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1.5m3单轨抓斗起重机设计【11张图纸】【带三维部分装置】【Word+CAD全套设计】
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目 录
1绪论1
1.1起重机的意义1
1.2单轨抓斗起重机国内外研究状况2
1.3单轨抓斗起重机的发展趋势：2
1.4单轨抓斗起重机的研究内容：4
2 总体方案确定及基本参数5
2.1总体方案确定5
2.2基本参数5
3 抓斗计算6
3.1 抓斗的几何尺寸6
3.2撑杆铰点位置确定：8
3.2.1 滑轮组倍率8
3.2.2钢丝绳计算8
3.3滑轮直径的确定9
3.4抓斗强度计算9
4 起升机构13
4.1传动比的计算13
4.2 机构效率14
4.3制动器的计算15
4.4卷筒装置18
5 起升机构减速箱25
5.1轴的计算25
5.2 齿轮校核（以第一对传动齿轮为例）36
6 运行机构41
6.1 传动比的计算41
6.2 运行摩擦阻力42
6.3 电动机容量的初选42
6.4 制动器计算44
6.5 验算电动机打滑45
结束语46
参考文献47
致谢48
1绪论
1.1起重机的意义
起重机械是用来对物料起重、运输、装卸和安装等作业的机械设备，它可以减轻体力劳动、提高劳动生产率或在生产过程中进行某些特殊的工艺操作，实现机械化和现代化。
起重机在搬运物料时，经历着上料、运送、卸料以及回到原处的过程，因此，起重机受的载荷是变化的，是一种间歇动作的机械。起重机一般由机械、金属结构和电气等三大部分组成。机械方面是指起升、运行、变幅和旋转等机构，即起重机一般是多动作的。轻小型起重设备一般是但动作的。
本设计为单轨抓斗起重机设计。当起重量不大时，多采用电动单轨起重机。这种起重机的特点是小车可以走到另一跨去，本设计侧重于机械方面的设计。主要机构有：起升机构、运行机构。
起升机构用来实现货物的升降，它是任何起重机械不可或缺的一部分，是起重机中最重要与最基本的结构。起升机构工作的好坏将直接影响到整台起重机的工作性能。起重机构主要由驱动装置、传动装置、卷绕系统、取物装置与制动装置组成。本设计的起重机起升机构采用电动葫芦。电动葫芦属于轻小型起重设备。它是将电动机、减速机构、卷筒等紧凑地集合成一体的起重机构。它可以单独使用，也可以作为电动单轨起重机、电动单梁或双梁起重机的小车来使用。由于电动葫芦结构非常紧凑，通常由厂家专门生产，价格便宜，从而得到了普遍的应用。电动葫芦可备有小车，以便在工字梁的下翼缘上运行，是吊重在一定范围内移动。钢丝绳电动葫芦工作安全可靠，起升速度较高，故在本设计中被采用。同时，为了减轻自重，减少零件数目，采用了锥形转子电动机。
运行机构的任务是使起重机或载重小车作水平运动。运行机构有无轨运行和有有轨运行之分。本设计采用有轨运行方式。这种方式在专门铺设的钢轨上运行，负荷能力大，运行阻力小。运行装置主要由运行支撑装置运行驱动装置两大部分组成。本设计着重于电动小车的设计。
设计过程中，首先要确定总体的设计方案，然后各部件机构、尺寸及相互间的连接方式等，最后对部件中各零件进行校核。
1.2单轨抓斗起重机国内外研究状况
随着现代工业的迅速发展，电子计算机的广泛应用，系统工程、优化工程、创造性工程、人机工程等现代化理论的发展，大大加快了现代工业的发展进程，使社会生产力又跃上了一个新水平。当今世界工业生产，由于市场竞争的需要，生产方式由单一品种的大批量向着多品种的变批量方向发展。30年代以来，物料搬运技术仅指的是各类起重运输设备，而90年代的物料搬运系统逐渐增加了许多自动化内容，包括自动识别、自动导向、自动计数、自动称重等。为了使生产和流动能够紧密配合，构成更大、更高效的物流系统，计算机技术得到了广泛的应用，单轨抓斗起重机的很多工作将被机器人和其它机器所取代。
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1ApplicationApplicationApplicationApplication andandandand developmentdevelopmentdevelopmentdevelopmentOfOfOfOf casecasecasecase basedbasedbasedbasedreasoningreasoningreasoningreasoning ininininfixturefixturefixturefixturedesigndesigndesigndesignAbstract:Abstract:Abstract:Abstract: Based on the case baseddesigning(CBD)methodology,thefixture similarity is in two respects: thefunction and the structure information.Then, the computer aided fixture designsystemiscreatedoncasebasedreasoning (CBR),in which the attributesof the main features of workpiece andstructure of fixture as case index codeare designed for the retrieve of thesimilar cases, and the structure andhierarchical relation of case library aresetupforstore.Meanwhile,thealgorithmbasedontheknowledgeguided in the retrieve of the similarcases, the strategy of case adapt at ionand case storage in which the case identif cat ion number is used to distinguishfrom similar cases are presented. Theapplicationofthesysteminsomeprojects improves the design efficiencyand gets a good result .Keywords:Keywords:Keywords:Keywords:casebasedreasoning;fixturedesign;computeraided design(CAD)Fixtures are devices that serveas the purpose of holding the workpiecesecurelyandaccurately,andmaintaining a consistent relationshipwithrespecttothetoolswhilemachining.Becausethefixturestructure depends on the feature of theproduct and the status of the processplanning in the enterprise, its design isthe bottleneck during manufacturing,whichrestrainstoimprovetheefficiency and leadtime. And fixture2design is a complicated process, basedonexperiencethatneedscomprehensive qualitative knowledgeaboutanumberofdesignissuesincludingworkpiececonfiguration,manufacturing processes involved, andmachining environment. This is also avery time consuming work when usingtraditionalCADtools(suchasUnigraphics, CATIA or Pro/E), whichare good at performing detailed designtasks, but provide few benefits fortaking advantage of the previous designexperience and resources, which areprecisely the key factors in improvingthe efficiency. The methodology of casebasedreasoning(CBR)adaptsthesolution of a previously solved case tobuild a solution for a new problem withthe following four steps: retrieve, reuse,revise, and retain 1. This is a moreuseful method than the use of an expertsystemtosimulatehumanthoughtbecause proposing a similar case andapplying a few modifications seems tobe self explanatory and more intuitivetohumans.Sovariouscasebaseddesignsupporttoolshavebeendevelopedfornumerousareas2-4,such as in injection molding and design,architectural design, die castingdiedesign, process planning, and also infixture design. Sun used six digitals tocompose the index code that includedworkpieceshape,machineportion,bushing, the 1stlocating device, the 2ndlocating device and clamping device5.But the system cannot be used for otherfixture types except for drill fixtures,and cannot solve the problem of