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出钢机的现状分析摘要：本文介绍出钢机的类型以及工作过程，列举现代企业对出钢机的改进方法和改进后所产生的效益，同时阐述自己的设计理念.关键词：出钢机 加热炉 故障 液压 横移 改进措施前言：出钢机是冶金轧钢行业，加热炉区的机械设备之一，出钢机的作用是将加热后的红钢坯推出加热炉进入辊道进行轧制，其形式结构与轧制条件和轧制种类有关。出钢机的概述：出钢机位于炉后出钢口，通过出钢机输出动力，将加热处理过后的钢坯推出进入辊道进行轧制。该设备分机械型和液压型二种，用户可根据实际需要选购。 结构特点及工作原理 ：机械型出钢机由电机、减速机及机械传动部分、壳体等组成，其主要特点是推行平稳，推力大。液压型出钢机由液压油缸、液压泵站、平衡推杆及底座等组成。其主要特点是：结构简单、推力大、造价低。横移式出钢机的工作过程：在连轧工艺中，出钢机将钢坯不断地推出加热炉，使钢坯进入轧制状态。例如某厂加热炉设备，位于炉后的出钢机将钢坯一个接一个地推出加热炉，当轧制其他尺寸的钢坯或者推钢机速度放慢时，最后一根需要推出的钢坯位置发生变化。因此为了能够准确的推出钢坯需要将出钢机进行横移，推杆对准钢坯后将其推出。出钢机在推进时出钢机不能推入钢坯，否则可能发生钢坯移位，推出了其他的钢坯或者同时推出了两根钢坯，可能对出钢机和轧钢机产生损坏，影响到整个生产线的生产。在出钢机推杆返回时，推钢机可以往加热炉推入钢坯。出钢机的目前状况： 出钢机是冶金轧钢行业，加热炉区的机械设备之一。出钢机一旦出现问题，整条连轧线将会停止生产，所以出钢机是轧制线上的重要生产设备；降低出钢机的故障时间和延长设备的使用寿命对生产是十分有益的。随着现代冶金企业连铸连轧技术的发展，其对设备正常运行的要求也越来越高，一些原有的设备需要淘汰更新，作为重要设备之一的出钢机也在之内。以下将举出国内一些企业对出钢机结构的改进方案。杭州钢铁集团公司的小轧步进式加热炉的出钢机推送钢坯，其推杆由两段面钢坯焊接而成，由12只托辊托送。在使用和维护过程中，发现的问题有：1)推钢不畅，制约生产节奏。2)托辊使用寿命短，拆换艰难。3)推杆使用寿命短。杭钢技术人员通过对托辊和托梁进行设计改进后实施的效果为：1)改进后的12只托辊中，任何一只失效，都可在不停机的状态下，从侧面进行整体快速抽换。2)通过调整轴座下的垫片，可以调整辊面高低，确保12只托辊均匀承受推杆压力，推杆推送阻力小。3)改善了托辊轴承的润滑条件，人工加油简易方便。4)提高了推杆和托辊、托梁的使用寿命减少维修工作量。改进后一年多来，设有更换过推杆和托辊。 安阳钢铁集团有限责任公司中板出钢机位于加热炉出炉侧，用于将加热到出炉温度的热钢坯从炉内托出，并平稳地放在出炉辊道上。该设备由导向座、出钢杆、活动架、升降机构、压轮装置、支承装置、升降机构传动装置、横移传动装置等机构组成。自1995年5月开始试生产以来该设备故障频繁，经实际验证，其托坯能力5t，无法满足大坯料轧崩的要求，为此对该设备进行了改造。通过对问题的分析，提出的改进措施为：1)针对原出钢机链条打滑现象采用了齿轮齿条式结构保证了传动精度的可靠。2)针对出钢杆变形失稳的情况，将出铜杆设计为整体铸钢结构，同时加快出钢杆的行走速度，使出钢杆头部在加热炉内的时间比原来减少10秒钟，减少了出钢杆头部因受热而变形的可能。3)为了保证齿轮齿条的充分啮合，将出钢杆头部压轮置于齿轮上方，同时，将压轮位置确定在出钢杆自由状态时的中部，有效地减小了压轮使用过程中承受的正压力，同时改善了出钢杆的局部受力情况。从1999年12月对出钢机改进以来,适应了大坯料生产的要求，加快了生产的节奏，保证了高附加值钢板的轧制 同时，使用至今未出现一起事故，减轻了维修劳动强度，提高了作业率。出钢机的特点： 以上是国内的一些企业通过对原本的出钢机进行了设计改造后，大大的减少了故障次数和维修次数，极大的提高了生产效率，从而给企业带来了经济效益。通过实习参观、查阅书刊资料和结合自身的理解性。本人认为在生产中使用液压横移式加热炉出钢机更为合理。 出钢机分为纵向驱动部分和横向驱动部分。纵向驱动部分主要控制推杆的运动；横向驱动部分主要功能是调节推头所指的横向位置。在横向驱动部分本人将选择机械摩擦式推动顶杆的方式而否定液压推动的方式理由有以下几点：1）液压推动受其行程的限制而摩擦式不会受到限制；2）摩擦式出钢机顶杆冷却方式简单、有效而液压推杆冷却方式较为复杂；3）摩擦式出钢机顶杆损坏后更换更简单。横向驱动部分将选择液压横移方式，其优点有：1）纵向驱动部分选择了机械摩擦式，若横移选择了机械方式将会增加制作成本及复杂程度；2）液压机构体积小，占地面积也小，设备成本也低；3）液压机构运行稳定性好，运行精确，操作简单方便，受外界干扰影响小。根据分析来看，这种液压横移式加热炉出钢机实用性强，可靠性也更高。在综合情况考虑下，这种形式的出钢机也更能受到企业的青睐，相信会给企业带来很大的效益。参考文献：1邹家祥. 轧钢机械. 北京：冶金工业出版社， 2007.2申永胜. 机械原理教程. 北京：清华大学出版社，2005.3濮良贵.纪名刚. 机械设计. 北京：高等教育出版社，2006.4朱新才.周秋沙. 液压与气动技术. 重庆：重庆大学出版社，2003.5王兰美. 机械制图. 北京：高等教育出版社，2004. 6温诗铸.黄平. 摩擦学原理. 北京：清华大学出版社，2002.7周明雄.凌士德.姜晓峰. 加热炉出钢机设计改进J：浙江冶金，2002.28安斌. 推钢式加热炉附属机械设备的开发与研制J：机械工程与自动化，2004.29张海波. 带钢厂出钢机的改进J：维普资讯 10陈滇怀.王春明. 出钢机运行的定位控制J：一重技术，1997.1.11陈定晖.宋志东. 加热炉出钢控制方式的改进J：浙江冶金，2002.512陈维新. 重钢中板厂85 t推钢机设计J： 重型机械科技，2007.313刘京华.李子文. 小型连轧机的工艺与电气控制M.北京：冶金工业出版社.14欧阳周.汪振华.刘道德. 毕业论文和毕业设计说明书写作指南M.长沙：中南工业大学出版社，1996.CHINESE JOURNAL OF MECHANICAL ENGINEERINGVo1.22，No.1，2009DOI：103901CJME200901109，available online at ； Water Hydraulic 22 Directional Valve with Plane Piston Structure GONG Yongjun，YANG Huayong ，and WANG Zuwen1 Laboratory of Fluid Power Transmission and Control Dalian Maritime University,DaLian 116026,China2 The State Key Lab of Fluid Power Transmission and Control Zhejiang University,Hangzhou 310027,ChinaReceived July 13，2008；revised November 19，2008；accepted December 3，2008；published electronically February 20，2009Abstract：Due to the fire resistance and environmental compatibility，using water as the working fluid in hydraulic circuits is receiving an increasing attention by both manufactures and usersThis hydraulic directional valve is developedWhen new water hydraulic directional valve is designed and manufactured，this paper introduces a water hydraulic 22 directional valve and its principleThe valve is composed of a hydraulically operated seat valve and a magnetic 32 direction valveAimed at the serious leakage and impact generating easily in reversing