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QTZ125塔式起重机总体 臂架、变幅机构设计（63m吊臂）【12张CAD图纸和说明书】

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QTZ125塔式起重机总体 臂架、变幅机构设计（63m吊臂）【12张CAD图纸和说明书】 qtz125 塔式起重机 总体 整体 臂架 机构 设计 63 吊臂 12 十二 cad 图纸 以及 说明书 仿单
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摘要

QTZ125型塔式起重机布置合理，外形美观，使用方便，维修简单，工作平稳，就位快捷方便、高效。该塔机为上回转，水平臂架，小车变幅，液压自升式多用途塔机，起重力矩为1250KN2m，最大起重量为10T，独立架设最大起升高度可达200m，最大变幅为63m。

? 变幅机构是为了满足物料装卸工作位置要求，充分利用自身的起吊能力（幅度减少能提高起重量），实现改变幅度的工作机构，并用来扩大塔式起重机的工作范围，提高生产率。

 QTZ125塔式起重机是通过移动牵引起重小车实现变幅的。工作时吊臂安装在水平位置，小车由变幅牵引机构驱动，沿着吊臂轨道（弦杆）移动。小车变幅的优点是：变幅时物料做水平移动，安装就位方便；速度快、功率省；幅度有效利用率大。其缺点为：吊臂承受较大的弯距，结构笨重，用钢量大。绳索牵引式变幅机构的小车依靠钢丝绳牵引沿吊臂轨道运行，其驱动力不受附着力的限制，故能在略呈倾斜的轨道上行走，又由于驱动装置在小车外部，从而使小车自重大为减少，所以适用于大幅度起重量较大的起重机。在塔式起重机中大都采用绳索牵引式变幅机构，这样既可以减轻吊臂载荷，又可以使工作可靠，而且因为驱动装置放在吊臂根部，平衡重也可以减少。

关键词：QTZ125塔机、变幅机构、绳牵引小车式


ABSTRACT

QTZ125 tower crane has reasonable layout, beautiful appearance, it is convenient to use, it is simple to repair, it works stable convenient and efficient. The rotary mode is turning on,ir has horizontal jib,    trolley, hydraulic jack-up multi-purpose cranes, its lifting moment is 1250KN 2 m and the maximum lifting weight is 10T the maximum lifting height and amplitude is 200m and 63m.

Luffing mechanism make full use of its lifting capacity of (reduction can improve the weight) to meet the requirement of the material handling work location to change the working mechanism of amplitude and to expand the scope of tower crane work, improve productivity.

QTZ125 tower crane changes amplitude through a mobile traction lifting trolley. When the crane works the jib is installed in a horizontal position, the car alongs the crane rail (chord) move which drived by amplitude traction mechanism.The advantages are: when the trolley works the material move horizontally, it is convenient to install; it has fast speed, it saves power and the effective utilization rate is great. Its shortcomings are: the jib beers a big bending moment, heavy structure and a large quantity of steel. Rope traction luffing car moves along the boom in orbit rely on wire rope traction, its driving force is not affected by adhesion, it can be walking in slightly inclined orbit and because the driver in the car outside, so that the weight of the car is reduced greatly so it is suitable for large amplitude heavy crane. Most of the tower use crane rope traction luffing mechanism which not only can reduce the crane load but also can make reliable work and because the drive device on the jib root the balance weight can also reduced.

Keywords: QTZ125 tower crane, luffing mechanism, rope trolley type


目录

第一章 前言··················································································1

1.1塔式起重机概述············································································1

1.2塔式起重机的发展趋势····································································3

第二章 总体设计············································································4

2.1 概述························································································4

2.2 总体设计方案的确定······································································5

2.2.1金属结构·················································································5

2.2.2工作机构················································································25

2.3 总体设计原则············································································29

2.3.1 整机工作级别··········································································32

2.3.2 机构工作级别··········································································32

2.3.3 主要技术性能参数····································································32

2.4平衡臂与平衡重的计算···································································33

2.5起重特性曲线·············································································35

2.6塔机风力计算·············································································37

2.6.1工作工况Ⅰ············································································38

2.6.2工作工况Ⅱ·············································································42

2.6.3工作工况Ⅲ·············································································44

2.6.4非工作工况Ⅳ···········································································46

2.7整机的抗倾翻稳定性·····································································48

2.7.1工作工况Ⅰ·············································································49

2.7.2工作工况Ⅱ·············································································50

