeling, finite element simulation and experiment, theory and method for straightening the bending of elevator guide rail are researched.This dissertation is divided into 7 chapters:
Chapter 1 gives a review of the current elevator guide rail machining technology based on the machining process. The origin and precaution of guide rail bending as well as the limits are clarified in this chapter. Then, the necessity of guide rail bending straightening is given. Based on the survey, present level of the research for guide rail bending straightening is brought up in chapter 1.
In order to verify the bending deformation characteristics, chapter 2 obtains some characteristic parameters, such as the position of straightening pressure head and fulcrum as well as the initial bending curvature. It also focuss on the key problems in the guide rail straightening process, such as the bending point, the bending value and whether it needs to be straightened or not, which are mainly determined by human experiences. An automatic guide rail bending measurement system is developed in this chapter. The measurement system could provide a full length measurement and the bending value of the guide rail. The method for constructing bending curve and its mathematical expression based on the bending measurement data is presented in chapter 2. The statistical analysis for bending deformation has been done. Furthermore, the bending judging criteria are clarified, as well as the method to determine the position of straightening pressure head and fulcrum is given. In this chapter, calculation formula of initial bending curvature is presented as well. Briefly, chapter 2 solves problems such as the bending point, bending value and whether it needs to be straightened or not, which provides a foundation for the guide rail bending straightening.
There are two bending forms in guide rails:the lateral bending and warpage. Obviously, the guide rail bending is a complex two-dimensional bending, which makes each of their straightening formula completely different. Therefore, analysis of the material model, stress-strain relationship, basic curvature relationship and curvature moment relationship based on elastic-plastic mechanics are presented in chapter 3. Considering that there are two kinds of guide rails:the trackless waist and waist rail, both of their straightening models and recurvation curvature formula are provided respectively. Furthermore, the straightening control parameters (mainly straightening stroke calculation formula) are presented in this chapter. Based on straightening stroke calculation formula, the straightening stroke corresponding to certain initial bending deflection could be calculated directly, which make the implement of bending straightening much more convenient. At last, an application example is given, and the error source is analyzed.
As the warpage direction is a non-symmetrical section, and section dimension has a sudden change, so the bending straightening is much more complicated compared with lateral bending. In view of this, based on the analysis of waist rail warpage section features and its straightening characteristics, chapter 4 derives the straightening moment formula and straightening curvature formula in certain initial warpage for 4 different bending degrees, using stress-strain relationships in elastic-plastic mechanics. The relationship between recurvation curvature and initial curvature is presented as well, which lays a foundation for the warpage bending straightening. In chapter 4, in order to make the straightening work be carried out much more conveniently, further expression of straightening control parameters combined with warpage straightening theory and practices is presented. At the end of this chapter, an application of presented model is brought up to validate its feasibility. Analysis on model's error source is provided as well. At last, warpage straightening theoretical formula for trackless waist is presented under three different circumstances.
Chapter 5 focused on the elevator guide rail bending straightening issues. Finite element simulation models for lateral bending and warpage are constructed based on ANSYS. Then, simulation is taken to analyze the process of lateral bending and warpage based on the presented model. By exerting a series of loadings, the corresponding pressure stroke and residual deflection of lateral bending as well as warpage could be obtained. Lateral bending and warpage straightening load-stroke curves could be get as well. Furthermore, curves from the experiment and curves form the model are compared to validate the effectiveness of the presented model. A modified model is given based on the guide rail straightening simulation data. That is to say, based on the simulation data of the stroke-deflection model, a modified model expression is provided. Straightening stroke could be obtained directly from the modified model. The computing speed and accuracy improved compared with the former model.
Taking elevator guide rail as the object, chapter 6 conducted lots of experimental researched on lateral bending and warpage straightening problems. After the validation of finite element simulation on the straightening theoretical model, a feasibility verification of lateral bending and warpage straightening theoretical model is carried out based on the experiment data. Furthermore, a comparison of lateral bending and warpage straightening control parameters among the three manners such as theoretical model, FES and experiment are presented. At the end of this chapter, a prediction model and its expression of lateral bending and warpage are presented based on the experiment data.
A conclusion of this paper is made and the prospect of further research in this area is presented in chapter 7.
