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工程设计学报  2024, Vol. 31 Issue (6): 810-822    DOI: 10.3785/j.issn.1006-754X.2024.04.112
优化设计     
基于结构功能衍生系数的桥式起重机金属结构优化设计
董青(),张天祥,戚其松,徐格宁
太原科技大学 机械工程学院,山西 太原 030024
Optimization design of metal structure of bridge crane based on structural function derivative coefficients
Qing DONG(),Tianxiang ZHANG,Qisong QI,Gening XU
School of Mechanical Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China
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摘要:

起重机是八大特种设备之一,其结构设计的合理性对于设备安全运行、提质增效至关重要。为此,提出了一种基于结构功能衍生系数的桥式起重机金属结构优化设计方法。首先,利用解释结构模型准确描述了起重机不同零部件之间的相互作用和影响关系,分析了起重机结构的复杂性,识别出对起重机金属结构强度影响较大的参数并对其进行优化设计;其次,在有限元仿真的基础上,将结构功能衍生系数与拟合函数相结合,寻找出最佳的设计参数组合;最后,以300/100 t-30 m通用桥式起重机为工程实例,通过仿真使整机的质量减小了2 035.113 kg,验证了所提方法的有效性。基于结构功能衍生系数的起重机金属结构优化设计方法,解决了传统的优化方法中忽略了起重机各零部件之间复杂的相互作用的问题,可在确保起重机服役安全性的基础上实现其金属结构的轻量化设计。

关键词: 解释结构模型结构功能衍生系数优化设计桥式起重机金属结构    
Abstract:

Crane is one of the eight special equipment, the rationality of its structural design is crucial for the safe operation, quality improvement, and efficiency enhancement of the equipment. Therefore, an optimization design method of metal structure of bridge crane based on structural function derivative coefficients was proposed. Firstly, the interpretive structure model was used to accurately describe the interactions and influence relationships between different parts of the crane, the structure complexity of the crane was analyzed to identify and optimize the parameters that had a significant impact on the strength of metal structure of the crane. Secondly, based on the finite element simulation, the structural function derivative coefficients were combined with fitting functions to find the optimal combination of design parameters. Finally, a 300/100 t-30 m bridge crane was taken as an engineering example, and the mass of the whole crane was reduced by 2 035.113 kg through simulation, and the effectiveness of the proposed method was verified. The optimization design method of metal structure of crane based on structural function derivative coefficients solves the problem that the complex interactions between various parts of crane is ignored in the traditional optimization method, and can realize the lightweight design of metal structure on the basis of ensuring the safety of crane service.

Key words: interpretative structure model    structural functional derivative coefficient    optimization design    bridge crane    metal structure
收稿日期: 2024-02-19 出版日期: 2024-12-31
CLC:  TH 215  
基金资助: 国家自然科学基金资助项目(52105269)
作者简介: 董 青(1989—),女,副教授,博士,从事重大装备数字孪生、疲劳寿命预测、安全评估、报废决策及其相关专业软件开发等研究,E-mail: qingdong@tyust.edu.cn, https://orcid.org/0009-0004-7653-1673
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引用本文:

董青,张天祥,戚其松,徐格宁. 基于结构功能衍生系数的桥式起重机金属结构优化设计[J]. 工程设计学报, 2024, 31(6): 810-822.

Qing DONG,Tianxiang ZHANG,Qisong QI,Gening XU. Optimization design of metal structure of bridge crane based on structural function derivative coefficients[J]. Chinese Journal of Engineering Design, 2024, 31(6): 810-822.

链接本文:

https://www.zjujournals.com/gcsjxb/CN/10.3785/j.issn.1006-754X.2024.04.112        https://www.zjujournals.com/gcsjxb/CN/Y2024/V31/I6/810

图1  起重机金属结构优化设计流程图
图2  起重机组成
符号元素序号元素序号元素序号元素
S1主梁S8小车从动车轮组S15副横梁S22大车主起升电机
S2大车台车梁S9副小车架车轮组S16主起升定滑轮装配S23副起升定滑轮装配
S3大车连接梁S10

小车运行电机

(三合一)

S17主起升动滑轮装配S24副起升动滑轮装配
S4大车台车S18主吊钩组S25副吊钩组
S5大车车轮组S11小车台车S19

主起升卷

筒组

S26副起升卷筒组
S6

大车运行电机

(三合一)

