Lightweight Design Of Key Components Of Construction Vehicle Pump-Motor

After decades of development,foreign high-pressure hydraulic plunger pumps and motors have formed a complete product line.Compared with traditional mechanical and electrical transmissions,hydraulic transmission has great force and torque,compact structure,strong arrangement and flexibility,convenient control,can realize infinitely variable speed in a wide range,prevent overload,high safety,stable operation,Quick response and other advantages.The pump and motor hydraulic components studied in this paper are applied to engineering vehicles.In response to the country’s dual carbon policy,we strive to achieve two major strategic goals of carbon peaking by 2030 and carbon neutrality by 2060.In terms of overloading requirements of engineering vehicles,to meet the needs of customers,based on this goal,the hydraulic components of pumps and motors are light-weighted to achieve energy saving and emission reduction,and prevent overloading.Therefore,the hydraulic components of plunger pumps and motors are lightweight.Quantitative design is important.In this paper,a combination of dynamic characteristic analysis,test analysis,strength analysis and topology optimization is used to carry out a lightweight design of the hydraulic system composed of a plunger pump-motor on a certain type of engineering vehicle,and the following tasks are completed:(1)According to the structure and working principle of the plunger pump/motor and the working oil circuit of the hydraulic system,the simulation model of the hydraulic system composed of the swashplate variable displacement plunger pump and the inclined axis quantitative plunger motor is built by the AMESim simulation software.(2)The dynamic characteristics of the entire hydraulic system are analyzed by the AMESim simulation platform,and the pressure of each working pipeline of the plunger pump and the motor,the internal pressure,flow and torque of the plunger cavity are obtained.The hydraulic pump/motor test bench is used to carry out the left and right limit test of the swash plate plunger pump and the forward and reverse rotation test of the inclined axis plunger motor.The reliability of the simulation model is verified by comparing the simulation and experimental analysis results.On this basis,the plunger cavity pressure,the working oil circuit and the control oil circuit pressure are extracted as the initial conditions for the subsequent mechanical analysis.(3)Analyze the force of the swash plate piston pump and the inclined axis piston motor,obtain the mechanical excitation of the mechanical moving parts of the piston pump and the motor,and use the HyperMesh preprocessing software and the ABAQUS strength analysis software to analyze the piston pump.The strength of the cylinder block,casing,pump cover and motor casing was analyzed,and it was verified that each part met the rigidity requirements and had a margin.According to the results,the parts that met the rigidity and rigidity margin were selected for lightweighting.(4)According to the technical requirements such as the rigidity and strength of the parts and the manufacturing process,ZL205 A cast aluminum alloy is selected as the lightweight material,and the casing of the plunger pump,the pump cover and the casing of the motor are used as the lightweight objects,and verified by strength analysis.The material meets the rigidity requirements,and the overall weight of the hydraulic system is reduced by about 30% by comparing the quality of the parts with different materials,which preliminarily realizes the lightweight of the hydraulic system.(5)Use Tosca optimization software to perform non-parametric topology optimization on the casing of the plunger pump/motor,optimize the structure of the parts according to the optimal material distribution map of topology optimization and practical application requirements,and remove the components that have little effect on the strength and stiffness of the parts and For materials in unnecessary parts,the strength of the optimized model is analyzed under the original working conditions to verify the reliability of the optimized model.By comparing the quality of the hydraulic system before and after optimization,it is found that the overall weight of the hydraulic system is reduced by 32%,which realizes the lightweight of the piston pump-motor hydraulic system of the engineering vehicle.