悬臂式斗轮取料机设计【全套含CAD图纸、说明书】
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本科生毕业论文姓 名：学 院：专 业：论文题目：专 题：指导教师： 20XX 年 6 月 摘 要悬臂式斗轮取料机堆取料机械中的一种，它广泛应用于港口、内陆的散料场所，主要用于取煤和矿石。悬臂式斗轮取料机主要由金属结构、臂式输送机、回 转机构、行走机构、斗轮机构、润滑装置、电气系统和安全装置组成。工作时， 取料机沿着轨道行进，并能改变臂架的角度。悬臂式斗轮取料机是由斗轮挖掘机 发展而来，它能与堆料机和输送机一起组成自动运输系统，随着国民经济的快速 发展，对取料机的需求也越来越大。 本文章主要是对斗轮机构和回转机构的设计，它们都是取料机的重要组成部 分。斗轮机构主要是通过销齿传动来驱动斗轮的转动，这种传动方式具有结构简 单、加工容易、造价低、拆修方便的优点。 在回转机构中，关键是回转支承。回转机构的工作原理是小齿轮与回转支承 的大齿轮啮合来带动整个回转体的转动，所以本文章将对回转支承进行选型并对 小齿轮进行设计。本文还对相对于斗轮取料能力进行了输送机的选型。 因为悬臂式斗轮取料机比较容易实现自动控制，所以本文章采用PLC 进行对 取料过程的控制。PLC 是个无触点装置，通过改变程序就可以改变生产工艺，PLC 已成为工厂自动化的强有力工具，得到了广泛的普及及推广应用，它具有可靠性 高，抗干扰能力强，编程直观、简单的优点。 关键词：悬臂式斗轮取料机；斗轮机构；回转机构，ABSTRACTBucketWheel Reclaimer Bucket-WheelReclaimer,and widelyused reclaimbulk cargo innerland steelstructure,jib belt conveyor,luffing mechanism, slewing mechanism,travling bridge,bucket wheel,lubrication,electrical equipment safetyaiding devices. canmove along rails slewjib,which can change amplitude. BucketWheel Reclaimer bucket-wheelexcavator,and can make up mechanizedtransport system Bucket-WheelStaker bletconveyor. economy,theneed BucketWheel Reclaimer mainabout bucketwheel slewingmechanism,which allvery important paper,thedriving between pingear bucketwheel run,this method have some advantage,for example,its structure uncomplicated,so lower.Also takedown slewingmechanism,the key rotorsupport. actionbetween rotorsupport paperchooses rotorsupport paperalso choose conveyorbelts,which reclaiming.Because BucketWheel Reclaimer paperdesigns reclaimingcourse PLC.PLC non-contactequipment,the procedures can changeproduction. hasbecame powerfultool factoryautomation, widely popular replication. highreliability,anti- interference capability programmingvisual,simple. Keywords BucketWheel Reclaimer; bucket wheel ;slewing mechanism；PLC目 录1 概述11.1 斗轮堆取料机简介11.2斗轮堆取料机分类21.3斗轮堆取料机市场需求31.4斗轮堆取料机国内发展现状41.5斗轮堆取料机的研究方向71.6设计课题及选题意义82 总体设计102.1总体设计概述102.2悬臂式斗轮取料机构成102.3悬臂式斗轮取料机的主要参数及其确定112.3.1取料的理论生产率112.3.2斗轮取料时每层深度122.3.3料堆高度122.3.4料堆长度122.4悬臂式斗轮取料机的工作性能参数及其确定122.4.1斗轮直径的确定122.4.2铲斗数目的确定132.4.3斗距的确定132.4.4铲斗容量q的确定132.4.5斗轮切割速度的确定143 部件设计153.1悬臂式斗轮取料机构设计153.1.1斗轮取料机构构成153.1.2斗轮驱动电机选用173.1.3液力偶合器选用183.1.4销齿传动设计193.1.5斗轮轴的设计及校核243.2上车回转机构设计283.2.1回转机构选型283.2.2 回转机构设计313.2.3齿轮轴设计及校核343.2.4小齿轮校核373.2.5回转支承的日常维修393.3带式输送机选型设计403.3.1带式输送机特点403.3.2带式输送机的驱动装置413.3.3带速的确定443.3.4滚筒直径的确定453.3.5托辊的选型463.3.6张紧装置的选用473.3.7制动装置473.4变幅机构473.5配重的安装473.6行走机构484 悬臂式斗轮取料机的控制系统设计524.1取料机的工艺流程524.2控制流程图554.3 控制工作原理564.3.1 控制过程简介564.3.2 传感器选用56总 结58参考文献59附 录60翻 译63致 谢76翻 译原文Motorized Pulleys Solve Harsh Environmental Problemsat North American Ship Loading TerminalsKeywords: Motorized Pulleys, Ship Loaders, Bucket Wheel Stacker Reclaimers, Conveyor Belts1 AbstractThis paper presents design and operational challenges faced by three different ship loading facility operators, one handling export coal on the Gulf of Alaska and two handling taconite iron ore pellets on the North American Great Lakes. Extreme temperatures and abrasive materials, coupled with a need for compactness, made internally-powered and hermetically-sealed Motorized Pulleys the optimal design choice for driving ship loader and bucket wheel reclaimer conveyor belts.Originally a European idea, the Motorized Pulley was slow in gaining acceptance in North America in the twentieth century.However, the internally-powered conveyor belt drive has recently become more popular,especially where ambient conditions, material handled, or compact equipment design make exposed drives difficult to integrate and operate.2 IntroductionWhat do Seward, Alaska; Superior, Wisconsin; and Escanaba, Michigan have in common? Each is the location