本文關(guān)鍵詞： 在役流動(dòng)式起重機(jī) 臂架結(jié)構(gòu) 潛在失效模式 風(fēng)險(xiǎn)評(píng)估 疲勞剩余壽命評(píng)估 可修復(fù)性評(píng)估與決策　出處：《太原科技大學(xué)》2017年博士論文　論文類型：學(xué)位論文

【摘要】：流動(dòng)式起重機(jī)作為現(xiàn)代物料搬運(yùn)的特種設(shè)備,廣泛應(yīng)用于建筑、冶金、造船、電力、石化、能源等領(lǐng)域。臂架結(jié)構(gòu)作為流動(dòng)式起重機(jī)的主要承載結(jié)構(gòu)件,其結(jié)構(gòu)復(fù)雜、服役條件苛刻且易損傷失效,是工程機(jī)械中附加值較高、量大面廣的共性關(guān)鍵部件。如何有效可靠地評(píng)價(jià)在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)的現(xiàn)役性能、安全狀態(tài)、剩余壽命,以確保臂架結(jié)構(gòu)修復(fù)的最佳準(zhǔn)入期,延長(zhǎng)其使用壽命,使其材料利用率最大化,實(shí)現(xiàn)節(jié)能減排的效果是制造企業(yè)、用戶、特種設(shè)備監(jiān)管部門共同關(guān)心的問題。迄今為止,在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)風(fēng)險(xiǎn)評(píng)估、壽命評(píng)估和可修復(fù)性評(píng)估與決策尚無相關(guān)方法和標(biāo)準(zhǔn)可依。對(duì)于如何判定延用、修復(fù)、更換、報(bào)廢缺乏方法和標(biāo)準(zhǔn)的支撐。針對(duì)上述問題,本文主要開展了如下研究工作:1)為有效預(yù)測(cè)在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)的潛在失效模式,構(gòu)建基于實(shí)例推理的臂架結(jié)構(gòu)潛在失效模式預(yù)測(cè)模型。通過調(diào)研、收集流動(dòng)式起重機(jī)臂架結(jié)構(gòu)有限失效模式歷史信息,建立流動(dòng)式起重機(jī)臂架結(jié)構(gòu)失效模式模糊數(shù)據(jù)庫,在機(jī)型匹配的條件下,構(gòu)建與待評(píng)估起重機(jī)同機(jī)型、不同典型使用工況的失效模式實(shí)例庫,結(jié)合實(shí)例推理技術(shù),預(yù)測(cè)待評(píng)估起重機(jī)臂架結(jié)構(gòu)的潛在失效模式,利用流動(dòng)式起重機(jī)臂架結(jié)構(gòu)參數(shù)化有限元模型和仿真計(jì)算平臺(tái),修正潛在失效模式,為后續(xù)風(fēng)險(xiǎn)評(píng)估、疲勞剩余壽命評(píng)估提供基礎(chǔ)性信息及數(shù)據(jù)。2)針對(duì)多重耦合失效模式下在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)安全性問題,提出基于潛在失效模式的臂架結(jié)構(gòu)風(fēng)險(xiǎn)評(píng)估方法。以在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)潛在失效模式為基礎(chǔ),采用改進(jìn)DEMATEL法,建立臂架結(jié)構(gòu)危險(xiǎn)點(diǎn)及其各級(jí)評(píng)價(jià)指標(biāo)間的直接、間接影響模糊關(guān)系矩陣,推導(dǎo)各級(jí)指標(biāo)的影響度矩陣與被影響度矩陣,得到各級(jí)評(píng)價(jià)指標(biāo)的中心度和原因度,分析評(píng)價(jià)指標(biāo)間的關(guān)聯(lián)性與影響性,根據(jù)關(guān)聯(lián)度與影響度分配權(quán)重,結(jié)合模糊綜合評(píng)價(jià)理論,量化臂架結(jié)構(gòu)的失效風(fēng)險(xiǎn),實(shí)現(xiàn)多重耦合失效模式下在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)的風(fēng)險(xiǎn)評(píng)估。3)針對(duì)流動(dòng)式起重機(jī)工作載荷在時(shí)空上間歇、循環(huán)的隨機(jī)性,導(dǎo)致實(shí)測(cè)載荷的隨機(jī)性以及試驗(yàn)條件的局限性,使得大規(guī)模載荷譜試驗(yàn)難以實(shí)施的問題,提出基于數(shù)理統(tǒng)計(jì)技術(shù)的隨機(jī)載荷譜獲取方法和基于人工智能預(yù)測(cè)技術(shù)的當(dāng)量載荷譜預(yù)測(cè)方法。通過采集、統(tǒng)計(jì)、記錄特定時(shí)段內(nèi)不同特征參數(shù)下起重機(jī)的工作循環(huán)次數(shù)簇,形成小樣本的實(shí)測(cè)載荷譜,利用數(shù)理統(tǒng)計(jì)技術(shù)(按常用的6種概率分布模型對(duì)起重量樣本進(jìn)行分布擬合,應(yīng)用AIC信息準(zhǔn)則對(duì)概率分布模型進(jìn)行評(píng)價(jià),給出起重量樣本的最佳概率分布模型)與拉丁超立方抽樣相結(jié)合或新型智能優(yōu)化算法的人工智能預(yù)測(cè)技術(shù),獲取定檢周期內(nèi)的隨機(jī)或當(dāng)量起重量樣本,根據(jù)流動(dòng)式起重機(jī)額定起重量表、起升高度曲線和額定起重力矩表,確定對(duì)應(yīng)起重量的臂架工作長(zhǎng)度、工作幅度,刻畫符合工程實(shí)際的隨機(jī)特征參數(shù)和與之一一對(duì)應(yīng)的工作循環(huán)次數(shù),得到定檢周期內(nèi)的隨機(jī)載荷譜或當(dāng)量載荷譜,為疲勞剩余壽命評(píng)估提供基礎(chǔ)性數(shù)據(jù)。4)針對(duì)在役流動(dòng)式起重機(jī)服役過程面臨多失效模式耦合,導(dǎo)致其臂架結(jié)構(gòu)安全性難以確定的問題,提出基于工作循環(huán)載荷動(dòng)力效應(yīng)及多失效模式耦合的流動(dòng)式起重機(jī)臂架結(jié)構(gòu)疲勞剩余壽命評(píng)估方法。以獲取的隨機(jī)或當(dāng)量載荷譜為基礎(chǔ),根據(jù)流動(dòng)式起重機(jī)工作循環(huán)過程,建立考慮工作循環(huán)載荷動(dòng)力效應(yīng)的臂架結(jié)構(gòu)危險(xiǎn)點(diǎn)處第一主應(yīng)力-時(shí)間歷程理論仿真模型,模擬再現(xiàn)檢測(cè)周期內(nèi)流動(dòng)式起重機(jī)工作循環(huán)過程中臂架結(jié)構(gòu)危險(xiǎn)點(diǎn)處第一主應(yīng)力的時(shí)間歷程,利用雨流計(jì)數(shù)法,提取對(duì)應(yīng)危險(xiǎn)點(diǎn)的雙參應(yīng)力譜,結(jié)合損傷容限設(shè)計(jì)及斷裂力學(xué)理論,構(gòu)建基于隨機(jī)或當(dāng)量載荷譜的疲勞剩余壽命評(píng)估模型,估算單一及耦合失效模式下臂架結(jié)構(gòu)對(duì)應(yīng)危險(xiǎn)點(diǎn)處的疲勞剩余壽命,為損傷臂架結(jié)構(gòu)可修復(fù)性評(píng)估與決策提供門檻條件。