suddenly, an improved structure of water space seal is changed to direct seal，compaction force between main valve spool and main valve pocket was logically designed and damper in pilot valve port is matched with sensitive cavity in main valveFrom the view of flow control，the methods of cavitations resistance of the directional water hydraulic valve are investigatedThe computational fluid dynamics approaches are applied to obtain static pressure distributions and cavitations images in the channel of the main stage of the valve with two kinds of structure The results show that the method of optimized spout can effectively restrain cavitationsThe work provides some useful reference for developing water hydraulic control valve with the lower noise and lower vibrationMeantime，the structural parameters are optimized on the basis of information obtained from simulationStatic test，dynamic test and life test are accomplished，and the results show that the water hydraulic directional valve possesses good property, its pressure loss is 1.1MPa lower, switching time is shorter than 0.025 sand its strike crest is 0.8MPa lowerThe valve possess fine dynamic performance with the characteristic rapidly action and lower impulsionKey words：water hydraulic，directional valve，structure optimization，flow field analysis1 IntroductionFor its abundant transmission mediaEnvironmentally friendly, clean and safe，fire resistant，and so on，water hydraulic technology has been turned out to be a focus of research in the field of fluid power transmission and controll Water hydraulic valve as one of the key components，is studied extensivelyThe traditional oil hydraulic directional valve is of spool pilot valve，rotary valve or cone valveAlthough the unbalance force on the rotary valve and the pilot pool valve are weak，the force to operate them are weaker and the leakage are usually bigger with a larger tolerance for the relative movement of the valves and valve seats For its low viscositythe loss of leakage of water hydraulic system is much higherFor the same clearance and pressure，the loss of leakage of the water hydraulic system is several decade times that of oil hydraulic system In order to maintain a reasonable low leakage the clearance should be extremely small，which may lead to difficulty of machiningat the same timeit is easily for the moving parts to be choked and stuck As for the cone valvealthough has a smaller leakage，unbalanced axial fore on the valve exist，so a stronger force is needed to operate it For the incompressible and high stiffness，the hydraulic shock of the water hydraulic directional valve is more serious So how to lessen the leakagehow to realize direction change with low or even no hydraulic shock and how to improve its static and dynamic characteristic are the key issues of study So far-there is no report on the study of water hydraulic directional valve. In this Paper，a new serial of water hydraulic valves has been provided based on the change of seal pattern，reasonable design of pre-tightening force，and optimization of the flow passage2 Experimental Working Principle of the Water Hydraulic Directional Valve Fig.1 shows the water hydraulic directional valveIt is electrohydraulic directional valveThe pilot stage is a 23 electromagnetic directional ball valveBeing different from traditional oil hydraulic valvea valve pocket is added to the main valve，and the main valve pocket is over fitted to the valve bodyThe main valve spool is fitted to the main valve pocket，and the surface sealing is achieved by the plane of the valveLip-type packing are set in both ends to achieve no leakageThe spring is for compensation of the