of a major rail-to-ship bulk storage and transfer facility, owned and operated by a railroad company. Each is located on water north of 45N latitude, where winter temperatures can drop to 40 F (-40C) and humidity reach nearly 100%. And each handles abrasive and/or corrosive material. One other important feature is common to these facilities.the Rulmeca Motorized Pulley. Rulmecas internally-powered and hermetically-sealed Motorized Pulley was selected to upgrade key drives on shiploader and bucket wheel reclaimer conveyor belts.This paper will review each facilitys layout, throughput, and particular challenges and it will explain why designers selected Motorized Pulley technology. These successful applications will help explain the growth in acceptance of Motorized Pulley technology in North America, especially in harsh environments.3 Motorized Pulley TechnologyThe Motorized Pulley concept was developed in the 1950s to provide a reliable means of driving belt conveyors. Equipment designers quickly discovered that enclosing the drives motor and gearbox within a hermetically-sealed and oil-filled pulley shell not only made the drive compact, it also greatly improved the drives reliability and service life.Fig. 1: Rulmeca Motorized Pulley encloses motor and gearbox within hermetically-sealed oil-filled shell to protect moving components from harsh environment while saving space.Compactness, reliability, long service life, and limited maintenance requirements made the Motorized Pulley a popular conveyor drive for bulk handling equipment designers in Europe. Large machinery such as bucket wheel reclaimers, ship loaders, and tunnel boring equipment soon had Motorized Pulleys installed as original equipment. And plant operators began replacing worn exposed conveyor drives with Motorized Pulleys at facilities handling materials such as fertilizer, sand & gravel, steel, ore, and wood products.Each Motorized Pulley consists of an AC squirrel-cage induction motor, directly coupled to a helical/spur gearbox,mounted on a fixed(non-rotating) shaft, and hermeticallysealed within the cylindrical pulley shell.Todays Motorized Pulley incorporates a wide array of powers and speeds as well as optional features ,such as built-in mechanical backstops, anti-condensation heaters, and electro-mechanical brakes.4 Allouez Dock #54.1 Synopsis of UpgradeBurlington Northern Santa Fe Railroad(BNSF) recently completed the overhaul of two of three 40 year old crawler-mounted bucket wheel reclaimers at the companys rail-toship transfer terminal for taconite pellets located near Superior, Wisconsin.4.2 Objective of UpgradeThe objective of the upgrade was to reduce high maintenance expense while improving system reliability in the stockpile area. The upgrade included structural changes, replacement of on-board diesel engines, and the installation of RulmecaMotorized Pulleys. The challenge for BNSF operations was to keep the 40 year old machines working efficiently in spite of the fact that the machines manufacturerhad gone out of business more than 20 years ago. The original conveyor drives were a unique combination of components including AC motors, planetary gearboxes and pulleys mounted between the carrying and return strands of belt. Since original equipment manufacturers parts were no longer available and since the conveyor drives were non-standard, BNSF was forced to custom-build parts, an expensiveand time-consuming process. Engineering Design Services recommended Rulmeca Motorized Pulleys because: (1) they are compact and would fit within the reclaimers structure, (2) Rulmeca Motorized Pulleys and replacement parts are readily