S12小车架S27副减速器
S13副小车架S20主减速器S28副制动器
S7小车主动车轮组S14横梁S21主制动器S29大车副起升电机
表1  起重机元素
图3  起重机初始有向图
元素序号可达集元素序号可达集元素序号可达集
S1{S1, S2, S3, S11, S12, S13}S12{S1, S2, S3, S11, S12, S13}S21

{S1, S2, S3, S11, S12, S13, S14,

S16, S17, S18, S19, S20, S21}

S2{S1, S2, S3,S11, S12, S13}
S3{S1, S2, S3, S11, S12, S13}S13{S1, S2, S3, S11, S12, S13}S22

{S1, S2, S3, S11, S12, S13, S14,

S16, S17, S18, S19, S20, S21, S22}

S4{S1, S2, S3, S4, S11, S12, S13}S14

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18}

S23{S1, S2, S3, S11, S12, S13, S15, S23, S24}
S5{S1, S2, S3, S4, S5, S11, S12, S13}S15

{S1, S2, S3, S11, S12, S13,

S15, S23, S24}

S24{S1, S2, S3, S11, S12, S13, S15, S23, S24}
S6

{S1, S2, S3, S4, S5, S6,

S11, S12, S13}

S16

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18}

S25{S1, S2, S3, S11, S12, S13, S15, S23, S24, S25}
S7{S1, S2, S3, S7, S11, S12, S13}S17

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18}

S26{S1, S2, S3, S11, S12, S13, S15, S23, S24, S26}
S8{S1, S2, S3, S8, S11, S12, S13}S18

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18}

S27

{S1, S2, S3, S11, S12, S13, S15,

S23, S24, S26, S27}

S9

{S1, S2, S3, S9, S11, S12,

S13, S14, S16, S17, S18}

S19

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18, S19}

S28{S1, S2, S3, S11, S12, S13, S15, S23,S24, S26, S27, S28}
S10{S1, S2, S3, S7, S10, S11, S12, S13}S20

{S1, S2, S3, S11, S12, S13,

S14, S16, S17, S18, S19, S20}

S29

{S1, S2, S3, S11, S12, S13, S15, S23,

S24, S26, S27, S28, S29}

S11{S1, S2, S3, S11, S12, S13}
表2  起重机元素的可达集
元素序号先行集元素序号先行集
S1{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S14{S9, S14, S16, S17, S18, S19, S20, S21, S22}
S15{S15, S23, S24, S25, S26, S27, S28, S29}
S2{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S16{S9, S14, S16, S17, S18, S19, S20, S21, S22}
S17{S9, S14, S16, S17, S18, S19, S20, S21, S22}
S3{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S18{S9, S14, S16, S17, S18, S19, S20, S21, S22}
S19{S19, S20, S21, S22}
S4{S4, S5, S6}S20{S20, S21, S22}
S5{S5, S6}S21{S21, S22}
S6{S6}S22{S22}
S7{S7, S10}S23{S15, S23, S24, S25, S26, S27, S28, S29}
S8{S8}S24{S15, S23, S24, S25, S26, S27, S28, S29}
S9{S9}S25{S25}
S10{S10}S26{S26, S27, S28, S29}
S11{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S27{S27, S28, S29}
S12{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S28{S28, S29}
S13{S1, S2, S3, S4, S5, S6, S7, S8, S9, S10, S11, S12, S13, S14, S15, S16, S17, S18, S19, S20, S21, S22, S23, S24, S25, S26, S27, S28, S29}S29{S29}
表3  起重机元素的先行集
图4  基于ISM的起重机零部件层次结构及连接关系

