【摘要】：冶金橋式起重機(jī)主要用于冶金車間煉鋼、鍛造、熱處理等冶金過程中的物料吊運(yùn),其利用等級(jí)高,工作極其繁重,各機(jī)構(gòu)運(yùn)行和制動(dòng)頻繁,且起升載荷接近或等于額定載荷。同時(shí),冶金車間工作環(huán)境溫度高、灰塵大、工作環(huán)境惡劣。又因冶金橋式起重機(jī)承受載荷變化多樣、危險(xiǎn)面大、危險(xiǎn)因素多、作業(yè)環(huán)境復(fù)雜等特點(diǎn)造成橋式起重機(jī)事故發(fā)生率較高。據(jù)不完全統(tǒng)計(jì),在2006年~2011年間發(fā)生的370起起重機(jī)事故中,冶金橋式起重機(jī)事故128起,占事故總數(shù)的37.54%,居各類起重機(jī)事故之首。因此,對(duì)冶金橋式起重機(jī)進(jìn)行故障模式及其影響分析是非常有必要的。不僅可以有效降低冶金橋式起重機(jī)故障發(fā)生率,提高系統(tǒng)可靠性,從而降低或消除事故發(fā)生率,減少維護(hù)成本,提升企業(yè)的經(jīng)濟(jì)效益。針對(duì)FMEA在冶金橋式起重機(jī)上的應(yīng)用,本文主要做了如下工作:(1)統(tǒng)計(jì)分析了近年來的起重機(jī)事故案例,通過分析確定了橋式起重機(jī)事故發(fā)生比例,易發(fā)生事故的環(huán)節(jié),設(shè)備主要失效形式以及事故中易失效的結(jié)構(gòu)或零部件。結(jié)合事故案例,歸納整理冶金橋式起重機(jī)關(guān)鍵零部件及金屬結(jié)構(gòu)的故障模式,并就各個(gè)故障模式產(chǎn)生機(jī)理進(jìn)行了闡述。(2)以某鋼廠450t冶金橋式起重機(jī)為研究對(duì)象,對(duì)其進(jìn)行了傳統(tǒng)形式的FMEA完整分析。并基于模糊置信算法及灰色關(guān)聯(lián)決策,以450t冶金橋式起重機(jī)主起重機(jī)構(gòu)為例,進(jìn)行了故障危險(xiǎn)度評(píng)價(jià)的改良計(jì)算。在傳統(tǒng)的FMEA分析風(fēng)險(xiǎn)優(yōu)先數(shù)評(píng)級(jí)中,發(fā)生度、檢測(cè)度與嚴(yán)酷度的評(píng)價(jià)均基于簡(jiǎn)單的打分評(píng)級(jí),存在很大的主觀因素影響。采用模糊置信算法,以置信度的形式,用含概率的模糊等級(jí)評(píng)價(jià)故障模式的三個(gè)風(fēng)險(xiǎn)因子。對(duì)于故障模式風(fēng)險(xiǎn)因子等級(jí)無法確定的情況,采用置信結(jié)構(gòu)進(jìn)行區(qū)間評(píng)價(jià)或不完全評(píng)價(jià),這樣避免了在信息不全面的條件下主觀臆斷的情況,提升了FMEA風(fēng)險(xiǎn)評(píng)價(jià)的適用性和準(zhǔn)確性。(3)基于冶金橋式起重機(jī)FMEA分析與狀態(tài)監(jiān)測(cè),參與開發(fā)了冶金橋式起重機(jī)健康監(jiān)測(cè)與預(yù)報(bào)可視化系統(tǒng)。并基于該系統(tǒng)對(duì)450t冶金橋式起重機(jī)易失效區(qū)域進(jìn)行了結(jié)構(gòu)應(yīng)力監(jiān)測(cè),監(jiān)測(cè)數(shù)據(jù)可供設(shè)備管理人員實(shí)時(shí)了解起重機(jī)金屬結(jié)構(gòu)關(guān)鍵部位的應(yīng)力狀態(tài)。設(shè)備管理人員可通過提取應(yīng)力時(shí)程曲線,對(duì)結(jié)構(gòu)進(jìn)行疲勞壽命估算,確定結(jié)構(gòu)的疲勞狀態(tài),以便及時(shí)作出調(diào)整,對(duì)結(jié)構(gòu)潛在故障進(jìn)行預(yù)處理,將故障消除在潛伏期。
[Abstract]:Metallurgical bridge crane is mainly used for lifting materials in metallurgical process such as steelmaking, forging and heat treatment in metallurgical workshop. Its utilization grade is high, the work is extremely heavy, the operation and braking of each mechanism are frequent, and the lifting load is close to or equal to the rated load. At the same time, metallurgical workshop working environment high temperature, dust, bad working environment. The accident rate of bridge crane is high due to the characteristics of metallurgical bridge crane, such as varied load, large hazard surface, many risk factors and complex working environment. According to incomplete statistics, among 370 crane accidents from 2006 to 2011, 128 accidents occurred in metallurgical bridge cranes, accounting for 37.54 of the total number of accidents, ranking first among all kinds of crane accidents. Therefore, it is necessary to analyze the fault mode and influence of metallurgical bridge crane. Not only can the accident rate of metallurgical bridge crane be reduced effectively, the system reliability can be improved, thus the accident rate can be reduced or eliminated, the maintenance cost can be reduced, and the economic benefit of the enterprise can be improved. In view of the application of FMEA in metallurgical bridge crane, the main work of this paper is as follows: (1) the case of crane accident in recent years is statistically analyzed. The main failure forms of equipment and the structure or parts that are prone to failure in accidents. Combined with the accident case, the fault modes of key parts and metal structures of metallurgical bridge crane are summarized, and the generating mechanism of each failure mode is expounded. (2) taking 450 t metallurgical bridge crane in a steel plant as the research object, In this paper, the traditional form of FMEA complete analysis is carried out. Based on fuzzy confidence algorithm and grey correlation decision, the improved calculation of fault risk evaluation is carried out by taking 450 t metallurgical bridge crane as an example. In the traditional FMEA analysis risk priority rating, the degree of occurrence, the degree of detection and the severity of the evaluation are based on a simple rating, there are a lot of subjective factors. The fuzzy confidence algorithm is used to evaluate the three risk factors of the fault mode in the form of confidence degree and fuzzy grade with probability. When the risk factor level of the fault mode can not be determined, the confidence structure is used for interval evaluation or incomplete evaluation, which avoids the subjective assumption under the condition of incomplete information. The applicability and accuracy of FMEA risk assessment are improved. (3) based on the FMEA analysis and condition monitoring of metallurgical bridge crane, a visual system for health monitoring and prediction of metallurgical bridge crane is developed. Based on the system, the structural stress monitoring of 450 t metallurgical bridge crane is carried out. The monitoring data can be used for equipment managers to understand the stress state of the key parts of crane metal structure in real time. The equipment manager can estimate the fatigue life of the structure by extracting the stress time history curve and determine the fatigue state of the structure so as to adjust the structure in time to pretreat the potential faults of the structure and eliminate the faults in the latent period.
【學(xué)位授予單位】：武漢工程大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2015
【分類號(hào)】：TH215

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本文編號(hào)：2423716