available, and (3) Rulmeca has a long successful track record of supplying conveyor drives for bucket wheel reclaimers.4.3 Operating DataAs summarized in Table 2, Allouez Dock #5 consists of an 87 acre (0,3 km2) facility providing 5.5 million tons of storage capacity in a stockpile area 3.5 miles (5,6 km) from the dock and 72,000 tons of storage in the dock silos. A conveyor system, 5.7 miles (9,2 km) in length, links the 2 rail car unloaders, the 3 stacker reclaimers, and the ship loader. Taconite pellets usually arrive in BNSF trains of 150 cars each 35 feet (10,7 m) long “H-1” type at 1,800 ft3 (51) capacity and are loaded into special lake vessels. Up to 185 car trains can haul 20,000 tons of taconite pellets, at a gross train weight of 27,000 tons. Winter temperatures can reach 30 F (-34C). Typically, ice does not cover all of Lake Superior, but near-complete sheets of ice, from a few inches to several feet thick, do form in the harbor area of Superior and St. Louis Bays. As early as mid-November and persisting as late as early May, ice in the Soot Locks or the harbor ends the shipping season. Frozen blocks of pellets can be found in the stockpiles as late as August and September. The 75 BNSF employees at Allouez Dock #5 unloaded 537 trains or 79,201 cars in 2003.4.4 Motorized Pulley ExperienceEngineering Design Services and Rulmeca engineers first presented the Motorized Pulley upgrade concept for the bucket wheel reclaimers to BNSF personnel in 1995, suggesting a “Dual Drive” arrangement for the tail conveyor due to its requirement of 200 HP (150 kW). Allouez Dock had been maintaining the bucket wheel machines without the assistance of the original equipment manufacturer for more than 10 years in 1995. However, the dual drive concept was relatively new at that time and eight years would elapse before the first bucket wheel reclaimer was upgraded. By 2003 original gearbox rebuilds had gotten very expensive. That year three Model 800H Motorized Pulleys, with 31.5 inch (800 mm) diameter and 57 inch (1400 mm) face width were purchased. BNSF operations personnel installed them in 2004. Each Motorized Pulley provided 120 HP (90 kW) at a belt speed of 768 fpm (4 m/s) on a power supply of 460V/3ph/60Hz, generated by the newly-installed on-board diesel generator. The compact design minimized structural modifications and greatly simplified the “Nested Dual Drive” configuration beneath the tail conveyor. The successful upgrade of the first machine encouraged BNSF to upgrade a second Bucket Wheel Reclaimer, completed in 2005, using three 100 HP (75kW) Rulmeca Motorized Pulleys. The third and final set of Motorized Pulleys was delivered July 2006. Engineering Design Services not only assisted BNSF personnel with initial design to insure a smooth retrofit, Roger Meittunen also traveled to the Rulmeca Motorized Pulley factory in Germany to observe final assembly of the first three Motorized Pulleys and obtain aftermarket service training on the Model 800H units to insure long-term success of the Motorized Pulleys at Allouez Dock.Fig. 2: 4,000 TPH Bucket Wheel Reclaimer in its second season after the 2004 Motorized Pulley upgrade. Note one Motorized Pulley beneath the boom conveyor and two under the tail conveyor.5 Escanaba, Michigan5.1 Synopsis of UpgradeThe Escanaba Ore Dock transfers 8 MTPY of taconite pellets from rail to lake vessels at the Lake Michigan terminal. The Chicago and Northwest Railroad replaced two worn-out Motorized Pulleys on the their bucket wheel reclaimer in 1985, after approximately 15 years of service, when the original Motorized pulley manufacturer went out of business. John Kirkegaard