第1章从电梯导轨加工工艺流程出发,对电梯导轨加工技术现状进行了调研分析,阐述了电梯导轨弯曲变形的产生原因以及目前的变形预防措施的局限性,从而引出导轨弯曲变形校直的必要性,综述了电梯导轨弯曲变形校直的研究现状。
第2章为探索导轨的弯曲变形特征,得出校直压力头、支撑点的位置及初始弯曲曲率等校直特征参数,研制了电梯导轨全自动弯曲变形测量系统。实现了对导轨的全长自动测量,从而得出导轨的弯曲变形量,提出基于导轨弯曲测量数据构建其弯曲变形特征曲线及表达式的方法,对导轨的弯曲变形特征进行了统计分析,进而给出导轨的弯曲校直判定准则以及校直压头、支点的位置确定方法,给出导轨弯曲变形的初始弯曲曲率的计算公式。围绕导轨何处、何种弯曲、弯曲量为多少、是否需要校直等问题提出了解决方案,为导轨弯曲校直理论模型的研究打下了基础。
第3章针对电梯导轨的弯曲变形既有水平的侧弯变形,又有垂直方向的翘曲变形,为复杂的二维弯曲变形,两种变形模式的校直理论方程有着根本性的区别。为此,本章在利用弹塑性力学分析了弯曲变形校直过程中的材料模型、应力-应变关系、基本曲率关系及曲率弯矩关系的基础上,考虑到导轨具有无轨腰、有轨腰这两种结构形式,分别建立了它们的侧弯变形校直模型,给出各自的校直理论方程,并进一步得出其校直控制参数即校直行程的计算表达式,利用该表达式可直接计算初始弯曲挠度对应的校直行程,为侧弯变形校直实施带来方便；最后进行了模型的实例应用,并对模型的误差来进行了分析。
第4章由于电梯导轨翘曲方向为非对称截面,且截面尺寸有突变,其弯曲变形校直相对其侧弯变形而言尤为复杂。为此,本章在分析带轨腰导轨翘曲截面特性及翘曲变形校直的特点的基础上,利用弹塑性力学分析了翘曲校直过程中的应力-应变关系,推导了其四种不同弯曲程度下的校直弯矩方程及校直一定初始翘曲的校直曲率方程,给出反弯曲率比与初始曲率比间的关系。为便于翘曲变形校直实践,进一步给出校直控制参数的表达式,有效的结合了翘曲校直模型与翘曲校直实践。并进行了模型的实例应用,验证了导轨翘曲校直模型的可行性,并对翘曲校直模型的误差进行了分析。最后给出了无轨腰导轨三种不同情况下的翘曲校直理论方程。
第5章针对电梯导轨弯曲校直问题,利用ANSYS有限元软件分别建立了其侧弯与翘曲校直的有限元仿真模型,通过比较模型与仿真两种方式得到的导轨的侧弯、翘曲校直载荷与校直行程参数,验证了导轨侧弯、翘曲校直模型的可行性；并基于导轨弯曲校直仿真数据,进一步提出导轨侧弯、翘曲校直修正模型,即基于仿真数据的行程-挠度模型,给出该修正模型的表达式,通过修正模型可直接根据初始侧弯、翘曲挠度得出对应的校直行程,校直行程的计算速度与精度相对导轨侧弯、翘曲校直理论模型有所提高。
第6章针对导轨的侧弯、翘曲变形校直问题,进行了大量的实验研究。在校直理论模型的有限元仿真验证后,进一步利用导轨校直实验数据验证了导轨侧弯、翘曲校直理论模型的可行性,对校直理论模型、有限元、实验三种方式下获得的导轨侧弯、翘曲校直控制参数进行了对比分析,进而提出基于校直实验数据的导轨侧弯、翘曲校直行程预测模型,给出模型表达式。
第7章给出了本学位论文的研究结论,展望了本领域的进一步研究方向。
As a component-oriented, the guide rail straightness directly influences the stability and security of an elevator, especially on a high-speed elevator. With the rapid increase of high-rise buildings, the demand and the quality requirements for high-speed, high precision elevators are increasing. In order to improve the guide rail straightness, bend straightening is essential for processing operations. At present, bending straightening of elevator guide rail basically remains at a lower level, which mainly depends on workers'experiences, this state reduces the machining accuracy and efficiency of elevator guide rail greatly. So, the development of automatic straightener for elevator guide rail become an urgent issues, but the automation and digital straightening still lacks systematic theory support. This dissertation by coalescing the theoretical modeling, finite element simulation and experiment, theory and method for straightening the bending of elevator guide rail are researched.This dissertation is divided into 7 chapters:
Chapter 1 gives a review of the current elevator guide rail machining technology based on the machining process. The origin and precaution of guide rail bending as well as the limits are clarified in this chapter. Then, the necessity of guide rail bending straightening is given. Based on the survey, present level of the research for guide rail bending straightening is brought up in chapter 1.