2.7.3非工作工况Ⅲ···········································································51

2.7.4工作工况Ⅳ·············································································51

第三章 塔身的设计计算·································································52

3.1塔身的总体模型···········································································52

3.2 塔身的受力分析及验算··································································53

3.2.1.塔身的受力分析·······································································53

3.2.2 塔身内力计算及组合··································································56

3.2.3 塔身整体稳定性和强度验算··························································59

第四章 变幅机构的设计和计算························································71

4.1变幅机构的形式··········································································71

4.2 确定卷筒尺寸············································································71

4.2.1 卷筒名义直径··········································································71

4.2.2 多层绕卷筒相关参数计算····························································72

4.3选择电动机、减速器、制动器、联轴器····················································72

4.3.1选择电动机·············································································72

4.3.2 选择减速器············································································73

4.3.3 变幅机构制动器的选择·······························································74

4.3.4变幅机构联轴器的选择································································75

4.4. 验算变幅速度···········································································77

4.5验算起、制动时间验算····································································77

4.6电动机发热校验···········································································79

4.7 校验卷筒强度············································································80

第五章  变幅小车的设计·······························································81

5.1 变幅小车的形式··········································································81

5.2 变幅小车的设计··········································································82

5.2．1 绳索牵引式小车构造及其驱动方式················································82

5.2.2运行小车牵引力计算···································································83

5.2.3 牵引绳最大张力·······································································86

5.2.4 选择牵引绳············································································87

5.2.5 牵引卷筒计算··········································································87

第六章 毕业设计小结····································································90

致谢····························································································91

参考书目·······················································································93

第一章 前言

1.1 塔式起重机概述

随着建筑行业的兴起，城镇人口的增多，高层建筑已经成为了一个趋势，来满足人们的住房需求。然而，在建筑行业中，能同时完成垂直升降和水平移动的起重机械很多，但综合其机动灵活性，起升高度，实用性等因素应用最广泛的是塔式起重机。

塔式起重机（tower crane）简称塔机，亦称塔吊，起源于西欧，是现代工业与民用高层建筑的主要施工机械之一。在高层建筑中其幅度利用率高达80﹪,与其它类型的起重机相比，塔式起重机的优势明显，它有多种类别、形式、性能、大小等，它的突出特点是工作效率高、适用范围广、回转半径大、操作方便可靠等。故塔式起重机在建筑安装工程中得到广泛应用。但是塔机的技术有待于提高。塔机的研究正向着组合式发展。所谓的组合式，就是以塔身结构为核心，按结构和功能特点，将塔身分解成若干部分，并依据系列化和通用化要求，遵循模数制原理再将各部分划分成若干模块。根据参数要求，选用适当模块分别组成具有不同技术性能特征的塔机，以满足施工的具体需求。推行组合式的塔机有助于加快塔机产品开发进度，节省产品开发费用，并能更好的为客户服务。


