【作者】 郝万军；

【导师】 王国强；

【作者基本信息】 吉林大学 ， 机械设计及理论， 2014， 博士

【摘要】 大型矿用挖掘机属于重大技术装备产品，其性能和可靠性直接影响着大型露天矿的开采和运行，代表了一个国家重矿行业的整体技术水平，对大型矿用挖掘机的设计理论、技术和方法进行深入研究，对于提升我国能源安全、资源安全，提高我国矿山机械产品的国际竞争力等具有重要意义。本文结合国家863“大型露天矿采矿技术与装备”项目的“75m3大型露天矿用挖掘机研制”（2012AA062001）课题，对大型矿用挖掘机的设计方法、工作装置及行走装置的虚拟样机、基于离散单元法的铲斗设计以及矿用挖掘机的数字化设计平台开发等方面进行了深入研究。在广泛查阅相关文献的基础上，综述了大型矿用挖掘机工作原理及国内外的发展现状，对挖掘工作机理、矿用挖掘机的工作装置、行走装置和铲斗的设计等关键技术进行了论述。分析了大型矿用挖掘机设计的特点，按照综合设计法的思想将矿用挖掘机产品的设计工作划分为规划阶段、实施阶段和检验阶段这三个阶段，并包含设计思想、设计环境、设计过程、设计目标、设计内容、设计方法及产品设计质量检验与评估这七个方面的内容，对各部分内容分别进行详细分析，为大型矿用挖掘机的设计提供一种理论指导方法。对大型矿用挖掘机工作装置的挖掘轨迹进行了理论分析，基于多体动力学理论建立了工作装置的虚拟样机，并基于虚拟样机进行了仿真分析；应用刚柔耦合理论对工作装置中的关键部件进行动态分析仿真，分别建立了以斗杆为柔体和以起重臂为柔体的工作装置虚拟样机，获得动态应力仿真数据，为工作装置的动态设计提供了条件。建立了履带行走装置的虚拟样机，对履带板与支重轮等关键部件的承载进行了分析研究。针对典型工况进行了动力学仿真分析研究，分析了履带板与地面的作用力变化规律、履带板与驱动轮之间啮合力的变化规律以及支重轮与导向轮的承载的变化规律。采用刚柔耦合仿真技术建立了履带行走装置虚拟样机，履带架被作为柔体进行处理，研究了行驶过程中履带架动态应力的变化规律。基于离散单元法理论进行了铲斗的挖掘过程仿真，分析了针对不同挖掘物料情况下的铲斗动力学响应和物料流动等内容，提取的铲斗受力和物料填充等信息可以为铲斗的优化提供理论依据，最后对铲斗进行了试验优化设计。进行了大型矿用挖掘机数字化设计平台的开发。在通用CAD/CAE/CAM技术平台基础上，建立了工程数据库，结合三维参数化模板技术、有限元模板技术等，开发了满足工程实际需求的矿用挖掘机数字化设计平台，提高了大型矿用挖掘机的设计效率。本文围绕大型矿用挖掘机的综合设计方法、工作装置及行走装置的虚拟样机仿真、基于离散单元法的铲斗设计和数字化设计平台的开发等内容进行了深入研究，为大型矿用挖掘机的设计研究提供了多种先进的分析方法与工具，为我国自主研制开发大型矿用挖掘机产品提供了科学依据。更多还原

【Abstract】 Nowadays in China, as there is numbers of large-scale opencast mines being built or planned,gradually being constructed and goes into production, the demands of large mining excavators areever rising which serves as crucial equipment in exploiting mines. Large mining excavator is a kindof important technical equipment, representing the national level of equipment manufacturingindustry for its performance closely relates to the construction and production of large-scaleopencast mine. Comprehensive researches of its designing theory, technique and methodsbecome significant and meaningful for our national energy security, resource safety and enhancingthe overall international competency of mining machinery equipment.This article refers to theprogram “Development of75m3Large-scale opencast mining excavator”, branch of a national “863Program”-Large-scale Opencast Mining Technology and Equipment and goes further in research ofthe key technique of large-scale mining excavator. After serious discussion of the design theoryand method of it, we come out with a theoretical guiding principle of its design. We also study onthe working unit and walking unit of large-scale mining excavator and build up digital prototype of it.Based on DEM (discrete element method), research on scoop design of mining excavator isongoing and a digital design platform of mining excavator is set up. The main research contentsare as follows:Based on literature research, a review is built up of large mining excavator’s working principleand its developing situation domestically and internationally. A summary of key techniques indeveloping mining excavator and the process of excavating working principle is completed. After adetailed analysis of research situation of working unit, walking unit and scoop design, finally wecome to an analytical result about the research of digital design platform.We study on the designing theory and method of large mining excavator. Regarding thecurrent situation that almost all researches about large mining excavator are focused on a certainpart structure, we make a deep research on the overall design theory and method of large miningexcavator. As for the large mining excavator which are significant equipment production but areproduced in single piece or small batch, they are specifically analyzed for their innate designingcharacteristic. Accordingly, following the synthetic designing method, design of excavator productsare divided into three steps, namely planning, designing and examining. Also, the design processinvolves seven contents: design principle, design environment, design process, design target,design content, design method and quality examination as well as evaluation. Moreover, carefulresearch analysis of every part is expected, thus it can provide a theoretical guidance for furtherdesign of large mining excavator.Research has been done of working unit design of large mining excavator. On the base ofanalyzing structure and composition of working unit of large mining excavators, we studied itsmechanism principle, analyzed in detail its excavatoring locus equation and moving vector relation.Virtual prototype of the working unit has be built up based on the theory of multi-body dynamics.Then study of the prototype has been accomplished. Dynamic simulation and analysis of key partsout of working unit has been processed with the application of Rigid-Flexible Coupling Theory. Digital prototypes have been set up, with bucket arm as flexible body and with boom as flexiblebody separately. Then with the simulation results of dynamic stress, advanced method andthoughts could be provided for detailed design of working unit.Research has been done of walking unit design of large mining excavator. Work has mainlybeen done like setting up the rigid-flexible coupling digital prototype of crawler travel unit andanalyzing crucial parts, for example, track plate and support wheel. Simulation and analysis areespecially carried out on grade climbing conditions, including the changing discipline of forcesbetween track plate and the ground, of meshing forces between track plate and driving wheel andof the loading of9support wheels as well as the guiding wheel. In the crawler travel unit which isbuilt by rigid-flexible coupling simulation, the crawler frame is taken as a flexible body, which can beused in the study of changing discipline about dynamic stress and strain when in the workingcondition of straight running.Theoretical analysis and study of scoop design in mining excavator has been carried out. Weoptimize the scoop capacity and analyze theoretically how to determine the excavatoringresistance. Process simulation of scoop excavatoring has been done with the help of discreteelement method. Analysis of scoop’s dynamic response and materials flow has been accomplishedregarding situation of different excavatoring stuff. The information collection of scoop forces andfilling stuff could provide theoretical foundation for scoop optimization. Finally experimentaloptimizing design of scoop has been successfully accomplished.Invention and development of digital design platform of large mining excavator has been done.After accurately orientation of the platform demands, the platform framework structure is designed.On the basis of NX technical platform of CAD/CAE/CAM, database technique is adopted forbuilding engineering database. Combining3D parametric template technique and FEM templatetechnique, mining excavator digital design platform which satisfy the real application has beeninitially set up. The function of the platform is more focused on the real engineering application,owning the characteristic of standard and ordered working process, convenient operation, whichcan impressively enhance the efficiency of series products design.更多还原