连接

序号

装配连接关系及尺寸符号参数传递关系符号
S22S21主起升电机轴直径—联轴器孔径—制动器轴直径d1Φ1d2主起升电机输出轴转速—联轴器转速n1
S22S12电机底座螺纹孔径—小车架固定孔径—小车架上盖板厚Φ2Φ3x14主起升电机转动产生力—小车架上盖板压力F1
S29S28副起升电机轴直径—联轴器孔径—制动器轴直径d3Φ4d2副起升电机输出轴转速—联轴器转速n2
S29S13电机底座螺纹孔径—小车架固定孔—小车架上盖板厚Φ5Φ6x14副起升电机产生的力—小车架上盖板压力F2
S21S20联轴器孔径—减速器轴直径Φ1d4联轴器转速—减速器输入轴转速n1
S21S12减速器底座螺纹孔径—小车架固定孔径—小车架上盖板厚Φ8Φ9x14减速器转动产生的力—小车架上盖板压力F3
S6S5大车运行电机轴直径—车轮组孔径d5Φ10大车运行电机输出轴转速—车轮组转速n3
S28S27副联轴器孔径—减速器孔径Φ11Φ12副联轴器转速—减速器输入轴转速n2
S28S13副制动器底座螺纹孔径—小车架固定孔径Φ13Φ14副减速器转动产生的力—小车架上盖板压力F4
S20S19主减速器输出轴直径—卷筒组孔径—卷筒轴直径d6Φ15d7起升减速器输出轴扭矩—卷筒扭矩M1
S5S4大车车轮组螺纹孔直径—台车螺纹孔径—台车主副腹板厚Φ16Φ17x7大车车轮组支撑力—大车台车压力F5
S27S26副减速器输出轴直径—副卷筒组孔径—副卷筒轴直径d8Φ18d9副起升减速器输出轴扭矩—副卷筒扭矩M2
S18S17吊钩组孔径—主起升动滑轮组孔径—销轴直径Φ19Φ20d10起重量—钢丝绳抗拉强度Gσ1
S19S17卷筒组卷筒半径—钢丝绳直经—定滑轮组滑轮半径r1d11r2钢丝绳上拉力—抗拉强度—抗压强度F6σ1σ2
S19S12卷筒组螺纹孔径—小车架螺纹孔径—小车架上盖板厚Φ21Φ22x14卷筒组压力—小车架上盖板支撑力F4
S10S7小车运行电机轴直径—小车运行车轮组孔径d12Φ23小车运行电机输出轴—车轮组转速n6
S4S2大车台车连接孔径—台车梁连接孔径—销轴直径Φ24Φ25d13大车台车支撑力—台车梁压力F5
S9S13副小车架车轮组螺纹孔径—副小车架螺纹孔径Φ26Φ27副小车架车轮组支撑力—副小车架压力F7
S26S24副卷筒组卷筒半径—钢丝绳直经—定滑轮半径r3d14r4副起升钢丝绳拉力—抗拉强度—卷筒抗压强度

F8

σ3σ4

S26S13副卷筒组螺纹孔径—副小车架螺纹孔径Φ28Φ29副卷筒组压力—副小车架上盖板支撑力F9
S25S24副吊钩组孔径—副起升动滑轮组孔径—销轴直径Φ30Φ31d15副起重量—钢丝绳抗拉强度G2σ3
S17S16主起升动滑轮半径—钢丝绳直径—定滑轮半径r2d11r5主起升和吊钩组质量—钢丝绳抗拉强度G3σ1
S16S14主起升定滑轮孔径—滑轮轴直径—横梁孔径—横梁主腹板厚—横梁副腹板厚Φ32d16Φ33x12x13主起升和吊钩组滑轮组质量—钢丝绳抗拉强度—横梁抗拉强度G4σ1σ5
S14S12横梁下盖板厚—小车基距—小车架上盖板厚x11l1x14横梁压力—小车架支撑力F10
S8S11小车从动车轮螺纹孔径—台车螺纹孔径—台车主腹板厚Φ34Φ35x16小车从动车轮组支撑力—小车台车压力F11
S7S1小车主动车轮组半径—大车主梁上盖板厚—轨距r6x1l2小车轮压/轨道摩擦系数—轨道摩擦力P1/u1f
S2S1大车台车梁螺纹孔径—大车主梁螺纹孔径—台车梁上盖板厚—主梁下盖板厚

Φ36Φ37

x5x2

大车台车支撑力—主梁上产生的压力F12
S3S2大车连接梁孔径—大车台车梁孔径—销轴直径—大车连接梁腹板厚—大车台车腹板厚

Φ38Φ39

d17x7x9

大车台车与连接梁运行过程中产生的推拉力F13
S24S23副起升动滑轮半径—钢丝绳直径—定滑轮半径r7d18r8副起升和吊钩组质量—钢丝绳抗拉强度G5σ3
S23S15副起升定滑轮孔径—滑轮轴直径—副横梁孔径Φ40d19Φ41副起升量和吊钩组滑轮组质量—钢丝绳抗拉强度—横梁抗拉强度G6σ3σ6
S15S13副横梁下盖板厚—小车基距—副小车架上盖板厚x11l1x14副横梁压力—副小车架支撑力F14
S12S11小车架孔径—小车台车孔径—销轴直径—小车架主腹板厚—小车台车主腹板厚