storageof the same index code that needs to beretained, which is very important inCBR6.1 Construction of a Case Index and3Case Library1.1 Case indexThecaseindexshouldbecomposedofallfeaturesoftheworkpiece,whicharedistinguishedfrom different fixtures. Using all ofthem wouldmake the operation inconvenient. Because the forms of theparts are diverse, and the technologyrequirementsofmanufacture intheenterprise also develop continuously,lots of features used as the case indexwill make the search rate slow, and themainfeatureunimportant,forthereason that the relative weight which isallotted to every feature must diminish.And on the other hand, it is hard toinclude all the features in the caseindex.Therefore,consideringthepracticality and the demand of rapiddesign, the case index includes both themajor feature of the workpiece and thestructure of fixture. The case index codeis made up of 16 digits: 13 digits forcase features and 3 digits for caseidentification number.The first 13 digits represent 13features. Each digit is corresponding toan attribute of the feature, which maybe one of“*”, “？”, “1”, “2”,“A” , “B” , “Z” , etc. In which,“*” means anyone, “?” uncertain,“0” nothing.The system rules: fixture type,workpiece shape, locating model cannotbe “*”or“?”. When the system isdesigned, the attribute information ofthe three items does not have theseoptions,whichmeansthecertainattribute must be selected.The last three digits are the caseidentification number, which means the13 digits of the case feature are the4same, and the number of these threedigits is used for distinguishing them.The system also rules: “000”is aprototypecase,whichisusedforretrieval, and other cases are “001”,“ 002 ” ,which are used forreferencecasestobesearchedbydesigners. If occasionally one of themneeds to be changed as the prototypecase, first it must be required to applyto change the one to “000”, and theformer is changed to referential caseautomatically.The construction of the case indexcode is shown in Fig.1.1.2 Case libraryThe case library consists of lots ofpredefined cases. Case representation isone of the most important issues in casebased reasoning. So compounding withthe index code,.1.3 Hierarchical form of CaseThestructuresimilarityofthefixture is representedas the wholefixture similarity, components similarityand component similarity. So the wholefixture case library, components caselibrary,componentcaselibraryoffixtureareformedcorrespondingly.Usuallydesigninformationofthewhole fixture is composed of workpieceinformation and workpiece procedureinformation, which represent the fixturesatisfyingthespecificallydesigningfunction demand. The whole fixturecase is made up of function components,which are described by the functioncomponentsnames and numbers. Thecomponentscaserepresentsthemembers.(functioncomponentand5other structure components ，maindriven parameter, the number, and theirconstrain relations.)The componentcase (the lowest layer of the fixture) isthe structure of function component andothercomponents.Inthemodernfixturedesigntherearelotsofparametric standard parts and commonnon standard parts. So the componentcaselibraryshouldrecordthespecification parameter and the way inwhich it keeps them.2 Strategy of Case RetrievalInthecasebaseddesignoffixtures ,the most important thing is theretrieval of the similarity, which canhelp to obtain the most similar case, andto cut down the time of adaptation.According to the requirement of fixturedesign, the strategy of case retrievalcombinesthewayofthenearestneighbor and knowledge guided. That is,first search on depth, then on breadth;the knowledge guided strategy means tosearch on the knowledge rule from rootto the object, which is firstly searchedby the fixture type, then by the shape ofthe workpiece, thirdly by the locatingmethod. For example, if the case indexcode includes the milling fixture offixture type, the search is just for allmillingfixtures,thenforboxofworkpiece shape, the third for 1plane+2pine of locating method. If there is nomatch of it, then the search stops ondepth, and returns to the upper layer,and retrieves all the relative cases onbreadth.Retrieval algorithms:1)Accordingtothecaseindexinformationoffixturecaselibrary,search the relevant case library;2)Match the case index code withthe code of each case of the case library,6and calculate the value of the similaritymeasure;3)Sorttheorderofsimilaritymeasure, the biggest value, which is themost analogical case.Similarity between two cases isbased on the similarity between the twocases.features.Thecalculationofsimilarity measure depends on the typeof the feature. The value of similaritycan