frictional forceBoth ends of the main valve spool are supported radically by bushes， which are made of wear-resisting materials， so the problem of abrasion is settled in this way Fig.1 Sketch of water hydraulic directional valve structureThe structural principle of the valve is as follows: there is damper at the valve port，two dampers in series act as half bridge resistant，and the controlling rib connects to the sensitive chamber on the right side of the valve by the central hole. When the electromagnet is out of power, main valve spool is moved to the right under the force of inlet, at the same time，water in the sensitive chamber is discharged through the pilot valve，and the main valve is openWhen the electromagnet is chargedwater for control is inducted to the sensitive chamber, and the main valve spool is compressed on the valve pocketand the main valve is shut down2.1 Design of the pressing force of main valve spoolThe contact surface of the main valve spool and the valve pocket is plane，there maintains a certain pressing force between them (Fig.2).The pressing force varies according to the change of control fluid pressure，the higher pressure is，the bigger the pressing force will beTherefore，leak age between the main valve spool and the valve pocket is nearly zeroThe stress condition of the main valve spool is as followsFig.2 Sketch of axial force of main valve spoolSuppose that the inlet pressure of the main valve is p，and pressure loss is neglected，so the pressing force of the main valve is p1,，we haveIt is obvious that p1 is positive，which ensures that the main valve spool is pressed against to the valve pocketIf pl is too weak，there will be leak age between the main valve spool and the valve pocket，and if pl is too high，the force for directional change will be bigger and abrasion between the main valve spool and the valve pocket will occursAccording to our experiments，the facial contact force for the main valve spool an d the valve pocket is at best 2 times the inlet pressure PIn the process of design，it is required that2.2 Meshing design of pilot valve damper and sensitive chamberFor the design of directional valve it is not only necessary for a quick directional change，but also a minimal hydraulic shockSo a dam per is set at the inlet of the pilot valve，two dampers in series act as half bridge resistant，a throttle backing pressure is then built up at the end of the main valve，which has a function of retardation andspeed-regulationProvided at any time, there is even pressure in thesensitive chamber an d the compressibility of the fluid omitted，equations will be acquired as follows：Where F is exterior force，f is frictional force，k is the stiffness of the spring，x is buffer distance，Ps is pressure of the sensitive chamber, Ad is area of the main valve spool end， m is the mass of main valve spool， a is shock accelerated velocity,p is differential pressure betweenimports and exports of dam per,A0 is flow area of the damper, v is shock velocity, qv is flow of the damper, cq is coefficient of discharge of inundated ports effluxFrom Eqs.(3)-(7)，the characteristic expression of the pilot valve port is deducedWhen shock energy is too big and throttling area is too smallshock is rather strong and can create bigger frontshock hump， and buffer effectiveness is not good；when the shock energy and throttling area are too big，shock is weak，buffering force is smaller, and residual velocity can exist which may create correlation equation assumed by Launder, the aeolotropism and eddy flow of turbulent current can be well predictedpacket oil phenomenon and bigger back-shock hump at the This paper uses Anisotropic