Φ42Φ43

d20x16x18

小车架压力—小车台车的支撑力F15
S11S1小车台车下盖板厚—主梁上盖板厚—轨距x17x1l2从动小车轮组轮压/轨道摩擦系数—小车轨道摩擦力P2/u1f
S13S1副小车架下盖板厚—主梁上盖板厚—轨距x15x1l2副小车轮组轮压/轨道摩擦系数—小车轨道摩擦力P3/u1f
S13S11副小车架孔径—小车台车孔径销轴直径Φ44Φ45d21副小车架压力—小车台车的支撑力F16
表4  起重机零部件连接关系
图5  起重机关键结构参数示意
结构参数初始值设计范围
桥架结构x12420~28
x22420~28
x3139~17
x4139~17
x53430~38
x62016~24
x73430~38
x8128~16
x92420~28
小车架结构x101612~20
x112016~24
x124036~44
x134036~44
x143632~40
x151612~20
x162420~28
x1753~7
x1853~7
表5  起重机金属结构关键参数的设计范围 (mm)
结构序号

x1/

mm

x2/

mm

x3/

mm

x4/

mm

应力/MPa序号

x5/

mm

x6/

mm

x7/

mm

应力/MPa序号

x8/

mm

x9/

mm

应力/MPa
桥架结构1202099142.961030163096.411982098.586
220241313101.391130203498.632082498.585
32028171775.9612302438100.592182898.584
4242099135.811334163096.4422122098.578
52424131398.611434203498.6123122498.610
62428171757.1315342438100.4824122898.581
7282099139.231638163096.3225162098.595
82824131381.921738203498.5026162498.584
92828171756.5018382438100.3327162898.580
结构序号

x10/

mm

x11/

mm

x12/

mm

x13/

mm

应力/MPa序号

x14/

mm

x15/

mm

x16/

mm

应力/MPa序号

x17/

mm

x18/

mm

应力/MPa
小车架结构112163636147.8810321220158.101933131.08
212204040129.3011321624141.662035130.99
312244444149.9512322028147.742137130.79
416163636146.5013361220148.432253130.91
516204040130.5614361624130.562355130.56
616244444148.9615362028147.812457130.53
720163636145.3316401220134.682573130.85
820204040127.2617401624120.672675130.75
920244444151.9518402028147.862777130.44
表6  不同结构参数下起重机金属结构的最大应力
结构参数参数水平
V1V2V3
桥架结构x1101.3998.6181.92
x2135.8198.6157.13
x3139.2381.9256.50
x4139.2381.9256.50
x598.6398.6198.50
x696.4498.61100.48
x796.3298.50100.33
x898.5898.6198.58
x998.5898.6198.58
小车架结构x10129.30130.56120.67
x11146.50130.56147.81
x12145.33127.26151.95
x13145.33127.26151.95
x14141.66130.56120.67
x15148.43130.56147.81
x16158.10141.66147.74
x17130.99130.56130.44
x18130.91130.56130.53
表7  不同参数水平下起重机金属结构的最大应力 (MPa)
结构参数离差平方和影响因子
桥架结构x1241.70.022 6
x23099.90.289 8
x33639.50.340 1
x43639.50.340 1
x512.40.001 2
x619.812 10.001 9
x718.152 90.001 7
x812.70.001 2
x912.50.001 2
SST10 695.70
小车架结构x10372.650.131 5
x11241.920.0854
x12381.260.134 6
x13381.260.134 6
x14338.970.119 6
x15281.360.099 3
x16574.440.203 3
x17130.180.045 9
x18129.970.045 8
SST2 832.04
表8  起重机金属结构最大应力方差分析
结构参数第1次优化值/mm单调增减情况第2次优化值/mm单调增减情况第3次优化值/mm单调增减情况第3次优化值/mm单调增减情况
桥架结构x124-24-24-24-
x223+22+21+20+
x314-14-14-14-
x414-14-14-14-
x534-34-34-34-
x620-20-20-20-
x734+34+34+34+
x812-12-12-12-
x924-24-24-24-
ΔDCM13.567 52.489 71.411 90.334 1
Y1/MPa102.177 5104.667 2106.079 1106.413 2
小车架结构x1015+141312
x1120-202020
x1239+383736
x1339+383736
x1435+343332
x1516+161616
x1624-242424
x175+555
x185+555
ΔDCM210.863 79.86218.860 57.858 9
Y2/MPa141.423 7151.285 8160.146 3168.005 2
表9  起重机金属结构优化结果
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