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3立方米单向侧卸式装载机工作装置设计含开题及5张CAD图

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装载机俗称“铲车”,可以实现短距离运输及物料转运功能,在矿产、公路、港口等建筑施工领域广泛应用。过去三十年,随着经济快速发展,城市化建设的速度也不断加快,带动了工程机械行业的高速发展,装载机的产量也得到大幅增长。激烈的装载机市场竞争,也使得制约其技术发展的问题日益突出。国内装载机用户通常对价格十分敏感,对于装载机,新产品开发时的设计方案直接决定了大部分的制造和销售成本,同时设计方案的成熟度不仅直接决定了开发周期的长短,也会影响产品的可靠性和售后服务成本,导致产品的市场占有率下降,降低企业的市场竞争优势。一方面是质量控制不到位以及产能快速扩张带来的成本增加,另一方面是激烈的销售竞争导致的售价和利润率过低,因此国内装载机市场急需通过技术创新,实现产品升级,提高质量以及可靠性I2。许多装载机企业已开始增强自身的研发能力,探索更现代的设计方法(如研究设计理论、研究虚拟仿真技术在产品开发时应用、提高设计质量、科学验证缩短开发周期等)。装载机的关键零部件主要有发动机、桥箱、工作装置和车架等,整机生命周期的长短很大程度上取决于这些关键零部件的寿命。由于发动机、桥箱等零部件多由零部件制造厂商主导技术升级,因此在现有发动机及动力系统的基础上,如何通过工作装置的改进来提高产品的可靠性和生产效率是各主机厂关注的重点之一。目前关于工作装置优化设计的研究有很多,但大多数局限于理论层面,能否有效地指导实际工作,尚须必要的试验验证和实践的检验。因此对于工作装置的开发,为了适应当前技术升级的需求,进一步提高设计质量和方案的成熟度,急需探索更现代、更科学的方法。产中十分重要的生产工具。经过近90年的发展,装载机技术在人机工程、驾驶安全、油耗和生产效率方面,取得显著的进步,尤其一些先进的跨国公司,如卡特彼勒、小松、沃尔沃等十分注重对技术研发和创新的投入,致力于技术驱动市场的研究。当前高端装载机的主要技术特点是:广泛应用电控技术、液压伺服操纵、发动机执行严格的排放标准、采用自动变速箱及湿式制动桥等。上述大型跨国公司,起步早、技术积累丰富、也非常重视技术创新,因此目前装载机的技术升级很大程度上还是他们主导。1970年后,AutoCAD等计算机辅助制图技术得到迅速发展,与传统手工绘图相比,从图纸绘制、修改到存储、打印等都非常高效,很受技术人员青睐,开始快速在各个企业的研发中应用例。卡特彼勒、沃尔沃和小松等国外企业也在70年代初开始引进计算机辅助制图工具用于装载机的开发,工作装置的设计、评估和试验方法也随着计算机技术的发展不断改进1992年的时候沃尔沃的Ericson H发明了一种TP-link的工作装置(如图1-1所示),并申请了专利;这种机构的平动性非常好,举升物料时不容易撒料且结构相对简单,一直沿用至今7。1999年卡特彼勒的DeneveJA开发了一种“箱式”的TP-link 工作装置(如图1-2所示),在沃尔沃TP-link工作装置的基础上,将前部改为双摇臂结构8。到了1971年,中国的首台铵接轮式装载机Z450(即后来的ZL50)顺利完成,为国内的装载机行业拉开了序幕。1978年,根据国家标准部要求,天工院用“L”代表轮式取代“4,将Z450改为ZL.50:并在此基础上,制定了中国装载机的一系列标准9。后来,机械部又推荐用“9”代替“Z”作为装载机代码,并将9后面的数字更新为额定载重量的代码,将最后一位数字改为配置代码,如临工LG953,厦工XG955等等由于该命名规则并不是强制的,部分企业并没有执行。装载机在中国起步很晚,但得益于国内广大的市场需求,发展却是十分迅速。进入90年代后期,中国的装载机市场容量已超过世界总量的30%。到了21世纪,随着国民经济的快速发展,基础建设的遍地展开,国内装载机销量急速增长,跃居世界第-一。对于各个装载机生产企业,从综合实力比较,卡特彼勒、小松、沃尔沃等知名跨国集团排名靠前。国内装载机品牌按市场占有率依次为:临工(沃尔沃合资公司)、龙工、柳工、徐工、山工2008被卡特彼勒全资收购)、雷沃、厦工等。当前国产装载机的主要配置为:采用直喷式发动机、机械式换档的变速箱、定量液压系统(系统的工作压力较低,一般在16-18Mpa)、简单的电气系统(除液位及温度传感器外,基本无其它电控系统),总体的操作平顺性和舒适性要远低于国外高端品牌。但近几年,随着国内装载机厂商的技术更新,新一代国产品牌的高端装载机已经逐步与世界接轨,比如采用电喷式发动机(排放升级)。电控全自动变速箱,变量系统或定变量系统转向泵为变量泵),增加了电控和电气监测方面的功能,同时也更加注重整机外观和驾驶室内的操作舒适性I20I。中国装载机经历了50多年的快速发展,目前在各工程领域应用广泛,如于公路、铁路、建筑、港口、矿山等工程。国产轮式装载机也正在致力于打破低水平、低质量、低价位的印象与定位,从功能型产品逐步向经济实用型产品过度,从仿制逐步向高水平、高质量、中价位的自主开发产品过渡I21-22。近几年国内各大装载机生产商也不断和一些高校科研机构,开展了诸多方面的研究工作。长安大学博士万一品对装载机工作装置进行了仿真分析、载荷测试和疲劳寿命研究,包括仿真工作装置各交点的动态载荷,并通过有限元进行疲劳评估及试验验证I23-28。吉林大学马文星教授致力于装载机等工程机械的液力变矩系统和液力传动理论的研究l29-32。2015年吉林大学王松林在马文星教授的指导下,对 ZL50装载机的液力传动系统进行了节能研究133。随着国内装载机主机厂越来月重视产品的可靠性和效率,不断加大研发投入,致力于技术创新和升级。比如,柳工、临工加大跟采埃孚和沃尔沃的深度合作,促进国产自动变速箱和湿式桥的应用,将极大改善装载机传动系统的性能和燃油经济性。又如,对装载机工作装置的连杆机构改进:因其直接影响铲装效率,是重点要改进的对象。一直以来,工作装置等结构件可靠性的提升得益于国内巨大的装载机保有量,即主要还是依据客户反馈进行质量改进和提升。对于工作装置的设计从运动分析方面看,虽然借助于现代AutoCAD. Catia。uG.Cero等计算机辅助绘图工具,不仅改善了设计质量,还大大提高了设计效率,但设计方法仍是相对单一。以各个构件的几何关系和解析法为基础,计算量还是比较大,仍有很多改进的空间。从强度分析方面看,对工作装置各构件的强度分析以单一工况为主,企业内部尚没有非常成熟和系统的方法来评估工作装置的疲劳寿命。因此,在尽可能保证轻量化设计的同时,最大可能提高强度并保证疲劳寿命,则是很多企业要面临的问题。在20世纪初,装载机开始生产并得到广泛使用,早期装载机以蓄力作为动力的来源。动力装载机于20世纪20年代才出现;30年代,装载机在外观结构上发生了重大的突破,轮胎装载机也是在这一时期出现的;液压技术、柴油机于40年代开始应用到装载机上,这些先进技术的应用促使了四轮驱动装载机的诞生,装载机的牵引力也得到相应的增大,工作效率也得到大幅度提升3;到了50年代,汽车技术的迅猛发展,促进了工程机械专用底盘的普遍使用,与此同时液力变矩器在装载机上得到推广使用,这直接导致了液力机械传动模式的诞生。这种传动模式使得装载机牵引力性能得到大幅度提升,工作过程中能根据外界阻力的不断变化来不断调整本机速度;60年代初期较接型装载机的出现是装载机在结构上又一重大创新,其机动性能和转向性能较之前也得到很大程度上的改善。此后不久出现了电力驱动装载机,成功的将装载机设计水平推上了一个新高度P21。近年来设计人员不断对装载机工作装置的结构进行改进,使其工作效率不断提高,从而使装载机的应用范围越来越广,这样就促进了装载机制造业的发展,不但产品数量不断增加,而且产品质量也不断提高,新型号、新系列也不断涌现出来22。20世纪60年代以前,装载机的铲斗容量一般不超过4m3。随着工作装置结构的不断创新,铲斗容量得到大幅度提升。目前世界上最大的轮胎式装载机是美国“克拉克”设备公司在加拿大的分公司生产的“密执安”675型装载机,其斗容18.4 m3,如果用来装载比重较小的散状物料时,斗容高达27.5 m3。它用两台(315KW、684KW)总功率为999KW的发动机并联驱动。目前世界上最大的履带式装载机是日本小松D155S型,斗容为4.5m3,发动机功率为257KW123。装载机的产量和质量以美国为首,其次是日本和联邦德国。吉林大学的龚捷lI等学者以探求一条在铲掘作业过程中装载机耗能最少的轨迹为目标,分别给出了理想条件下的直线和曲线铲掘作业工况对应的轨迹方程,然后分别对两种铲掘作业过程进行运动学建模,实现了从直角坐标向空间坐动力:当下常用的装载机仍以柴油发动机作为动力来源,常与涡轮增压器配套使用来达到提高发动机自身功率和降低燃料消耗的目的。特大型装载机没有这么大的柴油机来适应其要求,“克拉克”公司在它的675型特大型装载机上,用两台柴油机并联起来解决这个问题。采用这种连接方式,不仅解决了单一柴油机动力不足的问题,同时也提高了装载机的工作效率。传动系统:近年来,小型液压驱动的轮式装载机得到了迅速的发展。在美国,全液压传动的轮式装载机占全部轮式装载机的40%以上。大中型轮式装载机大多仍采用液力机械传动,只是在一些传动元件上做了改进,采用了新技术。如美国“卡特皮勒”公司把双泵轮液力变矩器用在988B型轮胎式装载机上。双泵轮液力变矩器有内外两个泵轮,通过操作手柄可控制其中某一个泵轮进行工作,也可控制两个同时进行工作。因而使得变矩器的吸收功率和输出功率可在一个相当大的范围内进行无级匹配,充分利用发动机所做的功,提高装载机效率,进而提升了装载机的整机性能。制动系统:装载机的制动系统可认为由制动系统,停车制动和紧急制动三部分构成。制动器的形状以盘式居多B6。这种制动器作用时不仅可以强制循环油冷却,而且还可以产生较大制动力的面积,并且磨损后能自动补偿间隙。因此,这种制动器制动效果相对更好,而且耐用使用寿命长。工作装置:由于近年来装载机应用范围扩大到矿山,除一般的装载机作业外,还要进行一定的铲掘作业,因此近年盛行反转式单摇臂连杆机构。2.2工作装置的设计要求及主要技术参数2.2.1设计要求在工作装置设计过程中应首先考虑以下几点要求-(1)设计的基本要求:设计生产的装载机应具有良好的作业性能:铲斗插入物料时所受的插入阻力要小:铲掘物料时可提供较大的掘起力:在作业过程中整机功耗小,工作机构的构件受力均匀,强度寿命满足使用要求:结构和杆件尺寸符合生产要求:结构应简单,布局要紧凑,便于制造和维修。第3章工作装置设计在第二章中,主要阐述了连杆机构的设计方法,由于装载机的每一个作业循环中,工作装置各个部件的受力大小和受力方向也是不断变化的,因此确定了连杆机构的设计后,还需研究装载机的典型应用工况,分析连杆机构的受力。接下来装载机典型应用工况的筛选和定义,是进行工作装置设计、改进的重点。另外还需综合考虑其它方面,如倾翻稳定性、在不同位置时的掘起力和举升力是否足够、各个较接点的受力对轴承设计的影响等等。其中某些参数还取决于其它的系统参数,如掘起力除了跟连杆机构有关,还跟液压系统的选型密切相关:因此连杆机构的设计过程必然是一个不断改进的过程。本章节以L120为例阐述装载机的典型工况及其工作装置的设计。