Maskinfabrik A/S supplied the replacement known as “JOKI Motorized Pulleys,” now called Rulmeca Motorized Pulleys. The two 40 inch (1 m) diameter 200 HP (150 kW) Motorized Pulleys are still in service after more than 20 years.5.2 Objective of UpgradeThe objective of the upgrade was to secure reliable drives for the 4000 TPH reclaimer boom and tail conveyors from an established Motorized Pulley manufacturer with readily available replacement parts. JOKI had been an established brand for 30 years at that time.Fig. 3: Traveling ship loader loads pellets into 64,000 DWT lake vessel at 4,000 TPH, filling it injust 16 hours.Fig. 4: Bucket Wheel boom is hydraulically luffed and transfers 4,000 TPH of taconite pellets on a 60 inch (1,5 m) wide belt at 715 FPM (3,6 m/s).5.3 Motorized Pulley ExperienceThe Rulmeca Motorized Pulleys installed on the bucket wheel reclaimer in 1985 are still in service and have now outlasted the original 16 year old pulleys by five shipping seasons. They have enabled the Escanaba Ore Dock to transload more than 150 million tons of taconite pellets during their service life.Fig. 5: Drawing shows unique double end housing arrangement on “drive side” of 200 HP (150 KW) Motorized Pulley. Development of different designs and more powerful Motorized Pulleys is in progress at Rulmeca FAA GmbH6 ConclusionThe long service lives promised by large Rulmeca Motorized Pulleys at three major transloading facilities with harsh operating conditions demonstrate the value of Motorized Pulley technology. There are now more than 130,000 Motorized Pulleys, 1 HP (0,75 kW) and larger, in service in North America. Including fractional HP Motorized Pulleys, there are nearly 1 million units in service. A proven design, which hermetically seals its drive system within a compact and oil-filled pulley shell, and a reliable source of supply and after market service will enable conveyor operators and system designers to take advantage of Motorized Pulley technology in North America and the rest of the world for many years to come.中文译文电动滚筒克服北美船运装载终端的恶劣环境问题关键字: 电动滚筒, 船运装载机, 斗轮堆取料机, 传送带1 概要这篇论文介绍了三个不同船运装载操作工所面临的设计和操作上的挑战，一个在阿拉斯加海湾装载用于出口的煤，另两个在北美五大湖装载铁矿石。极端的温度、具有腐蚀性的原料, 再加上需要良好的密封性，这些都使得具有内在动力而且密封性良好的电动滚筒成为驱动船运装载机和斗轮堆取料机传送带的最佳选择。最初，电动滚筒是一个欧洲人的想法，在二十世纪的北美已经慢慢接受了它。然而，具有内在动力的传送带驱动器近来变得很流行，特别是在那些因为外在环境、原料性质或者设备需要紧凑的设计使得暴露在外面的驱动机无法融入设备而且会运转困难的地方。2 绪论西华德、阿拉斯加州，瑟谱雷尔、威斯康星州，埃斯科拿巴、密歇根州有什么共同点呢？每一个地方都是主要的铁路-船运的中转贮料场所，而且都有由铁路公司拥有和操作的中转设备；每一个地方都坐落在北纬45的水平线上，那里冬天的温度能降到零下40C而且湿度接近100%；每个地方都处理那些有腐蚀性的原料。另一个重要特征是它们都拥有陆美嘉电动滚筒，陆美嘉的电动滚筒因具有内在动力而且密封性良好被选用来升级驱动货运船与斗轮堆取料机传送带的驱动机。这篇论文介绍每个设备的设计、生产量还有一些特殊的挑战，它将解释为什么设计人员选择电动滚筒技术，这些成功的应用将帮助我们解释北美地区特别是有恶劣环境的地区为何越来越多的应用电动滚筒技术。3 电动滚筒技术电动滚筒技术这一概念是在十九世纪五十年代为了给驱动带式输送机定义而发展起来的。装置设计者很快发现将驱动器的马达和变速箱嵌入一个具有良好密封性并且充满油的皮带轮罩里不仅可以使驱动器紧凑，而且它能大幅提高驱动器的可靠性和工作寿命。 图1: 陆美嘉电动滚筒将马达和变速箱嵌入嵌入一个具有良好密封性并且充满油 皮带轮罩里为了在恶劣环境中保护移动部件同时节省空间。紧凑、可靠、长时间服务寿命和有限的维护要求使电动滚筒成为欧洲散装运输设备设计者喜欢的输送机驱动器。大型机械设备像斗轮堆取料机、船用装载机和隧道挖掘设备使电动滚筒能像原先设备一样被安装，而且设备操作者开始在运输散料诸如化肥、沙石、铁矿石和木材制品时用电动滚筒替换旧的且暴露在外的输送机驱动器。每个电动滚筒把一个鼠笼式交流感应电动机，直接连接在一个螺旋式齿轮变速箱，安装在一根固定的轴上并将柱形皮带轮罩密封好。现在的电动滚筒包括一组动力和速度设备还有其它附加设备诸如机械支持物、加热器、电动机械刹车等。4 Allouez 5号码头4.1 升级计划圣达菲北部布林顿铁路公司最近大修两台近40年历史的斗轮堆取料机，它们放在离瑟谱雷尔、威斯康星州不远的地方，平时用来将铁路运输的铁矿石转至船上。4.2 升级目的这次升级目的是为了减少高额的维护费用同时提高在散料场地工作时的系统可靠性，这次升级包括对结构的改进、船上柴油机的替换和陆美嘉电动滚筒的安装。这次BNSF公司的改进计划所面临的问题是使这些有40年历史的机器能有效的运转起来，尽管这些机器的生产商在20多年前就已经倒闭。原先的传动机驱动器是一个由好几个部件组成的独特设备，它包括交流电动机、变速箱和安装在运输与回程带之间的滑轮。由于原先的设备制造厂商的一些部件不能用了，而且输送机的驱动器不是标准的，BNSF公司不得不定制这些部件，这是个即费时又费钱的过程。工程设计维护公司建议使用陆美嘉电动滚筒有以下理由： （1）它们简洁紧凑适合于取料机的结构；（2）陆美嘉电动滚筒和取代部分很好用；（3）陆美嘉公司早已成功推出各种用于斗轮堆取料机的输送机驱动器，技术较成熟。4.3 运行数据Allouez 5号码头包括87英亩拥有五百五十万吨储存能力的场地，它离码头大概3.5英里的路
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