内容简介：
1496 IEEE TRANSACTIONS ON SYSTEMS, MAN, AND CYBERNETICS PART A: SYSTEMS AND HUMANS, VOL. 42, NO. 6, NOVEMBER 2012Using Machine Vision and Hand-Motion Control to Improve Crane Operator Performance Kelvin Chen Chih Peng, William Singhose, and Purnajyoti Bhaumik AbstractThe payload oscillation inherent to all cranes makes it challenging for human operators to manipulate payloads quickly, accurately, and safely. Manipulation difficulty is also increased by nonintuitive crane-control interfaces. This paper describes a new interface that allows operators to drive a crane by moving a hand-held device (wand or glove) freely in space. A crane-mounted camera tracks the movement of the hand-held device, the position of which is used to drive the crane. Two control architectures were investigated. The first uses a simple feedback controller, and the second uses feedback and an input shaper. Two operator studies demonstrate that hand-motion crane control is faster and safer than using a standard push-button pendent control. Index TermsControl interface, cranes, input shaping,machine vision, oscillation.I. INTRODUCTIONRANES PLAY a key role in maintaining the economicFig. 1. Standard push-button pendent crane control.In addition to facing the challenges of controlling large-amplitude lightly-damped payload swing, operators must alsoCvitality of modern-day industry. Their importance can be master nonintuitive control interfaces. Fig. 1 shows the pendentseen at shipyards, construction sites, and warehouses and ina wide variety of material-handling applications. The effec-tiveness of crane manipulation is an important contributor to industrial productivity, low production costs, and worker safety. One inherent property of cranes that is detrimental to efficientoperation is the natural tendency for the payload to oscillate like a pendulum, a double pendulum 1, or with even more complex oscillatory dynamics 2. Significant effort has been made to develop control schemes to reduce the oscillatory response from both issued commands and external disturbances 3-9. There has also been research in controlling cranes that contain rotational joints, which adds an extra level of complexity due to their nonlinear dynamics 10-13. Operators who manip-ulate a crane using traditional interfaces such as push-button pendents benefit from oscillation-suppression technology. They generate safer (less collisions with obstacles) and more efficient crane motions (faster task completion times and less operator button pushes) than operators without such compensation 10, 14-16.Manuscript received September 26, 2010; revised April 7, 2011, June 10, 2011, and February 9, 2012; accepted April 6, 2012. Date of publication June 8, 2012; date of current version October 12, 2012. This work was supported in part by Siemens Industrial Automation, by the Manufacturing Research Center, Georgia Institute of Technology, and by Boeing Research and Technology. This paper was recommended by Associate Editor E. J. Bass. The authors are with the Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332 USA (e-mail: kccpeng ; Singhose; pjbhaumik). Color versions of one or more of the figures in this paper are available online at .Digital Object Identifier 10.1109/TSMCA.2012.2199301control of a typical overhead crane. The operator must be adeptin the cognitive process of transferring the desired manipulation path into a sequence of button presses that will produce the desired crane motion. For example, if the operator wants to drive the crane through a cluttered workspace, then the desired path must be mapped into a sequence of events where the “forward (F),” “backward (B),” “left (L),” and “right (R)” buttons are pushed at the correct time and in the correct se-quence. Furthermore, as operators move through the workspace to drive the crane and monitor its progress, they may rotate their bodies and change the direction they are facing. In such cases, the “forward” button causes motion to the left, right, or even backward. As an additional challenge, the operator can only directly drive the overhead trolley, not the payload. Therefore, the operator must account for the time lag between the commanded motion of the trolley, which can be many meters overhead, and the delayed oscillatory response of the payload.While significant strides have been made to improve the operational efficiency of cranes by controlling the dynamic response to issued commands, relatively little consideration has been given to the way in which operators issue those commands 17. It has been proven that interfaces that are tailored to the cognitive processes associated with specific control systems have beneficial effects 18-20. For example, in the field of laparoscopic surgery, medical robots such as the da Vinci improve on the traditional procedure by allowing surgeons to operate in a more ergonomic manner and with less cognitive load 21, 22. The controls move in the same direction as the end effectors for da Vinci, unlike traditional laparoscopic 1083-4427/$31.00 2012 IEEE PENG et al.: USING MACHINE VISION AND MOTION CONTROL TO IMPROVE CRANE OPERATOR PERFORMANCE 1497procedures where surgeons have to reverse map the controls due to the instruments pivot point at the point of insertion. This paper presents a novel control interface that allows an operator to drive a crane by moving a hand-held device in space. Machine vision is used to track the position of the device (a wand or a glove), which is then used to generate the command signal to drive the crane. The hand-motion control interface is well tailored to the task of driving a crane through a cluttered workspace because it eliminates the cognitive map-ping process that is necessary with traditional control interfaces. As a result, operators no longer need to account for the direction in which they are facing. The manual dexterity required for safe and efficient