LoaderLoaders are commonly known as forklifts, which can realize short-distance transportation and material transfer functions, and are widely used in construction fields such as minerals, highways, and ports. In the past three decades, with the rapid economic development, the speed of urbanization has also been accelerating, which has led to the rapid development of the construction machinery industry, and the output of loaders has also increased substantially. The fierce competition in the loader market has also made the problems restricting its technological development increasingly prominent. Domestic loaders users are usually very price-sensitive. For loaders, the design plan during the development of new products directly determines most of the manufacturing and sales costs. At the same time, the maturity of the design plan not only directly determines the length of the development cycle, but also affects it. The reliability of the product and the cost of after-sales service have led to a decline in the market share of the product and reduced the companys market competitive advantage. On the one hand, the cost increase caused by the inadequate quality control and the rapid expansion of production capacity. On the other hand, the price and profit margins caused by the fierce sales competition are too low. Therefore, the domestic loader market is in urgent need of technological innovation to achieve product upgrades and improvements. Quality and reliability I2. Many loader companies have begun to enhance their own R&D capabilities and explore more modern design methods (such as research on design theories, research on the application of virtual simulation technology in product development, improvement of design quality, scientific verification and shortening the development cycle, etc.).The key components of the loader mainly include the engine, the bridge box, the working device and the frame, etc. The life cycle of the whole machine largely depends on the life of these key components. Since most parts such as engines and axle boxes are upgraded by component manufacturers, how to improve the reliability and production efficiency of products through the improvement of working devices on the basis of existing engines and power systems is the concern of various OEMs. One of the key points. At present, there are many researches on the optimal design of working devices, but most of them are limited to the theoretical level. Whether it can effectively guide the actual work still needs necessary experimental verification and practical verification. Therefore, for the development of working devices, in order to adapt to the needs of current technological upgrades, and to further improve the design quality and the maturity of the scheme, it is urgent to explore more modern and scientific methods.A very important production tool in production. After nearly 90 years of development, loader technology has made significant progress in terms of ergonomics, driving safety, fuel consumption and production efficiency. In particular, some advanced multinational companies such as Caterpillar, Komatsu, Volvo, etc. have paid great attention to technology research and development. And investment in innovation, dedicated to technology-driven market research. The main technical features of current high-end loaders are: extensive use of electronic control technology, hydraulic servo control, strict emission standards for engines, automatic gearboxes and wet brake bridges. The above-mentioned large-scale multinational companies started early, have accumulated rich technologies, and attach great importance to technological innovation. Therefore, the current technological upgrade of loaders is largely dominated by them.After 1970, AutoCAD and other computer-aided drawing technologies have developed rapidly. Compared with traditional manual drawing, it is very efficient from drawing, modification, storage, and printing. It is very popular with technicians and began to be quickly applied in the research and development of various enterprises. example. Foreign companies such as Caterpillar, Volvo and Komatsu also began to introduce computer-aided drawing tools for the development of loaders in the early 1970s. The design, evaluation and test methods of working devices have also been continuously improved with the development of computer technology.In 1992, Ericson H of Volvo invented a TP-link working device (as shown in Figure 1-1) and applied for a patent; this mechanism has very good translational properties and is not easy to spread when lifting materials. The material and the structure are relatively simple, and it has been used until now. 7. In 1999, Caterpillars DeneveJA developed a box-type TP-link working device (as shown in Figure 1-2), which was used in the Volvo TP-link working device. On the basis of this, the front part is changed to a double rocker structure 8.In 1971, Chinas first ammonium wheel loader Z450 (later ZL50) was successfully completed, which opened the door to the domestic loader industry. In 1978, in accordance with the requirements of the National Standards Department, Tiangong Institute replaced 4 with L Representative Wheel, and changed Z450 to ZL.50: and on this basis, it formulated a series of standards for Chinas loaders. 