5)針對(duì)在役流動(dòng)式起重機(jī)損傷臂架結(jié)構(gòu)的延用/修復(fù)/更換/報(bào)廢問題,從結(jié)構(gòu)現(xiàn)役性能可利用性、修復(fù)技術(shù)可行性、經(jīng)濟(jì)可行性、環(huán)境資源可行性的維度,建立損傷臂架結(jié)構(gòu)可修復(fù)性綜合評(píng)估與決策模型。對(duì)于具有疲勞剩余壽命(修復(fù)準(zhǔn)入期)的各損傷臂節(jié)截面拉應(yīng)力區(qū)域(壓應(yīng)力區(qū)域)的危險(xiǎn)點(diǎn),分析其檢測(cè)周期節(jié)點(diǎn)處的可靠性(危險(xiǎn)點(diǎn)的強(qiáng)度冗余性),聯(lián)合可靠性閾值(最小強(qiáng)度冗余因子),確定危險(xiǎn)點(diǎn)處現(xiàn)役性能的可利用性,根據(jù)修復(fù)工藝過程,量化技術(shù)可行性評(píng)價(jià)指標(biāo),評(píng)價(jià)修復(fù)技術(shù)的可行性,以企業(yè)特定時(shí)段內(nèi)流動(dòng)式起重機(jī)損傷臂架結(jié)構(gòu)的修復(fù)總費(fèi)用為基礎(chǔ),采用作業(yè)成本法,追溯不同失效特征對(duì)應(yīng)損傷臂節(jié)的修復(fù)成本,形成修復(fù)成本數(shù)據(jù)庫,利用改進(jìn)相關(guān)向量機(jī),預(yù)測(cè)與待評(píng)估流動(dòng)式起重機(jī)各損傷臂節(jié)失效特征對(duì)應(yīng)的修復(fù)成本,結(jié)合購(gòu)置新品臂架結(jié)構(gòu)所需費(fèi)用,評(píng)價(jià)損傷臂架結(jié)構(gòu)修復(fù)的經(jīng)濟(jì)性,判斷臂架結(jié)構(gòu)修復(fù)的環(huán)境資源效益,給出損傷臂架結(jié)構(gòu)可修復(fù)性的綜合決策結(jié)果,為報(bào)廢及相關(guān)標(biāo)準(zhǔn)的制定提供重要的理論依據(jù)。6)為便于工程應(yīng)用,基于VC++6.0/C#平臺(tái),將以上理論和方法集成,開發(fā)“流動(dòng)式起重機(jī)臂架結(jié)構(gòu)風(fēng)險(xiǎn)與壽命評(píng)估及可修復(fù)性決策系統(tǒng)”,為在役流動(dòng)式起重機(jī)臂架結(jié)構(gòu)潛在失效模式預(yù)測(cè)、風(fēng)險(xiǎn)評(píng)估、載荷譜預(yù)測(cè)、疲勞剩余壽命估算、可修復(fù)性綜合評(píng)估與決策提供軟件技術(shù)支持。
[Abstract]:The mobile crane as a special equipment of modern material handling, widely used in building, metallurgy, shipbuilding, electric power, petrochemical, energy and other fields. The mobile crane jib structure as the main bearing structure, its structure is complex, harsh conditions and easy to damage and failure is high value-added service, engineering machinery, common key components a large amount of wide. How to effectively and reliably evaluate the performance in active service, the mobile crane jib structure of the safety state of residual life, to ensure the best access period of boom structure repair, prolong the service life, the material utilization is maximized, achieve the effect of energy saving and emission reduction is a manufacturing enterprise, the user. Common concern of special equipment supervision department. So far, the risk structure of existing mobile crane arm frame evaluation, life assessment and maintainability evaluation and decision method and standard. Shang Wuxiang closed on On how to determine the use, repair, replacement, scrap the lack of methods and standards support. To solve the above problems, this paper carried out research work as follows: 1) for predicting the potential in the service mode of mobile crane boom structure failure, construction of CBR arm structure prediction model based on potential failure mode. Through research. Collect the mobile crane jib structure finite failure mode of historical information, establish the mobile crane boom structure failure mode in fuzzy database, models, conditions, construction and evaluation for the same type of crane, the failure mode of different working conditions of the