基于数字样机的4M20型压缩机故障分析方法研究

发布时间：2018-05-19 06:46

本文选题：往复式压缩机 + 撞缸故障　；参考：《华东理工大学》2017年硕士论文

【摘要】：基于数字样机的虚拟试验方法近年来在国防、船舶、航空航天、汽车等制造行业得到了广泛应用。在以计算机可视化图形仿真基础建立的数字样机上,通过开展虚拟试验,并结合实物样机进行试验数据校正的方法,具有试验成本低、周期短、试验数据重复性好和数据可视化等特点,故越来越受到工程学界的重视。因此对该试验方法在工程上的应用研究具有重要的学术研究意义和重大工程应用价值。上海氯碱化工股份有限公司使用的4M20型往复式氢气压缩机是烧碱装置氢气压缩单元的关键机组。两台压缩机中的B机一级压缩系统因活塞杆拉伸发生了多次撞缸故障,对安全生产造成了严重影响。本课题针对其撞缸故障进行分析,采用数字样机建模方法,开展了相关理论分析和试验测试工作,寻找故障原因并提出改进,以确保生产设备的平稳运行。本文建立了该压缩机的数字原型样机进行试验,研究中分别采用Solidworks软件、ADAMS软件和ANSYS软件,模拟往复式压缩机在各种工况下的工作形态,对往复式压缩机一级压缩系统进行动力学仿真和有限元分析。同时,使用测试仪器对活塞杆拉伸段的化学成分、金相结构和表面状态进行测试,并将数字样机测试的结果和物理试样测试的结果进行对比分析。将基于数字样机的虚拟试验方法应用于该氢气压缩机的故障分析过程中,可以直观得到可视化的活塞杆受力工况下的载荷图谱和应力分布图谱,通过与物理试样测试数据对比,证明得到用于分析活塞杆受力的数据是可信真实的。该试验方法可用于工程故障案例分析,具有实用可靠和可视化的特点。
[Abstract]:The virtual test method based on digital prototyping has been widely used in defense, ship, aerospace, automobile and other manufacturing industries in recent years. In the digital prototype built on the basis of computer visual graphic simulation, the method of virtual test and test data correction combined with physical prototype has the advantages of low test cost and short period. Because of its good repeatability and visualization, more and more attention has been paid to the test data. Therefore, it is of great academic significance and great engineering application value to study the application of this test method in engineering. The 4M20 reciprocating hydrogen compressor used by Shanghai chlor-alkali chemical co., Ltd is the key unit of hydrogen compression unit of caustic soda plant. The first stage compression system of B machine in the two compressors has suffered many cylinder failures due to piston rod drawing, which has seriously affected the safety of production. Based on the analysis of the cylinder collision fault, the paper uses the digital prototype modeling method, carries out the relevant theoretical analysis and test work, finds out the causes of the failure and puts forward some improvements to ensure the smooth operation of the production equipment. In this paper, the digital prototype of the compressor is established for test. In the study, Solidworks software Adams and ANSYS software are used to simulate the working pattern of reciprocating compressor under various working conditions. The dynamic simulation and finite element analysis of the first stage compression system of reciprocating compressor are carried out. At the same time, the chemical composition, metallographic structure and surface state of the tensile section of the piston rod were measured by means of a test instrument, and the results of the digital prototype test and the physical sample test were compared and analyzed. The virtual test method based on digital prototype is applied to the fault analysis of the hydrogen compressor. The visual load and stress distribution charts of the piston rod under the loading condition can be obtained directly, and compared with the test data of the physical sample. It is proved that the data obtained for the analysis of piston rod force is credible and true. The test method can be used in engineering fault case analysis and has the characteristics of practicality, reliability and visualization.
【学位授予单位】：华东理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TQ114.2;TQ051.21

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