9. Later, the Ministry of Machinery recommended to use 9 instead of Z as the loader code, and the number after 9 was updated to the code for the rated load, and the last digit was changed to the configuration code, such as Lingong LG953, XG955, etc. Because this naming rule is not mandatory, some companies have not implemented it.Loaders started very late in China, but thanks to the vast domestic market demand, their development is very rapid. In the late 1990s, Chinas loader market capacity has exceeded 30% of the worlds total. In the 21st century, with the rapid development of the national economy and the spread of infrastructure construction, the sales of domestic loaders have grown rapidly, ranking first in the world. For each loader manufacturer, Caterpillar, Komatsu, Volvo and other well-known multinational groups rank top in terms of comprehensive strength. According to the market share, the domestic loader brands are: Lingong (Volvo joint venture), Lonking, Liugong, Xugong, Shangong (wholly acquired by Caterpillar in 2008), Lovol, Xiagong, etc. The main configurations of the current domestic loaders are: direct injection engine, mechanical shift gearbox, quantitative hydraulic system (the working pressure of the system is low, generally 16-18Mpa), simple electrical system (except for liquid level and Besides the temperature sensor, there is basically no other electronic control system), and the overall operating smoothness and comfort are much lower than those of foreign high-end brands. However, in recent years, with the technological update of domestic loader manufacturers, a new generation of high-end loaders of domestic brands have gradually integrated with the world, such as the use of electronic injection engines (emission upgrades). Electronically controlled automatic gearbox, variable system or fixed variable system (steering pump is variable pump), increased the functions of electronic control and electrical monitoring, but also paid more attention to the appearance of the whole machine and the operating comfort in the cab I20I.Chinas loaders have experienced rapid development for more than 50 years and are currently widely used in various engineering fields, such as highways, railways, construction, ports, mines and other projects. Domestic wheel loaders are also committed to breaking the impression and positioning of low-level, low-quality, and low-cost products, gradually shifting from functional products to economical and practical products, and from imitation to high-level, high-quality, and medium-priced autonomous products. Development product transition I21-22. In recent years, major domestic loader manufacturers have also continued to conduct research in many aspects with some university scientific research institutions.Dr. Wan Yipin from Changan University conducted simulation analysis, load test and fatigue on the working device of the loaderLife study, including simulation of the dynamic load at each intersection of the working device, and fatigue evaluation and test verification through finite element I23-28.Professor Ma Wenxing of Jilin University is devoted to the research of hydraulic torque conversion system and hydraulic transmission theory of loader and other construction machinery l29-32.In 2015, Wang Songlin of Jilin University, under the guidance of Professor Ma Wenxing, conducted energy-saving research on the hydraulic transmission system of the ZL50 loader 133.As domestic loader OEMs pay more and more attention to the reliability and efficiency of their products, they continue to increase R&D investment and are committed to technological innovation and upgrading. For example, Liugong and Lingong increased their in-depth cooperation with ZF and Volvo to promote the application of domestic automatic transmissions and wet bridges, which will greatly improve the performance and fuel economy of the loader drive system. Another example is the improvement of the linkage mechanism of the loaders working device: because it directly affects the efficiency of shoveling, it is the focus of improvement.For a long time, the improvement of the reliability of working devices and other structural parts has benefited from the huge domestic inventory of loaders, that is, quality improvement and enhancement are mainly based on customer feedback.Regarding the design of the working device, from the perspective of motion analysis, although with the help of modern AutoCAD. Catia. Computer-aided drawing tools such as uG.Cero not only improve the design quality, but also greatly increase the design efficiency, but the design method is still relatively simple. Based on the geometric relationships and analytical methods of each component, the amount of calculation is still relatively large, and there is still much room for improvement.From the perspective of strength analysis, the strength analysis of each component of the work device is mainly based on a single working condition, and there is no very mature and systematic method to evaluate the fatigue life of the work device within the enterprise. Therefore, while ensuring the lightweight design as much as possible, increasing the strength and ensuring the fatigue life as much as possible is a problem faced by many companies.At the beginning of the 20th century, loaders began to be produced and widely used. Early loaders used power storage as a source of power. Power loaders only appeared in the 1920s; in the 1930s, a major breakthrough occurred in the appearance and structure of loaders, and tire loaders also appeared during this