k- model to simulate flow end of the shockTherefore，in the case of proper design，it is required that the damper should match with sensitive chamber，and the damper should have good performance and linearityAccording to experience，linearity of the damper should be less than 30 3 Flow Field Simulations and AnalysisWhen the directional valve is being designed Its pressure loss should be as small as possiblePressure loss of the directional valve usually is determined by experimentDevelopment of calculated hydromechanicsprovides a scientific approach to calculate pressure loss of the directional valve with complex flow passageIt turned out to be an effective method to make use of numerical calculation， with which optimization of the movement，flow and structure of the hydraulic component can be done3.1 Mesh divisionThe mesh of water hydraulic directional its main valve passage is shown in Fig3Main valve passage is threedimensional symmetrical structure， the passages threedimensional model is used for mesh division and flow field calculation in the studyFig3 Mesh of main valve flow passageBecause area gradient of flow field of the computational domain varies greatly, for the purpose of improving calculation accuracy and reducing amount of calculation work，the computational domain has been divided into multiple small sectorsInitial computational mesh is created in GambitIn high speed domain of the main valve port and nearby, velocity gradient is very big，and complex flow pattern exists，better structuring meshes in this domain and coarser unstructured meshes in other areaare applied32 Mathematic model321 Anisotropic k- turbulent modelBecause Anisotropic k-model adopt Reynolds stress correlation equation Assumed by Launder, the aeolotropism and eddy flow of turbulent current can be well predicted. This paper uses Anisotropic k- model to simulate flow pattern of flow field of the directional valves main valve，calculation equation of its turbulent kinetic energy k and turbulent dissipated energy is as follows：Calculation equation of turbulent current frequency isWhere，ui is fluctuation velocity sector in i direction ， ujis fluctuation velocity component in the J direction，P is fluid density, and is absolute viscosity3.2.2 Cavitations modelGas phase volume percent equation can be expressed aswhere，a is gas phase，aa is gas phase volume percent，Pa is gas phase densityl is fluid phasePl=998.2 kgm 3 (fluid phase density)，and l-aa is fluid phase volume percentMean density isAnd mal，is mass transfer between gas phase and fluid phase due to cavitations，it is expressed aswhere Pv is vaporization pressure；n is number of bubbles per unit volume；R is bubble radius which is expressed as3.3 Simulation results and analysis3.3.1 Flow characteristic analysisNumerical calculation is carried out with Fluent softwareIn the calculation there are some assumptions as followsReynolds stress The fluid is uncompressible，flow is of thermal insulation，and there is no slip on the wal1Suppose that the opening of valve port is 4 mmthe inlet flow is 120 Lminand the outlet pressure is the pressure of working water circuit，whose absolute pressure is 1MPaFig.4 shows the static pressure isoline along axial symmetry plane in the flow passage of the main valveIt can be seen that at the nozzle between the main valve spool and main valve pocketthe pressure contour is denser and pressure drop is bigger, which lowered to 0.7MPaFig4 Pressure isoline of mainvalve flow passage(MPa)Fig5 shows the velocity vector distribution along axial symmetry plane in main valve flow passageIt can be seen that after fluid enter chamber, spiral vortex is formed near the main valve