operation is also reduced. Additionally, the control algorithm minimizes payload swing without signifi-cantly slowing the system response. Therefore, the burden of manually reducing payload oscillation is removed. This allowsthe operator to concentrate solely on the path planning and finalpositioning of the payload.Hand-motion control offers other cognitive advantages over traditional interfaces. There are two primary divisions of cogni-tive control: analytic problem solving and perceptual process-ing 23. Perceptual processing tends to be faster and can be performed in parallel, while analytic processing takes longer and typically progresses serially. Analytic problem solving also tends to be more prone to error 23, 24. The results of many studies also suggest that people prefer, and adopt, perceptual processing when possible 16, 23, 25, 26. From this perspective, hand-motion control helps operators by lowering the cognition level required to drive the crane. Operators no longer need to think analytically about the sequence of buttons to push or to account for the swinging payload; they only need to move the hand-held device to the desired position or along a desired path. This allows the operators to perform simpler perceptual processing.The major contribution of this paper is the novel hand-motion control interface. The benefits of this interface are validated by human operator studies. Section II describes the novel inter-faces (the wand and glove). The control algorithms that are used in conjunction with the interfaces are discussed in Section III. This is followed by the operator studies in Section IV and conclusions in Section V.II. INTERFACES FOR HAND-MOTION CRANE CONTROLThe application investigated in this paper is for a single-pendulum point-mass payload that is suspended from a motor-ized overhead crane. The 10-ton industrial bridge crane shown in Fig. 2 was used for experimental verifications. A bridge crane consists of a fixed overhead runway, a bridge that travels along the runway, and a trolley that runs along the bridge. Laser range sensors measure the trolley position along the runway and the bridge. The hook, which represents the payload, is suspended from the trolley by cables. A Siemens programmable logic controller is used to control the motor drives and acts as the central control unit. Commands to the crane can be issued with a push-button control pendent, the wand or glove for hand-motion control, or other devices 17. A downward-pointing Siemens Simatic VS723-2 camera mounted on theFig. 2. Typical bridge crane.Fig. 3. Driving a crane by moving a reflective wand.trolley measures the position of the hook. Reflectors mounted on the topside of the hook aid vision-detection algorithms 27. There are two hand-held devices for hand-motion cranecontrol: 1) The wand, shown in Fig. 3, is a reflective ball mounted to the end of a hand-held pole, and 2) the glove, shown in Fig. 4, has a circular reflector attached to the backside. Fig. 5 shows a schematic diagram of hand-motion controlusing machine vision. The crane-mounted camera is used to concurrently track the positions of the wand/glove and the hook. Because all reflectors appear as bright blobs in the camera image, a K -means clustering algorithm is used to distinguish the wand/glove reflectors from the hook reflectors 28. The camera refresh rate is approximately 140 ms. The position of the wand/glove relative to the crane is used to generate an error signal to drive the overhead trolley. 1498 IEEE TRANSACTIONS ON SYSTEMS, MAN, AND CYBERNETICS PART A: SYSTEMS AND HUMANS, VOL. 42, NO. 6, NOVEMBER 2012Fig. 6. Standard pendent controller.Fig. 7. Standard push-button pendent control response.Fig. 4. Driving a crane by moving a reflective glove.Fig. 8. PD hand-motion controller. A. Standard Push-Button Pendent Control The block diagram for standard pendent control is shown in Fig. 6. The operator analyzes the workspace, considers the required manipulation goal, and then decides on a course of action. This plan is then implemented by pushing buttons on the control pendent. These buttons send energy to the motors and move the overhead crane trolley. The suspended payload is moved indirectly by the motion of the trolley.Fig. 5. Schematic of hand-motion crane control.III. HAND-MOTION CRANE CONTROLLERSThree control architectures were investigated. First, the stan-dard push-button pendent controller was used as the baseline for performance comparisons. Then, a proportional-derivative (PD) feedback controller was investigated for its suitability in hand-motion crane control. Finally, an input shaper was added to the PD controller in order to reduce payload swing.Note that, from the perspective of the control architecture, the wand and the glove are identical. Both devices are used to communicate the operators desired position to the controller. For this reason, there is no distinction between the wand and glove in the simulation and experimental verification results that are presented in this section. However, in terms of er-gonomics during operation, the wand has a greater reach and can drive the crane toward tight spaces, such as corners. On the other hand, the glove sacrifices range of reach for a smaller size and ease of use.Computer-simulated responses for point-to-point movementsof approximately 2 and 3 m using the pendent controller are shown in Fig. 7. Pressing a pendent button for a certain amount of time issues a trapezoidal velocity command to the crane motors. Due to the pendulum-like nature of the payload, this type of trolley movement will, in general, induce significant payload oscillations.B. PD Hand-Motion ControlThe well-known and popular PD controller represents one of the simplest forms of feedback control. It is the most commonly used feedback method in industry and has been applied to the control of cranes 29, 30. It provides a realistic choice for hand-motion crane controllers. The PD hand-motion control block diagram is shown in Fig. 8. The position of the wand or glove is compared to the position of the overhead crane (neglecting the vertical height difference) to generate the error signal e. The command generator converts the error signal (a positional measurement) into a velocity command that can be sent to the motor drives. If e is within the designed range specified by e0 and e100 , then the command generator linearly PENG et al.: USING MACHINE VISION AND MOTION CONTROL TO IMPROVE CRANE OPERATOR PERFORMANCEFig. 