period; hydraulic technology and diesel engines began to be applied to loaders in the 1940s. The application of these advanced technologies prompted the birth of the four-wheel drive loader, the traction of the loader was also increased, and the work efficiency was also greatly improved3; in the 1950s, the rapid development of automobile technology promoted the special purpose of construction machinery. The widespread use of the chassis and the popularization of hydraulic torque converters on loaders at the same time directly led to the birth of the hydraulic mechanical transmission mode. This transmission mode greatly improves the traction performance of the loader. During the working process, the speed of the machine can be adjusted continuously according to the continuous changes of external resistance; the appearance of the more connected loader in the early 1960s is another important structural aspect of the loader. Innovative, its maneuverability and steering performance have also been greatly improved compared to before. Shortly thereafter, electric drive loader appeared, which successfully pushed the design level of loader to a new height P21.In recent years, designers have continuously improved the structure of the loaders working device to increase its work efficiency, which has made the loaders application range wider and wider, which has promoted the development of the loader manufacturing industry, and not only the number of products continues to increase. , And the quality of products is constantly improving, and new models and new series are constantly emerging 22.Before the 1960s, the bucket capacity of loaders generally did not exceed 4m3. With the continuous innovation of the working device structure, the bucket capacity has been greatly increased. At present, the worlds largest tire loader is the Michigan 675 loader produced by the Canadian branch of the American Clark Equipment Company, with a bucket capacity of 18.4 m3. If it is used to load bulk materials with a small specific gravity At the same time, the bucket capacity is as high as 27.5 m3. It uses two (315KW, 684KW) engines with a total power of 999KW to drive in parallel.The worlds largest crawler loader is currently the Komatsu D155S, with a bucket capacity of 4.5m3 and an engine power of 257KW123.The output and quality of loaders are led by the United States, followed by Japan and the Federal Republic of Germany.1.2.2 Current status of domestic researchOnly in the 1950s did my country begin to produce small loaders based on automobile chassis, equipped with working devices, and front-wheel drive rear wheels. This kind of loader can only be used to load loose light materials because of its low traction. In the early 1960s, a department specializing in the management of scientific research and production of construction machinery was established, a scientific research institution was established, and a factory specializing in the production of loaders was prepared. During this period, my country began to develop loaders with special chassis. More successful examples include: Z4H2 semi-rotary loaders trial-produced by Chengdu Construction Machinery Factory and Tianjin Construction Machinery Research Institute in 1967; Tianjin Mechanical Engineering Research Institute and Liuzhou Engineering Research Institute in 1970 The ZL50 loader, which was trial-produced by the machinery factory, uses a twin-turbo torque converter and a planetary power shift gearbox, wide-base low-pressure tires, a reversing single-link mechanism working device, and dump-connected steering 125l. And designed a three-in-one mechanism-that is, the use of a one-way clutch to solve the three problems of the loader after stalling, steering and diesel exhaust braking when going down a long slope, making the machine more suitable for northern my country Low temperature, long slopes in southern mountains.The appearance of the ZL series loader independently designed and produced in my country is very similar, and the degree of commonality of parts is also very high. For example, the general parts of ZL50 and ZLA40, ZL30 and ZL20 loaders are all up to 70%, which creates favorable conditions for mass professional production.Modern design methodology integrates finite element analysis, dynamic design, and reliability design. It has developed rapidly in the past two decades and has been widely used in mechanical product design. In foreign countries, the related research on working devices is not independent, but closely integrated with finite element analysis. Italys Fiat Aris and Caterpillar, Japans Komatsu Manufacturing Co., Ltd. and other large loader manufacturing companies have also applied modern design methodology to the design of loader products and achieved satisfactory results. In China, on the one hand, the Ministry of Machinery has entrusted relevant units to carry out research on the design and production technology of loaders and their key components. On the other hand, some domestic construction machinery manufacturers have introduced advanced manufacturing technologies from major loader manufacturers such as Germany and the United States to promote The rapid development of domestic loaders