ZL50装载机滚柱式超越离合器失效分析及设计工艺研究

发布时间：2018-12-25 19:59

【摘要】：自20世纪80年代至今,ZL50型轮胎式装载机一直是中国国内装载机的主力机型。滚柱式超越离合器与液力变矩器联合使用在装载机上,具有车辆通过性强、自动无级变速、自动防止发动机过载等诸多优点,是装载机传动系统的最常见结构之一。本文简单介绍了超越离合器的相关背景知识和装载机的相关知识,简单介绍了滚柱式超越离合器的工作过程以及滚柱式超越离合器在装载机传动系统中的作用。对于滚柱式超越离合器的设计及工艺分析,最常见的假设都是超越离合器的滚柱和内环凸轮均匀受力。而在实际工况中,超越离合器的所有滚柱按照理想状态均匀受力是很少存在的,并且,超越离合器的微观上的受力不均匀,往往是导致早期疲劳源的主要原因。本文介绍了有限元法的相关知识,然后对ansys和ansys workbench软件进行简单介绍,并根据装载机传动系统的实际工况,以地面附着条件将导致轮胎打滑限制发动机动力的发挥为条件确定了工作载荷,通过动力匹配计算,系统地对滚柱式超越离合器进行了受力分析；在此基础上对超越离合器滚柱均匀受力和不均匀受力都进行了有限元分析。本文介绍了滚柱式超越离合器的主要失效形式,然后通过对滚柱式超越离合器失效反馈数据和制造过程制造过程的分析,总结影响滚柱式超越离合器失效产生的因素。最后分析了结构参数和制造误差对离合器失效的影响。本文在对滚柱式超越离合器的失效分析与受力分析的基础上,在结构设计、材料设计、工艺设计等方面提出了提高超越离合器可靠性的措施。通过内环凸轮和隔离环的材料、加工工艺等提出改进措施,提高它们的可靠性,并对隔离环和弹簧定位进行结构优化,改善它们的受力状态,使之更加趋于合理。通过大量的实践和改进,ZL50型超越离合器的故障率大幅度的下降,由异常波动时期的4%-5%下降到1%甚至0.5%以内,并且进一步通过了过程稳定控制,达到了ISO 9000国际标准的产品性能要求。
[Abstract]:Since 1980 s, ZL50 tire loader has been the main type of domestic loader in China. Combined use of roller overrunning clutch and hydraulic torque converter in loader has many advantages, such as strong vehicle passing, automatic stepless speed change, automatic prevention of engine overload, and so on. It is one of the most common structures of loader transmission system. This paper briefly introduces the background knowledge of overrunning clutch and the relative knowledge of loader, and briefly introduces the working process of roller overrunning clutch and the function of roller overrunning clutch in the drive system of loader. For the design and process analysis of the roller overrunning clutch, the most common assumption is that the roller and the inner ring cam of the overrun clutch are subjected to uniform force. However, in the actual working conditions, all the rollers of the overrunning clutch are rarely subjected to uniform forces according to the ideal state, and the uneven force on the micro level of the overrunning clutch is often the main cause of the early fatigue source. This paper introduces the knowledge of finite element method, and then introduces the software ansys and ansys workbench simply, and according to the actual conditions of the loader transmission system, The working load is determined under the condition that the ground attachment condition will lead to the tire skidding and limiting the engine power. The force analysis of the roller overrunning clutch is carried out systematically through the dynamic matching calculation. On this basis, the finite element analysis of uniform force and uneven force on the roller of overrunning clutch is carried out. This paper introduces the main failure forms of the roller overrunning clutch, and then summarizes the factors that affect the failure of the roller overrunning clutch through the analysis of the failure feedback data and the manufacturing process of the roller overrunning clutch. Finally, the effects of structural parameters and manufacturing errors on clutch failure are analyzed. On the basis of failure analysis and force analysis of roller overrunning clutch, this paper puts forward some measures to improve the reliability of overrunning clutch in the aspects of structure design, material design, process design, etc. Through the material of inner ring cam and isolation ring, processing technology and so on, the improvement measures are put forward to improve their reliability, and the structure of isolation ring and spring positioning are optimized to improve their stress state and make them more reasonable. Through a great deal of practice and improvement, the failure rate of the ZL50 type overrunning clutch has been greatly reduced from 4- 5% in the abnormal fluctuation period to 1% or even 0.5%, and the process stability control has been further passed. Meet the ISO 9000 international standards of product performance requirements.
【学位授予单位】：山东大学
【学位级别】：硕士
【学位授予年份】：2011
【分类号】：TH133.4;TH243

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