typical case base, combined with case-based reasoning technology to evaluate the potential prediction model of crane jib structure the failure of the mobile crane with jib structure parametric finite element model and simulation platform, correction of potential failure mode for the subsequent risk assessment, The remaining fatigue life provides the basic information and data.2 assessment) for multiple failure mode coupling in existing mobile crane boom structure security assessment method of jib structure risk potential failure mode is proposed. The existing mobile crane boom structure potential failure mode based on improved DEMATEL method, set up the arm frame structure and its risk evaluation at all levels between direct and indirect effects of the fuzzy relation matrix, affect the derived indicators at all levels of the matrix and influence matrix, at all levels of evaluation index centrality and causes analysis, relevance and impact evaluation index, according to the correlation degree and influencing degree of weight distribution, combined with the the theory of fuzzy comprehensive evaluation, the failure risk of the boom structure, realize the coupling multiple failure modes in the risk assessment of existing mobile crane boom structure for mobile.3) Crane work load in time and space, intermittent, random cycle, resulting in limitation of measured load randomness and test conditions, the test load spectrum is difficult to implement large-scale problems, put forward random load spectrum acquisition method of mathematical statistics and prediction method of equivalent load forecasting technology based on artificial intelligence. By collecting the spectrum, statistics, records within a particular time period of different characteristic parameters of crane operation cycles of clusters, forming small samples of measured load spectrum, using statistical techniques (according to 6 kinds of commonly used to sample weight distribution fitting, probability distribution model and application of AIC information criteria for evaluation of the probability distribution model gives the best probability distribution model the weight of the sample) and Latin hypercube sampling combined with artificial intelligence or intelligent optimization prediction technology, obtain periodic inspection in random Or the equivalent weight of the sample, according to the mobile crane rating table, lifting height curve and rated load moment, determine the corresponding arm working length, the weight of the working range, describe the stochastic parameters in accordance with engineering practice and corresponding work cycles, get the random load periodic inspection the spectrum or equivalent load spectrum, fatigue life assessment to provide the basic data for.4) in the service of mobile crane service faces many failure modes coupling, the safety of arm frame structure is difficult to determine, a job evaluation method based on cyclic loading dynamic effect and multiple failure modes coupled flow frame the structure of the crane arm fatigue residual life. In order to obtain the random or equivalent load spectrum as the