I271.The following are examples of optimization of loaders by some domestic scholars:Qi Jianjia 28 of Heilongjiang Institute of Technology used MATLAB software as the platform to conduct in-depth optimization research on the loader working device using the ant colony algorithm. Through the analysis of the optimization results, it can be seen that the linkage transmission ratio is significantly increased after optimization, and the work efficiency of the loader is obtained. Significantly improved.Zhang Songqing 29l and other scholars of Henan Mechanical and Electrical College summarized and analyzed the influence of the working device on the performance of the loader, aiming to improve the overall performance of the loader, established a mathematical model of the working device, and related the mathematical model. The research work has obtained satisfactory research results, and effectively solved the technical problems existing in the design and production of the loader.Scholars such as Gong Jie lI of Jilin University aim to find a trajectory that consumes the least energy of the loader during the shoveling operation. They respectively give the trajectory equations corresponding to the straight and curved shoveling operating conditions under ideal conditions, and then respectively The kinematics modeling of the two shovel and excavation operation processes has realized from the Cartesian coordinates to the space sittingPower: At present, the commonly used loaders still use diesel engines as power sources, and are often used in conjunction with turbochargers to achieve the purpose of increasing the engines own power and reducing fuel consumption. The extra-large loader does not have such a large diesel engine to meet its requirements. Clark company uses two diesel engines in parallel on its 675 extra-large loader to solve this problem. Using this connection method not only solves the problem of insufficient power of a single diesel engine, but also improves the working efficiency of the loader.Transmission system: In recent years, small hydraulically driven wheel loaders have developed rapidly. In the United States, full hydraulic drive wheel loaders account for more than 40% of all wheel loaders. Most of the large and medium-sized wheel loaders still use hydraulic mechanical transmission, but some transmission elements have been improved and new technologies have been adopted. For example, the American Caterpillar company uses a double-pump wheel hydraulic torque converter on the 988B tire loader. The double pump wheel hydraulic torque converter has two pump wheels inside and outside, and one of the pump wheels can be controlled to work by operating the handle, or two pump wheels can be controlled to work at the same time. As a result, the absorbed power and output power of the torque converter can be steplessly matched within a considerable range, making full use of the work done by the engine, improving the efficiency of the loader, and thereby improving the overall performance of the loader.Braking system: The braking system of the loader can be considered to be composed of three parts: braking system, parking brake and emergency braking. The shape of the brake is mostly B6 disc. This kind of brake can not only force the circulating oil to cool, but also generate a larger area of braking force, and can automatically compensate for the gap after wear. Therefore, the braking effect of this kind of brake is relatively better, and it has a long service life.Working device: In recent years, the scope of application of loaders has been expanded to mines. In addition to general loaders, certain shoveling operations must be carried out. Therefore, the inverted single-rocker linkage mechanism has become popular in recent years.Some companies in the United States, the Federal Republic of Germany and the United Kingdom have developed a forced unloading bucket. Its rear arm is a movable push plate. When the bottom of the bucket is in a horizontal position or a slight inclination, the push plate moves forward. Forcibly push the material out and unload it. The advantage of this forced unloading bucket is that it can unload all the viscous materials from the bucket cleanly, enhance the unloading height and unloading distance: reduce the height of the material falling during unloading, thereby reducing the impact on the transport vehicle 37.Hydraulic system: With the popularization and application of hydraulic technology, hydraulic systems have also been diversified and rapidly developed. Recently, the pressure of the hydraulic system of loaders is as high as 30MPa, far exceeding the general pressure specified by the industry of 15MPa-20MPa. In recent years, some new settings have been adopted in the hydraulic system of the loader so that the power of the engine can be fully utilized during the operation of the loader. For example, the hydraulic system of the US Case 380 and Ford A62, A64, and A65 loaders are equipped with a hydraulic automatic control valve. This valve can make the valve not shovel, and its full power can be used for traction. Similarly, when traction is not required, all its maximum power is used for shoveling.Operating system: In recent