| With the development of modern civil engineering and construction industry,the large demand of sand and gravel aggregate has driven the demand for improvement of aggregate bulking equipment.At present,most of the aggregate bulking equipment used by domestic enterprises adopt semi-automatic operation mode,which requires manual operation of valve mechanism to complete the control of discharging flow rate and discharging volume,and there are problems such as difficult to control the flow rate of aggregate,low efficiency,poor accuracy of discharging and serious pollution.Therefore,this paper aims to design a highly controllable bulk loading machine to complete the automation and precision of aggregate bulk loading.This paper firstly analyzes the shortcomings of the structure design and control method of the existing bulk loading machine,and then improves it based on the reference of the domestic and foreign bulk loading equipment design by combining the needs of enterprises.The overall structure design,finite element analysis of key components and control system design were completed,and finally a new type of aggregate bulk loader meeting the requirements of accurate discharging was realized.The specific research contents are as follows:(1)Overall design of the aggregate bulk loader.By analyzing the functions of each mechanical structure of the bulk loader,the modularization process is carried out;based on the specific technical indexes and design requirements,the parts selection of the mechanical structure is carried out;and based on the 3D modeling software Solid Works and the structural design of each part,the overall design of the bulk loader is completed.(2)Finite element analysis of key parts of the aggregate bulk loader.Based on the finite element software ANSYS,the static and convergence analyses were conducted on the rotating valve spool,shell and frame,which are the main force-bearing parts of the bulk loader,under the maximum load condition,to study whether the structural strength and stiffness of the bulk loader can meet the design requirements and verify the feasibility of the structural design;the redundant parts with redundant analysis results were optimized,and the optimized spool structure with35.15% mass reduction was obtained;the modal analysis was conducted on the frame to ensure that the frame has a high quality.Modal analysis is conducted to ensure that the frame has strong stability and reliability.(3)Design of precise control system for aggregate bulk machine.According to the control requirements,the blanking control process and control system architecture were determined.The fuzzy control of the valve closing process was based on the fuzzy control algorithm to realize the precise control of the blanking process.Use electrical components to design electrical control cabinet and combine PLC program control;The design of the electrical control cabinet and the design of the PLC program to the bulk machine feeding machinery automatic control basic control requirements;The whole process is simulated and monitored in real time by configuration simulation.(4)Test and improvement of aggregate bulk machine prototype.Trial prototype,complete the on-line debugging of the whole electromechanical system;To solve the problem of delayed material and blocked rotation encountered in debugging,the load test was carried out after modification of the scheme and the comparison test with the traditional model was carried out.The results show that it takes 10 minutes and 12 seconds on average for the new bulk machine to complete the aggregate canning of a truck with a loading capacity of 45 tons,and the efficiency is nearly doubled.In addition,no aggregate spills during the canning process,and the precision of blanking reaches the design goal.The aggregate bulker system designed in this paper effectively improves the efficiency of aggregate loading,suppresses dust generation,and achieves 98.1% accuracy of discharging,which has certain application value for aggregate transportation industry. |
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