basis, according to the process of the mobile crane work cycle, considering the dynamic effect of cyclic loading The jib structure of dangerous point of the first principal stress time history simulation model, simulation of flow detection cycle time history of jib structure of dangerous point process crane work cycle in the first principal stress, the rain flow counting method, the extraction of the dangerous point corresponding to two parameter stress spectrum with damage tolerance the design and the theory of fracture mechanics, evaluation model of random fatigue life or equivalent load spectrum based on the estimation of the remaining fatigue life of single and coupled failure risk of jib structure corresponding to mode, damage to the jib structure repair assessment and decision-making threshold condition.5) in battle of mobile crane arm injury frame use / repair / replace / scrap, from the existing performance availability, feasibility, repair technical and economic feasibility of environmental resources, the feasibility of the establishment of jib structure dimension, damage repair The complex of comprehensive evaluation and decision making model. With the remaining fatigue life (access repair period) the injury of brachial sections of tensile stress area (compressive stress) risk, reliability analysis of its detection nodes (strength redundancy of the dangerous point), combined with the reliability threshold (the minimum strength redundancy factor) sure, the dangerous point of service performance can be used, according to the repair process, the feasibility of quantitative evaluation index, feasibility evaluation of repair technology, with the enterprise specific time period flow repair total cost of crane jib structure damage based on the activity-based costing, repair cost tracing different failure characteristics corresponding to damage the boom the cost of repair, the formation of the database, using the improved relevance vector machine, prediction and assessment for the repair cost of mobile crane arm joint failure characteristics corresponding to different damage, combined with the purchase of new jib structure The expenses needed for the economic evaluation of damage repair of jib structure, environmental resources effectiveness judgment of jib structure repair, given the damage of jib structure may be the result of comprehensive remediation decisions, provide an important theoretical basis for the formulation of.6 for scrap and related standards) for the convenience of engineering application, based on the VC++6.0/C# platform, the above theory and method integrated assessment of mobile crane boom structure risk and life development "and repair decision system" for the risk assessment of existing mobile crane boom structure prediction, potential failure mode, load spectrum prediction, fatigue residual life estimation, maintainability comprehensive evaluation and decision making to provide software technical support.

【學(xué)位授予單位】：太原科技大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2017
【分類號(hào)】：TH21
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本文編號(hào)：1449920