years, the operating system of loaders has evolved to simplify, and more and more loaders can control the loader to complete forward, reverse, gear shift, boom lifting and lowering, and buckets with a single lever.The lifting force is larger than when the forward rotation linkage mechanism is adopted, which is convenient for shoveling work. During the lifting process of the bucket, the swing range of the bucket back and forth is small (small change in the rear angle), and less material is scattered during the full-load transportation: when unloading, the unloading impact generated by the loader is small, which is not conducive to shaking off the sand: After the bucket is unloaded at the highest position, the bucket is sufficiently automatic to level when the boom is lowered (as shown in Figure 2-4(e): the number of links in the reversing linkage mechanism is small, so the rocker arm is driven It is relatively small. In order to improve this defect, the size of the component needs to be increased. However, after the size of the component is increased, the connecting rod will easily touch the side wall of the truck when unloading (as shown in Figure 2-4(f), and it will also easily block the driving. Sight of the operator: Considering the advantages and disadvantages of the structural style of the reversal linkage mechanism, this structural style is mostly used for shoveling rocks on the ground (as shown in Figure 2-4(d) and during a shovel excavation operation. It is rarely used in the work of up and down the material and the excavation work below the ground as shown in Figure 2-4(c)-Due to its limitations, the reversal double-link mechanism structure is currently less used in the production of loaders. The working device with a reversal single link structure has the advantages of simple structure, easy installation, and materials that are not easy to fall off. The working device of the ZL series loaders in my country is a reversal single-link structure. The American Caterpillar company has gradually transformed the 988 type loader with a forward-rotating double-link working device into a reversing single-link working device. Type 988B 44.2.2 Design requirements and main technical parameters of the working device2.2.1 Design requirementsThe following requirements should be considered first in the design process of working devices-(1) Basic requirements for design:The loader designed and produced should have good working performance: the insertion resistance of the bucket when inserting the material should be small: it can provide a larger digging force when shoveling the material: the power consumption of the whole machine is small during the operation, and the working mechanism The components are uniformly stressed, and the strength life meets the requirements of use: the structure and rod size meet the production requirements: the structure should be simple, the layout should be compact, and it is easy to manufacture and maintain.(2) Special requirements for design: If the bucket width and bucket capacity are too large, the insertion resistance acting on the bucket when shoveling materials is large, resulting in a small full load factor. Therefore, the width and volume of the bucket should be selected reasonably in the design to reduce the insertion resistance of the bucket during the shovel loading process, and achieve the performance requirements of full loading, stable transportation, and clean unloading-The loader shovel loads the materials to the designated place for unloading. In order to prevent the materials from falling out of the bucket, the lifting and translational requirements of the bucket should be considered. Excessive pursuit of bucket lifting and translation will not only bring difficulties to the design work, but the produced loaders cannot meet the requirements of absolute translation in a strict sense, and excessive pursuit of translation will inevitably reduce other performance of the work device. . Combined with the analysis of the actual use of the loader, it is only necessary to satisfy that the inclination angle of the bucket changes within a certain range during the lifting process, and the loaded material does not fall from the bucket. The inclination angle of the pile materials is about 27 (the natural pile angle is about 1:2), and the natural rest of the loose materials3 Mathematical model for optimal design of loaders working device3.1 Introduction to Virtual Prototyping TechnologyVirtual prototype technology is a new technology that effectively solves the problems in the traditional design and manufacturing process. It is a comprehensive application technology I7 that includes modeling technology, multi-domain simulation technology, and interactive user interface technology. It is based on the evolution of CAD and DFM technology. It further integrates information technology, advanced manufacturing technology and advanced simulation technology, and applies these technologies to the entire process of complex systems, so as to better comprehensively manage the entire system 8 .The traditional loader design and manufacturing process is to first demonstrate the design scheme, and then proceed to product production. In