spool comer, its central pressure is lower, and spiral vortex dissipates fluid kinetic energy by viscous frictionFig5 Velocity vector distributionof main valve3.3.2 Structure optimization and flow field analysisOn the basis of the analysis above，at the nozzle formed by the main spool and main valve pocket，the fluid will diffuse or shrink suddenly as is limited by the structurewhich may cause the streamline changing sharply, spiral vortex appeared on the comer point will dissipate thekinetic energy of the fluidall of which will cause great pressure 1oss In order to improve the performance of water hydraulic directional valvethe structure of nozzle has to be optimized Fig6 shows the comparison of flow passage before and after optimizationIn order to make the streamline smooth，the optimized valve spool is manufactured to be arc transitional surface，which voids appearance of death angleFig6 Comparison of flow passage beforeand after optimizationSimulation and computation of flow passage of the optimized main valve have been done under the same conditionand the pressure distribution in axial symmetry plane is shown as Fig7It can be seen that at the nozzle where fluid flows into the chamber, the density of pressureisoline decreases，pressure gradient reduces，and pressure loss reduces to 0.3MPa after the structure is optimizedFig7 Pressure isoline of flowpassage after optimization(MPa)The distribution of velocity vector after optimization along with axial symmetry plane is shown as Fig8Fig8 Velocity vector distributionof flow passage after optimizationThere is no spiral vortex on the corner point of main valve near the nozzle，so the optimized structure effectively restrains the appearance of low pressure area in the fluid field4 Experiment and Data Analysis41 Experiment device and methodThe water hydraulic directional valve designed is made of stainless materia1its rated pressure is 14 MPaand maximum flow up to 120 LminIn order to prove the correction of design principle and simulation results, experiments on both static and dynamic characteristics of the valve have been doneThe experiment method refers to related national standard GB 810687 of similar experiments of oil hydraulic directional valve The experiment has been done on the test rig of State Key Laboratory of Fluid Power Transmission and Control ofZheJiang University,Chinaas is shown in Fig.9Fig9 Test rig of water hydraulic componentsFig10 shows the schematic diagram of this experimentAs the medium of water is strongly corrosive， all components of this system are of stainless materialsFig10 Test principle of water hydraulic directional valve1Conversion 2Conversion motor 3 Tap water hydraulic pump4Filter 5Relief valve 6Thermometer 7 Pressure transducer8Valve tested 9Oneway throttle 1 0Flow meterDuring the experiment， relief valve 4 regulates the entrance pressure of the valve being checked，rotation speed of the variablefrequency electric motor 2 is regulated by frequencytransformer 3，which adjusts the discharge flow of water hydraulic pump 1The outlet backing pressure of the valve 9 is adjusted by oneway throttle valve 8 and is measured by flow meter4.2 Experiment results4.2.1 Flow-pressure difference experiment of water hydraulic directional valveIn the experiment of pressure lossrelief valve 4 serves as safety valve whose safety pressure is 18MPaThe valve tested is charged and then its spool is on the position of throughflowTo make the amount of fluid flowing through the valve 9 increase gradually from zero to rated flow by adjusting the discharge flow of water hydraulic pump，and choose several points to measure each points discharge pressure， based