起重机械风险评估方法与预防性检修策略研究

发布时间：2018-08-02 15:28

【摘要】：起重机械是隐藏危险因素最多,发生事故几率最大,事故后果最严重的机电类特种设备之一。目前,我国起重机械数量年均增长约20%左右,各类起重机械保有量已超过250万台。与此同时,涉及起重机械的伤亡事故占各类伤亡事故的比例也逐年上升。目前我国各地区、各行业发生在起重作业中的伤亡事故约占全部伤亡事故的25%左右。每年涉及起重机械事故的死亡人数在所有机械类事故死亡人数中居首位。因此,加强起重机械的安全管理和事故预防刻不容缓。风险评估是事故预防的前提和基础,目前针对起重机械的系统性安全评估方法欠缺,对于在役尤其是超期服役的起重设备而言,系统而实用的风险评估方法研究具有较大的理论意义和工程实用价值。目前,行业内采用法定定期检验制度来实现起重机械的安全运行和事故预防。该制度对于起重设备的安全运行,在一定程度上起到了基础性保障作用。然而,由于检验项目和检验周期基本固定,不区分企业和设备个体的差异,容易造成对一般设备的过度检验和高风险设备的检验不足；检验结果仅定性表示为“合格”与“不合格”,由于缺少零部件风险的定量计算,其安全状况的评估结果对起重机械事故预防的参考价值有限。论文围绕起重机械风险评估方法与预防性检修策略及若干相关问题开展研究工作,完成了起重机械主要零部件的FMEA分析、失效数据与通用失效概率信息的收集、钢丝绳小样本可靠性试验、起重机械的建模与仿真、零部件风险的定性与定量评估计算、起重机械RCM预防性检修策略的制定、起重机械风险评估实施规范及评估软件的编制等工作,论文具体研究内容如下：(1)在完成380多例起重机事故故障统计分析的基础上,建立了起重机械失效分析数据库。进行了失效模式与影响分析,得出了其全部失效模式,进而分析了对应的失效原因和失效后果。针对钢丝绳的典型失效模式弯曲疲劳和磨损,开展了小样本物理试验,获取了试验条件下的失效数据。设计了起重机零部件失效样本采集表,采用调查统计问卷和深入凌钢、鞍钢、三洋重工等起重机使用和制造企业实地调研等方式,获得了部分起重机零部件的大样本失效数据,进而完成了相应的失效寿命计算。(2)鉴于起重机零部件的现场失效数据通常比较有限,提出了基于Bayes理论的起重机零部件小样本可靠寿命预测方法。根据零部件研制阶段的试验数据和同类或相似部件的相关检测记录确定可靠性评估的验前分布,结合小样本现场可靠性试验数据,应用Bayes理论融合零部件的验前信息和现场试验数据,得到产品可靠寿命的验后分布,进而实现零部件失效寿命的预测。在缺少现场失效数据的情况下,该方法为起重机零部件失效寿命的获取提供了新途径。(3)利用有限元软件的二次开发功能建立了起重机械虚拟仿真试验平台。实现了塔式起重机的参数化建模与虚拟工况载荷的施加,利用Ansys软件自动获取整机的强度、刚度和稳定性分析结果,为起重机械受力结构的安全评估提供了依据。(4)在完成FMEA分析和获取主要零部件通用失效概率信息的基础上,基于RBI技术建立了起重机械定性风险评估模型,确定了起重机零部件的风险等级排序。基于层次分析法和灰色综合评价法,建立了起重机零部件失效概率的修正计算模型,结合零部件失效后果的定量化经济性评估,提出了起重机零部件的定量风险评估方法。最后,提出了应用上述成果,在起重机械风险评估中,对由定性风险评估确定为高风险零部件进行定量风险评估的实用性实施方法。(5)基于ACCESS数据库,以VB软件为开发工具编制了起重机械风险评估系统软件。该软件能够自动完成起重机零部件的定性和定量风险评估,输出WORD格式的评估报告,并给出相应故障零部件的检测部位、检测方法和检测周期建议。(6)开展了基于RCM技术的起重机械预防性检修策略研究。综合考虑零部件在维修间隔期内的可靠性、经济性和可用度,给出了有限使用期不完全预防维修周期的计算方法。针对具有可测量潜在退化过程的零部件,考虑其故障的发生过程,提出了基于首次检测和重复检测的非定期视情检修策略,基于经济性和可用度准则分别给出了首次检测和重复检测的最佳检测周期的计算方法。(7)综合理论研究成果,制定了起重机械风险评估实施规范。实施规范给出了层次分析法中各因子等级评定的实用量化评估准则,制定了起重机零部件定性和定量风险评估的标准化实施流程。最后,基于实施规范和评估软件完成了近20例典型起重机的风险评估工程应用。
[Abstract]:The lifting machinery is one of the special mechanical and electrical equipment which have the greatest hidden danger factors, the biggest accident probability and the most serious accident consequences. At present, the number of lifting machinery in China has increased by about 20% annually, and the quantity of all kinds of lifting machinery has exceeded 2 million 500 thousand. Meanwhile, the proportion of casualties involving heavy machinery accounts for the proportion of all kinds of casualties. There is a rise year by year. At present, there are about 25% of the casualties in all sectors of our country. The number of deaths involved in heavy machinery accidents is the first in all machinery accident deaths each year. Therefore, it is urgent to strengthen the safety management and accident prevention of the lifting machinery. The premise and foundation of accident prevention, the systematic safety assessment method for lifting machinery is lacking. For the lifting equipment in service, especially the overdue service, the research on the systematic and practical risk assessment method has great theoretical significance and practical value. At present, the legal periodic inspection system is adopted in the industry to realize the lifting. The safety operation of machinery and accident prevention. This system has played a basic role in the safe operation of the lifting equipment. However, because the inspection project and the inspection cycle are basically fixed, the difference between the enterprise and the equipment individual is not distinguished, and it is easy to cause the excessive inspection of the general equipment and the insufficient inspection of the high risk equipment. The result of the inspection is only "qualified" and "unqualified". Because of the lack of quantitative calculation of the risk of parts and components, the evaluation result of the safety condition has limited reference value to the prevention of lifting machinery accident. The FMEA analysis of the main parts of the lifting machinery, the collection of failure data and the general failure probability information, the reliability test of the wire rope small sample, the modeling and Simulation of the lifting machinery, the qualitative and quantitative evaluation of the risk of the parts and parts, the formulation of the preventive maintenance strategy of the lifting machinery RCM, the implementation of the lifting machinery risk assessment and the evaluation of the soft. The main contents of the paper are as follows: (1) on the basis of the statistical analysis of more than 380 crane accidents, the failure analysis database