Simulation and optimization of crawler chassis of idler replacement robot

doi:10.3785/j.issn.1006-754X.2024.03.217

Chinese Journal of Engineering Design

2024, Vol. 31

Issue (5): 603-613 DOI: 10.3785/j.issn.1006-754X.2024.03.217

Optimization Design

Simulation and optimization of crawler chassis of idler replacement robot

Liyong TIAN(

),Hua AO(

),Ning YU,Rui TANG

School of Mechanical Engineering, Liaoning Technical University, Fuxin 123000, China

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Abstract

In order to meet the needs of idler replacement robot operating on complex road surface and narrow long-distance roadway in coal mine, a crawler chassis with attitude adjustment mechanism was designed, and the mechanical performance analysis and key component optimization for the chassis were conducted based on the terrain characteristics of coal mine. Firstly, the dynamics model of the crawler walking mechanism was established by the multi-body dynamics simulation software RecurDyn, and six classical working conditions were simulated and analyzed. The rationality of the structure design of the crawler walking mechanism was verified by comparing the simulated and theoretical values of the tensioning force and driving torque of crawler. Then, the statics analysis for the attitude adjustment mechanism was conducted in the ANSYS Workbench software, and the topology optimization of its key components was carried out to improve material utilization and reduce weight. Finally, the stability of the crawler chassis was tested by conducting robot driving tests. The results showed that the maximum stress and mass of the transverse platform of the optimized attitude adjustment mechanism were reduced by 13.71 MPa and 36.92%, respectively. The robot could drive stably under different road conditions, and its attitude adjustment mechanism could work normally. The research results can provide reference for the driving performance optimization of crawler coal mine electromechanical equipment under complex working conditions.

Key words： crawler chassis multi-body dynamics simulation topology optimization tensioning force of crawler driving torque

Received: 27 November 2023 Published: 30 October 2024

CLC:

TD 528

Corresponding Authors: Hua AO E-mail: tianliyong2003@163.com;869847215@qq.com

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Cite this article:

Liyong TIAN,Hua AO,Ning YU,Rui TANG. Simulation and optimization of crawler chassis of idler replacement robot. Chinese Journal of Engineering Design, 2024, 31(5): 603-613.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2024.03.217 OR https://www.zjujournals.com/gcsjxb/Y2024/V31/I5/603

更换托辊机器人履带式底盘的仿真与优化

为满足更换托辊机器人在煤矿井下复杂路面上以及狭窄长运距巷道内作业的需求，设计了带有姿态调整机构的履带式底盘，并结合煤矿井下的地形特征对底盘进行力学性能分析和关键部件优化。首先，利用多体动力学仿真软件RecurDyn建立履带行走机构的动力学模型，对6种经典工况进行仿真分析，通过对比履带张紧力和行驶转矩的仿真值与理论值来验证履带行走机构结构设计的合理性。然后，在ANSYS Workbench软件中对姿态调整机构进行静力学分析，并对其关键部件进行拓扑优化，以提高材料利用率并实现减重。最后，通过开展机器人行驶试验来测试履带式底盘的稳定性。结果表明，优化后姿态调整机构横移平台的最大应力降低了13.71 MPa，质量减小了36.92%；机器人在不同路况下均能稳定行驶且其姿态调整机构可正常工作。研究结果可为复杂工况下履带式煤矿机电设备的行驶性能优化提供参考。

关键词： 履带式底盘, 多体动力学仿真, 拓扑优化, 履带张紧力, 行驶转矩

Fig.1 Operating environment of idler replacement robot

技术参数	取值及要求
环境温度/℃	-30~60
外形尺寸（长 $×$ 宽 $× 高$ ）/(m $× m × m$ )	$≤$ 4.50 $×$ 1.14 $×$ 1.60
整机质量/kg	$≤$ 4 500
行驶方式	履带行驶
驱动装置	防爆柴油机（国三标准）
行驶速度/(km/h)	$≥$ 3
爬坡角度/(°)	$≥$ 15
关节驱动方式	液压驱动
液压系统工作压力/MPa	$≤$ 21
控制模式	手动/电液控制
连续工作时长/h	$≤$ 5

Table 1 Main technical parameters of idler replacement robot

Fig.2 Overall structure of idler replacement robot

Fig.3 Three-dimensional model of chassis frame

Fig.4 Structure of unilateral crawler

Fig.5 Force analysis of crawler

Fig.6 Working principle of attitude adjustment mechanism

Fig.7 Overall structure of attitude adjustment mechanism

Fig.8 Working process of lifting and pitching platform

Fig.9 Working process of horizontal, vertical and rotating platforms

Fig.10 Working process of tilting platform

Fig.11 Dynamics model of idler replacement robot

Table 2 Characteristic parameters of different pavement

Fig.12 Schematic of three driving conditions

Fig.13 Tensioning force curves of crawler under different driving conditions

Fig.14 Driving torque curves of crawler under different driving conditions

Fig.15 Three-dimensional model of attitude adjustment mechanism

Fig.16 Finite element model of attitude adjusting mechanism

Fig.17 Stress nephogram of attitude adjustment mechanism

Fig.18 Topology optimization result of horizontal platform

Fig.19 Stress nephogram of optimized horizontal platform

Fig.20 Driving test site of idler replacement robot

Fig.21 Operating test site of attitude adjustment mechanism


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