be calculated for numerical values,for example, compareWorkpiece withthe weight of 50kg and 20kg. The valuecan also be calculated between nonnumerical values, for example, now thefirst 13 digits index code is all nonnumericalvalues.Thesimilaritymeasure of a fixture is calculated asfollows:where S is the similarity measureof current fixture, n is the number of theindex feature,is the weight of eachfeature,is the similaritymeasure of the attributeof the i2thfeature with the attributeof relativefeature of the j-th case in the caselibrary.Atthesametime, the value countsas follows:.Whereis the value of the indexattribute of the i-th feature, andis7the value of attribute of the relative i-thfeature of the j-th case in case library.So there are two methods to selectthe analogical fixture. One is to set thevalue.Ifthevaluesofsimilaritymeasure of current cases were less thana given value, those cases would not beselected as analogical cases. When thecase library is initially set up, and thereare only a few cases, the value can besetsmaller.Iftherearelotsofanalogical cases, the value should getlarger. The other is just to set thenumber of the analogical cases (suchas10), which is the largest value ofsimilaritymeasurefromthesortedorder.3CaseadaptationandCaseStorage3.1 Case adaptationThemodificationoftheanalogical case in the fixture designincludes the following three cases:1) The substitution of componentsand the component;2) Adjustingthedimensionofcomponents and the component whilethe form remains;3) The redesign of the model.If the components and componentof the fixture are common objects, theycan be edited, substituted and deletedwith tools, which have been designed.3.2 Case storageBefore saving a new fixture case inthecase library, the designermustconsider whether the saving is valuable.Ifthecasedoesnotincreasetheknowledge of the system, it is notnecessary to store it in the case library.If it is valuable, then the designer mustanalyzeitbefore savingittoseewhetherthecaseisstoredasaprototype case or as reference case. A8prototype case is a representation thatcan describe the main features of a casefamily. A case family consists of thosecases whose index codes have the samefirst 13 digits and different last threedigits in the case library. The last threedigits of a prototype case are always“000” . A reference case belongs to thesame family as the prototype case andis distinguished by the different lastthree digits.From the concept that has beenexplained, the following strategies areadopted:1) If a new case matches anyexisting case family, it has the samefirst 13 digits as an existing prototypecase, so the case is not saved because itis represented well by the prototypecase. Or is just saved as a referencecase (the last 3 digits are not “000”,and not the same with others) in thecase library.2) If a new case matches anyexisting case family and is thought tobebetteratrepresentingthiscasefamily than the previous prototype case,then the prototype case is substituted bythisnewcase,andthepreviousprototype case is saved as a referencecase.3) If a new case does not matchany existing case family, a new casefamily will be generated automaticallyand the case is stored as the prototypecase in the case library.4ProcessofCBRinFixtureDesignAccording to the characteristics offixture design, the basic information ofthe fixture design such as the name offixture, part, product and the designer,etc. must be input first. Then the fixturefile is set up automatically, in which all9componentsofthefixtureareputtogether.Thenthemodeloftheworkpiece is input or designed. Thedetailedinformationabouttheworkpiece is input, the case index codeis set up, and then the CBR begins tosearch the analogical cases, relying onthe similarity measure, and the mostanalogicalcaseisselectedout.Ifneeded, the case is adapted to satisfythe current design, and restored into thecaselibrary.Theflowchartoftheprocess is shown in Fig.3.5 Illustrating for Fixture Design byCBRThis is a workpiece (seeFig.4). Itsmaterial is 45# steel. Its name is seat.Its shape is block, and the product batchsize is middle, etc.Afixture is turningfixture that serves to turn the hole,which needs to be designed.The value of feature, attribute,case index code and weight of theworkpiece is show n in Tab.2.10Through searching, and calculatingthe similarity, the case index code of themostsimilarcaseis19325513321402000, and the detailedinformation is show n in Tab. 3.The similarity is calculated asfollows:So the value of similarity measureofthefixturewhichneedstobedesigned with the most analogic
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