order to verify whether the design plan is reasonable, it is first necessary to manufacture a physical prototype according to the design plan, and then perform related experiments on the prototype (such as braking performance, traction performance, climbing ability, etc.). Through the experiment, the unreasonable part of the design plan is found, and the design is modified. Plan, reproduce the prototype for verification. Only through the iterative design-test-modify-test process can the design scheme meet the design requirements I0. This process is complicated and lengthy, especially for systems with complex structures that cannot adapt to the instant market environment, and the continuous manufacturing of physical prototypes will also increase development costs. In the actual design and production process, many manufacturers have to reduce the number of prototype experiments in order to ensure that their products can be introduced to the market on time, so that there are unresolved problems when the products are on the market. However, manufacturing physical prototype verification invisibly prolongs the development cycle of new products. Market competition under the fierce background is not conducive to the long-term development of the company-Virtual prototype technology is used in the entire process of product development and design. From the perspective of improving the overall performance of the product, the design technology and analysis technology are effectively combined for use by engineers. The detailed dimensions of the parts and the constraint relations between the parts are virtualized on the computer to assemble the mechanical system to establish the overall mathematical model of the product 61. Use the system simulation module to simulate the motion form of the system in various real scenes, observe and test the mutual motion of each component. Continue to modify and improve the design plan until a plan that meets the design requirements is obtained, and then a physical prototype is manufactured for verification.The virtual prototype technology can be used to simulate the working motion trajectory and force changes of the product in a virtual environment, and it can also perform some experiments that are difficult for the physical prototype to help designers quickly judge whether the design plan is reasonable. Virtual prototype technology is used throughout the entire process of product development. The use of virtual prototype technology can improve the work efficiency of designers, shorten the research and development cycle, improve product design quality, reduce production costs, and benefit the long-term development of the enterprise (63-64) .Chapter 3 Working Device DesignIn the second chapter, the design method of the linkage mechanism is mainly explained. Because the force size and direction of the various components of the working device are constantly changing in each operation cycle of the loader, the linkage mechanism is determined After the design, it is necessary to study the typical application conditions of the loader and analyze the force of the linkage mechanism. Next, the selection and definition of typical application conditions of loaders are the focus of work device design and improvement. In addition, other aspects need to be considered comprehensively, such as overturning stability, whether the breakout force and lifting force are sufficient at different positions, and the influence of the force of each relatively contact on the bearing design, and so on. Some of these parameters also depend on other system parameters. For example, the breakout force is not only related to the linkage mechanism, but also closely related to the selection of the hydraulic system: Therefore, the design process of the linkage mechanism must be a process of continuous improvement. This chapter takes L120 as an example to illustrate the typical working conditions of the loader and the design of its working device.3.1 Determination of typical working conditions of loaderThe most common application of loaders is to load trucks. The movement route during work is very similar to the Y or V type (as shown in Figure 3-1). This article will uniformly refer to the operation of the loader as Y cycle. The general working process of ¥ cycle operation is as follows. The bucket cuts into the material pile horizontally (position 1), digs the material and collects the bucket (position 2), turns backwards and forwards while raising the bucket (position 3), and unloads after approaching the truck (position 4). Retract the bucket, turn to lower the boom at the same time, and cut into the pile again to start the next cycle. Several key positions of the bucket are shown in position 1-4 in Figure 3- Translational analysisDuring the whole lifting process from the ground position to the highest position, the smaller the change of the bucket retraction angle, the better the translational performance. When the bucket is shoveling loose objects obliquely (such as silt, gravel, etc.), in order to avoid material falling during the lifting process, it is usually required that the bucket has good translational mobility (I*4). The load calculation program can