on which the valves flow-Pressure difference performance curve can be achievedThe outlet backing pressure of the valve tested 9 can be adjusted by oneway throttle valve 8The value of the flow is read out on the flow meter 1 0，the pressure of inlet and outlet display on the indicating instrument of pressure transducer 7Comparison of the characteristic of flowPressure difference between the result of simulation and experimentis shown as Fig.11Fig.11 Characteristic curve of qvpFrom Fig.11，it can be seen that，for qv=l5 Lmin，the pressure difference between inlet and outlet mainly results from the main valve passage and increases slowly almost like a linear as the flow increasesIn addition，the test result is bigger than the simulation resultThis is because the pressure loss in the test is the sum of the pressure loss of main valve and pilot valve while the optimized result from simulation and computation only includes the pressure loss of main valveFrom the comparison of the structure of main valve before and after optimization，it can be noticed that the optimized pressure loss of main valve decreases notablyAttention should be paid to that for qv 30 Lmin the result of simulation shows that the pressure loss between inlet and outlet decreases as the flow increases；however, this case does not appear, which indicates that there is much discrepancy for the simulation when the flow is smal14.2.2 Experiment of dynamic characteristics of water directional valveAdjust the overflow valve 4 and oneway throttle valve，make the pressure of inlet Pi of the tested valve 9 be the rated pressure 14MPa，and the pressure of outlet P。be the given backing pressure， the amount of fluid flowing through the tested valve is 80 of maximum flowThencharge and discharge the tested valve under rated voltage and the data acquisition system picks the dynamic response curve of the tested water hydraulic directional valveas is shown in Fig.12Fig12 Dynamic response curve of waterhydraulic directional valveFrom Fig.12，the pressure decreasing time t1 is smaller than 0.05 sthe pressure increasing time t2 is smaller than 0.05 sand the charging time and discharging time are almost the same The direction change is quick， the pressure peak produced while reversing is decrease 6 ，and the reversing shock is small，which indicates good dynamic response characteristics423 Experiment on the life of water hydraulic directional valveRespectively set the pressure of inlet pressure of the tested valve to be variable value and the pressure of outlet P。to be remained the specified backing pressure and the amount of fluid flowing through the tested valve to be 100 Lmin， continuously charge and discharge the electromagnet of the tested valve up to l0000 times，and then check the main components of the tested valve，there should be no damage inordinate wearFigs13(a)，13(b)show the response curve of continuous directional change under pressure of 12MPa and 14MPa It is clarified that the dynamic responsive characteristics of the valve are nearly uniform，and direction change is reliable and prompt5 Conclusions(1)This new water hydraulic directional valves pressure loss is small under rated conditionand its speed of directional change is fast while its hydraulic shock is weaktherefore，good dynamic characteristics are obtainedIn the life experimentsthe directional valve operates normally, and its direction change is reliableThe performance of this kind is comparable to the same kind oil hydraulic valveFig13. Life test curve of water hydraulic directional valve(2)As for its leakage，traditional clearance sealing is taken place by directional sealing And for the contradiction of