9. Simulated PD controller with low gains. Fig. 10. Simulated PD controller with high gains.scales e. Otherwise, the command generator outputs either 0%or 100%. The values for e0 and e100 were 0.25 and 1.0 m.These were selected based on comfortable distances at whichthe crane followed the operator. The command generator isdescribed as 0% : e e0Command = 100% e e0 : e0 e e100 (1)1499100% 100 e0 : e e100 .Fig. 11. Starting and stopping with hand-motion control. A PD control law is then applied, and the result is passed through a saturator to ensure that crane velocity and accel-eration limits are not exceeded. Note that the position of the crane trolley, rather than of the payload, is used for feedback. This is because, in practice, sensing the position of the trolley (using laser range sensors) is much more reliable than sensing of the payload (using machine vision). Furthermore, the single-pendulum payload is an inherently stable plant: The payload will always come to rest directly beneath a stationary crane. Therefore, correct final positioning of the crane trolley ensures correct final positioning of the payload. 1) Simulation Verification: A crucial design challenge is the selection of PD gains. Computer simulations were constructed to aid the gain-selection process. Hand-motion trajectories werespecified as ramps in position with gradients equivalent to themaximum velocity of the 10-ton industrial crane (0.3577 m/s). This is approximately the speed of a slow walk and mimics the typical hand-motion trajectories from a human operator.Figs. 9 and 10 show the simulation results for PD hand-motion controllers with low and high feedback gains, respec-tively. These two figures show the inherent tradeoff in using the PD controller: With low gains, the crane was slow to respond, but the payload oscillation was small; with high gains, the crane moved quickly but at the expense of large payload oscillations. 2) Experimental Verification: The hand-motion control sys-tem was implemented on the 10-ton bridge crane. Thewand/glove trajectories produced by human operators were similar to those used in the simulations. The ramp gradient was approximately equivalent to the maximum velocity of the crane, and the move distance was approximately 2 m for the tests reported here.Fig. 11 shows an operator using hand-motion control to start and stop the crane. To start moving, the operator can exposeFig. 12. Experimental PD controller with low gains.the wand/glove to the camera at some distance away from the crane. When the crane approaches the desired position, theoperator lowers the wand/glove, which becomes undetectable by the camera. When the camera is unable to locate the position of the wand/glove, e is set to zero. Because the position of the wand/glove may be unknown at certain times, there are breaks in the curves that are labeled “Wand/Glove” in the experimental response plots.Figs. 12 and 13 show the experimental results for PD hand-motion controllers with low and high feedback gains using the glove interface, respectively. The experimental data re-inforce the results that were established by the simulations: Low gains produced slow crane movements and small payload oscillations, while high gains yielded fast crane movements but large payload oscillations. For safety reasons, minimizing payload oscillation is normally a higher priority than fast crane nn1500 IEEE TRANSACTIONS ON SYSTEMS, MAN, AND CYBERNETICS PART A: SYSTEMS AND HUMANS, VOL. 42, NO. 6, NOVEMBER 2012Fig. 13. Experimental PD controller with high gains.Fig. 14. PD with input shaper hand-motion controller.movements. Therefore, practical implementations of PD hand-motion controllers should only use low gains.C. PD With Input Shaper Hand-Motion ControlSection III-B demonstrated the inherent weakness in using PD hand-motion controllers (the tradeoff between low and high gains). However, performance can be improved with the addi-tion of an input shaper that modifies the shape of the command signal to reduce oscillation. Fig. 14 shows the new control block diagram that shows an input shaper inserted between the saturator and the crane blocks.1) Input Shaping: Input shaping is a technique that reduces the residual vibration of flexible systems by properly shaping the commands. This is accomplished by convolving the base-line input command with a series of impulses, known as an input shaper. The result is a shaped command that will reduceFig. 15. Simulated PD with input shaper controller.Fig. 16. Experimental PD with input shaper controller. is the natural frequency of the system, is the damping ratio, and Ai and ti are the ith impulse amplitude and time, respectively.Equation (2) gives the ratio of vibration with input shaping to that without input shaping. A constraint on residual vibration amplitude can be formed by setting (2) less than or equal to a tolerable level of residual vibration at the modeled natural fre-quency and damping ratio 32. For the simplest zero vibration (ZV) shaper, the tolerable amount of vibration is set to zero. This results in a shaper of the form 31, 33 residual vibration.In order to determine the impulse amplitudes and time loca-tions of an input shaper, certain design constraints must be sat-isfied. The primary design constraint is a limit
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