of lifting machinery is set up. The failure mode and influence analysis are carried out, and all the failure modes are obtained, and then the corresponding failure causes and the consequences of failure are analyzed. The typical failure mode of the rope is bending fatigue and wear. Small sample physical tests are carried out, and the failure data are obtained under the test conditions. A collection table for the failure sample of the crane parts is designed. The survey statistics questionnaire and the deep Ling steel, Anshan steel, SANYO heavy industry and other cranes are used in the field investigation and so on. The large sample failure data of heavy machine parts have been completed, and the corresponding failure life calculation is completed. (2) in view of the limited site failure data of the crane parts, a reliable life prediction method for small sample parts of the crane parts based on Bayes theory is proposed. The correlation detection records determine the pre test distribution of reliability evaluation, combined with the field reliability test data of small samples, and apply Bayes theory to fuse the pre test information and field test data of parts and components, get the post test distribution of reliable life of the product, and then realize the prediction of the failure life of the parts and components. The method provides a new way for obtaining the failure life of the crane parts. (3) a virtual simulation test platform for lifting machinery is established by using the two development functions of the finite element software. The parameterized modeling of the tower crane and the application of the load of the virtual working condition are realized. The strength, stiffness and stability of the whole machine are obtained by using the Ansys software. The result provides a basis for the safety assessment of the lifting mechanism. (4) on the basis of the FMEA analysis and the acquisition of the general failure probability information of the main parts, the qualitative risk assessment model of the lifting machinery is established based on the RBI technology, and the risk ranking of the crane parts is determined. Based on the analytic hierarchy process and the grey comprehensive evaluation, The modified calculation model of the failure probability of the crane parts is established, and the quantitative risk assessment method of the crane parts is put forward according to the quantitative economic evaluation of the failure consequences of the parts. Finally, the above results are put forward and the qualitative risk assessment is used to determine the risk of the high risk components in the risk assessment of the lifting machinery. The practical implementation method of quantitative risk assessment. (5) based on the ACCESS database and using VB software as the development tool, the lifting machinery risk assessment system software is developed. The software can automatically complete the qualitative and quantitative risk assessment of the crane components, output the evaluation report of the WORD format, and give the detection parts of the corresponding fault parts. The methods of detection and detection cycle are suggested. (6) a study on the preventive maintenance strategy of lifting machinery based on RCM technology is carried out. Considering the reliability, economy and availability of the parts during the maintenance interval, a calculation method for the incomplete maintenance period in the limited period of use is given. Considering the process of the failure, an unscheduled inspection strategy based on the first detection and repeated detection is proposed. Based on the economic and availability criteria, the calculation method of the best detection period for the first detection and repeated detection is given respectively. (7) the comprehensive theoretical research results have been made to implement the implementation standard of the risk assessment of the lifting machinery. The practical quantitative evaluation criteria for the evaluation of each factor in the analytic hierarchy process are given, and the standardized implementation process of the qualitative and quantitative risk assessment of the crane parts is formulated. Finally, the application of the risk assessment process for nearly 20 typical cranes is completed based on the implementation specification and evaluation software.
【学位授予单位】：东北大学
【学位级别】：博士
【学位授予年份】：2013
【分类号】：TH21

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