be used to easily obtain the changes in the entire lifting height and the bucket angle, and can be compared and analyzed with the reference model as required, as shown in Figure 3-21.The change of bucket angle is also closely related to the initial angle of the bucket (that is, the angle between the bottom of the bucket and the horizontal ground). In this chapter, the following three different initial states are selected for analysis (1 dump bucket to the bottom, 2 bucket flat, 3 bucket to the bottom), and compared with other models (as shown in Figure 3-24), the angle changes The smaller means the better the translation.From Figure 3-24, it can be seen that the translational performance of the reference model is better than that of the L120. The main reason is that the working device of the reference model is a forward-rotating eight-bar linkage structure, which is more translational than the Z-link mechanism. Better. From the state shown in 3 on the right side of the figure, it can be seen that the bucket angle of the reference model is almost unchanged from a certain height; the angle of the L120 has a slight change. The state of the middle 2 is mainly used when the linkage mechanism is matched with a flat fork (similar to the forklifts flat fork). Considering that the L120 is matched with a bucket and the restriction of the reverse six-bar linkage mechanism itself, and it is already at the back of the bucket The anti-overflow plate is added, so the current translational performance of L120 is accepted, and its connecting rod geometry is no longer adjusted.If the translation cannot meet the product positioning requirements, you can refer to the method in Chapter 2 to partially adjust the parameters of the comparison point or the connecting rod, and then perform analysis and evaluation again. 装载机 装载机通常被称为“叉车”,可以实现短距离运输和物料运输功能,并广泛用于矿产,公路和港口等建筑领域。在过去的三十年中,随着经济的快速发展,城市化的速度也在加快,这导致了工程机械行业的快速发展,装载机的产量也大大增加了。装载机市场的激烈竞争也使限制其技术发展的问题日益突出。家用装载机的用户通常对价格非常敏感。对于装载机,新产品开发期间的设计计划直接决定了大部分制造和销售成本。同时,设计计划的成熟度不仅直接决定了开发周期的长短,而且也影响了开发周期。产品的可靠性和售后服务成本已导致产品的市场份额下降,并降低了公司的市场竞争优势。一方面,由于质量控制不力和生产能力的迅速扩大而导致成本增加。另一方面,激烈的销售竞争造成的价格和利润率太低。因此,国内装载机市场迫切需要技术创新,以实现产品的升级和改进。质量和可靠性I2。许多装载机公司已经开始增强自己的研发能力,并探索更多现代设计方法(例如设计理论研究,虚拟仿真技术在产品开发中的应用研究,提高设计质量,科学验证并缩短开发周期,等等。)。装载机的关键部件主要包括发动机,桥架,工作装置和机架等。整机的使用寿命在很大程度上取决于这些关键部件的寿命。由于引擎和轴箱等大多数零件都是由组件制造商升级的,因此如何在现有引擎和动力系统的基础上通过改进工作装置来提高产品的可靠性和生产效率是各个OEM的关注点。关键点之一。目前,关于工作装置的优化设计的研究很多,但大多限于理论水平。它能否有效地指导实际工作还需要进行必要的实验验证和实践验证。因此,为了开发工作装置,以适应当前技术升级的需要,并进一步提高设计质量和方案的成熟度,迫切需要探索更多的现代科学方法。生产中非常重要的生产工具。经过近90年的发展,装载机技术在人机工程学,驾驶安全,燃油消耗和生产效率方面取得了长足的进步。尤其是一些先进的跨国公司,例如卡特彼勒,小松,沃尔沃等,都非常重视技术研发。并进行创新投资,致力于技术驱动的市场研究。当前高端装载机的主要技术特征是:广泛使用电子控制技术,液压伺服控制,严格的发动机排放标准,自动变速箱和湿式制动桥。上述大型跨国公司起步较早,已积累了丰富的技术,并高度重视技术创新。因此,当前的装载机技术升级主要由装载机主导。1970年之后,AutoCAD和其他计算机辅助制图技术得到了迅速发展。与传统的手工绘图相比,它在绘图,修改,存储和打印方面非常有效。它在技术人员中非常受欢迎,并开始迅速应用于各种企业的研发中。例子。卡特彼勒(Caterpillar),沃尔沃(Volvo)和小松(Komatsu)等外国公司也在1970年代初开始引入计算机辅助绘图工具来开发装载机。随着计算机技术的发展,工作设备的设计,评估和测试方法也得到了不断改进。1992年,沃尔沃的Ericson H发明了TP-link工作装置(如图1-1所示)并申请了专利。这种机制具有很好的平移特性,在举升物料时不容易扩散。材质和结构相对简单,至今一直使用。 7. 1999年,Caterpillar的DeneveJA开发了一种“盒式” TP-link工作装置(如图1-2所示),该装置用于沃尔沃TP-link工作装置。在此基础上,前部变为双翘板结构8。1971年,中国第一台铵轮装载机Z450(后称ZL50)成功完成,这为国内装载机行业打开了大门。 1978年,按照国家标准局的要求,天宫研究所用“ L”“代表轮”代替了“ 4”,并将Z450改为ZL.50:在此基础上,制定了一系列针对中国标准的标准。装载机。 9。后来,机械部建议使用“ 9”代替“ Z”作为装载机代码,并将9之后的数字更新为额定负载的代码,最后一位更改为配置代码,例如临工LG953,XG955等。“由于此命名规则不是强制性的,因此一些公司尚未实施。”。装载机在中国起步很晚,但由于国内市场的巨大需求,它们的发展非常迅速。在1990年代后期,中国的装载机市场容量已超过世界总量的30。进入21世纪,随着国民经济的快速发展和基础设施建设的普及,家用装载机的销售迅速增长,跃居世界第一。对于每个装载机制造商而言,卡特彼勒,小松,沃尔沃和其他知名跨国集团在综合实力方面均名列前茅。根据市场份额,国产装载机品牌有:临工(沃尔沃合资公司),龙工,柳工,徐工,山工(卡特彼勒于2008年全部收购),雷沃,夏刚等。目前国产装载机的主要配置是:直喷式发动机,机械变速箱,定量液压系统(系统的工作压力较低,一般为16-18Mpa),简单的电气系统(液位和温度传感器除外)基本上没有其他电子控制系统),整体操作的平滑度和舒适度远低于国外高端品牌。但是,近年来,随着国产装载机制造商的技术更新,国产品牌的新一代高端装载机已逐渐与世界融合,例如使用电子喷射发动机(排放升级)。电控自动变速箱,可变系统或固定可变系统(转向泵为可变泵),增加了电子控制和电气监控功能,但也更加注意了整机的外观和I20I驾驶室的操作舒适性。中国的装载机经历了50多年的快速发展,目前已广泛用于公路,铁路,建筑,港口,矿山和其他项目等各个工程领域。家用轮式装载机还致力于打破低水平,低质量和低成本产品的印象和定位,从功能性产品逐渐转变为经济型产品。实用的产品,从模仿到高级,高质量和中等价位的自主产品。 开发产品过渡I21-22。 近年来,国内主要的装载机制造商还继续与一些大学科研机构进行多方面的研究。长安大学万一品博士对装载机的工作装置进行了仿真分析,载荷测试和疲劳试验寿命研究包括模拟工作装置每个交叉点的动态载荷,以及通过有限元I23-28进行疲劳评估和测试验证。吉林大学马文兴教授致力于装载机等工程机械的液压转矩转换系统和液压传动理论研究129-32。2015年,吉林大学王松林在马文兴教授的指导下,对ZL50装载机的液压传动系统进行了节能研究133。随着国内装载机OEM越来越关注其产品的可靠性和效率,他们继续增加研发投资,并致力于技术创新和升级。例如,柳工和临工加强了与采埃孚和沃尔沃的深度合作,以促进家用自动变速器和湿桥的应用,这将大大提高装载机驱动系统的性能和燃油经济性。另一个例子是装载机工作装置的连杆机构的改进:由于它直接影响铲土的效率,因此是改进的重点。长期以来,工作装置和其他结构零件的可靠性提高得益于装载机的大量国内库存,即质量的提高和提高主要取决于客户的反馈。关于工作设备的设计,尽管借助了现代AutoCAD,但从运动分析的角度来看。卡蒂亚。 uG.Cero等计算机辅助绘图工具不仅提高了设计质量,而且大大提高了设计效率,但设计方法仍然相对简单。从各部件的几何关系和分析方法来看,计算量仍然比较大,还有很大的改进空间。从强度分析的角度来看,工作装置各组成部分的强度分析主要是基于单一的工作条件,在企业内部还没有非常成熟,系统的方法来评估工作装置的疲劳寿命。因此,在尽可能地确保轻量化设计的同时,增加强度并尽可能地确保疲劳寿命是许多公司面临的问题。20世纪初,装载机开始生产并广泛使用。早期的装载机使用蓄能器作为动力源。动力装载机仅在1920年代出现;在1930年代,装载机的外观和结构发生了重大突破,在此期间也出现了轮胎装载机。液压技术和柴油发动机在1940年代开始应用于装载机。这些先进技术的应用催生了四轮驱动装载机的诞生,装载机的牵引力也得到了提高,工作效率也大大提高了3。 1950年代,汽车技术的飞速发展促进了工程机械的特殊用途。底盘的广泛使用以及液压扭矩转换器在装载机上的普及同时直接导致了液压机械传动模式的诞生。这种传输方式大大提高了装载机的牵引性能。在工作过程中,可以根据外部电阻的不断变化来连续调节机器的速度; 1960年代初期,连接性更强的装载机的出现是装载机的另一个重要结构方面。与以往相比,它的创新性,可操纵性和转向性能也得到了极大改善。此后不久,出现了电动装载机,这成功地将装载机的设计水平推到了一个新的高度P21。近年来,设计人员不断改进装载机工作装置的结构以提高其
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本文标题:3立方米单向侧卸式装载机工作装置设计含开题及5张CAD图
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