In order to verify the bending deformation characteristics, chapter 2 obtains some characteristic parameters, such as the position of straightening pressure head and fulcrum as well as the initial bending curvature. It also focuss on the key problems in the guide rail straightening process, such as the bending point, the bending value and whether it needs to be straightened or not, which are mainly determined by human experiences. An automatic guide rail bending measurement system is developed in this chapter. The measurement system could provide a full length measurement and the bending value of the guide rail. The method for constructing bending curve and its mathematical expression based on the bending measurement data is presented in chapter 2. The statistical analysis for bending deformation has been done. Furthermore, the bending judging criteria are clarified, as well as the method to determine the position of straightening pressure head and fulcrum is given. In this chapter, calculation formula of initial bending curvature is presented as well. Briefly, chapter 2 solves problems such as the bending point, bending value and whether it needs to be straightened or not, which provides a foundation for the guide rail bending straightening.
There are two bending forms in guide rails:the lateral bending and warpage. Obviously, the guide rail bending is a complex two-dimensional bending, which makes each of their straightening formula completely different. Therefore, analysis of the material model, stress-strain relationship, basic curvature relationship and curvature moment relationship based on elastic-plastic mechanics are presented in chapter 3. Considering that there are two kinds of guide rails:the trackless waist and waist rail, both of their straightening models and recurvation curvature formula are provided respectively. Furthermore, the straightening control parameters (mainly straightening stroke calculation formula) are presented in this chapter. Based on straightening stroke calculation formula, the straightening stroke corresponding to certain initial bending deflection could be calculated directly, which make the implement of bending straightening much more convenient. At last, an application example is given, and the error source is analyzed.
As the warpage direction is a non-symmetrical section, and section dimension has a sudden change, so the bending straightening is much more complicated compared with lateral bending. In view of this, based on the analysis of waist rail warpage section features and its straightening characteristics, chapter 4 derives the straightening moment formula and straightening curvature formula in certain initial warpage for 4 different bending degrees, using stress-strain relationships in elastic-plastic mechanics. The relationship between recurvation curvature and initial curvature is presented as well, which lays a foundation for the warpage bending straightening. In chapter 4, in order to make the straightening work be carried out much more conveniently, further expression of straightening control parameters combined with warpage straightening theory and practices is presented. At the end of this chapter, an application of presented model is brought up to validate its feasibility. Analysis on model's error source is provided as well. At last, warpage straightening theoretical formula for trackless waist is presented under three different circumstances.
Chapter 5 focused on the elevator guide rail bending straightening issues. Finite element simulation models for lateral bending and warpage are constructed based on ANSYS. Then, simulation is taken to analyze the process of lateral bending and warpage based on the presented model. By exerting a series of loadings, the corresponding pressure stroke and residual deflection of lateral bending as well as warpage could be obtained. Lateral bending and warpage straightening load-stroke curves could be get as well. Furthermore, curves from the experiment and curves form the model are compared to validate the effectiveness of the presented model. A modified model is given based on the guide rail straightening simulation data. That is to say, based on the simulation data of the stroke-deflection model, a modified model expression is provided. Straightening stroke could be obtained directly from the modified model. The computing speed and accuracy improved compared with the former model.
Taking elevator guide rail as the object, chapter 6 conducted lots of experimental researched on lateral bending and warpage straightening problems. After the validation of finite element simulation on the straightening theoretical model, a feasibility verification of lateral bending and warpage straightening theoretical model is carried out based on the experiment data. Furthermore, a comparison of lateral bending and warpage straightening control parameters among the three manners such as theoretical model, FES and experiment are presented. At the end of this chapter, a prediction model and its expression of lateral bending and warpage are presented based on the experiment data.
A conclusion of this paper is made and the prospect of further research in this area is presented in chapter 7.
引文
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