#分析液壓盤式傳動裝置的可靠性

1、分析液壓盤式傳動裝置的可靠性為了進一步提高制動器和液壓傳動裝置的可靠性，增強監(jiān)測功能是必要的。如果制動器和液壓傳動裝置出現(xiàn)故障，特別是液壓的殘壓以及油污染會導致電磁換向閥的卡住等，都會造成嚴重后果。Inordertofurtherimprovethereliabilityofbrakeandhydraulictransmissiondevice,enhancethemonitoringfunctionisnecessary.Ifthebrakeandhydraulictransmissiondevicefailure,especiallytheresidualpressureandhydrau

2、licoilpollutionwillcausethesolenoidvalvestuck,willcauseseriousconsequences.1 盤式制動器的可靠性理解Reliabilityofunderstanding1discbrake從狹義可靠性理解，盤式制動器包含不可維修因素，如制動彈簧失效之后，影響制動力矩，需要更換新彈簧才能使制動器可靠性達到原有水平；閘瓦和閘盤之間摩擦系數(shù)衰減，也只能靠更換新閘瓦方能維持原有可靠性水平。從廣義可靠性理解，盤式制動器含有可維修因素，如閘瓦磨損后產(chǎn)生的間隙增大，經(jīng)調(diào)整便可達到原有可靠性；液壓站零件發(fā)生故障，修理后也能使制動器可靠性達到設(shè)計水平。

3、由此可知，制動器的工作可靠性是固有可靠性和使用可靠性的綜合反映。固有可靠性是由制動器設(shè)計制造及材料等因素決定的，在制動器產(chǎn)品出廠時便已明確，使用可靠性則是安裝、維護及操作等因素決定的，它反映了制動器固有可靠性在實際運行中的發(fā)揮程度，因此，固有可靠性的體現(xiàn)，受使用可靠性的限制，固有可靠性再高，使用可靠性卻較低，制動器的實際工作可靠性依然不會高。Understandingfromthenarrowreliability,discbrakeincludesnotrepairfactors,suchasafterthebrakespringfailure,effectofbrakingtorque,t

4、heneedtoreplacethenewspringinordertomakethebrakereliabilityreachtheoriginallevelbetweenbrakeshoeandthebrakedisc;frictioncoefficientofattenuation,canonlyrelyonthemorechangenewshoeinordertomaintaintheoriginallevelofreliability.Understandfromthegeneralizedreliability,discbrakecomprisingrepairfactors,su

5、chastheclearanceofbrakewearaftertheincrease,theadjustmentwillbetheoriginalreliability;hydraulicstationcomponentfailure,repaircanmakebrakereliabilityreachedthedesignlevel.Therefore,theworkingreliabilityofbrakeisthecomprehensivereflectionofinherentreliabilityandthereliabilityof.Inherentreliabilityisde

6、terminedbythebrakedesignandmanufacturingmaterials,inthebrakeproductsfactoryhasbeenclear,theuseofreliabilityisdecidedtoinstallation,maintenanceandoperationfactors,itreflectstheinherentreliabilityofbrakeperformancedegree,intheactualoperation,becauseofthis,reflectedtheinherentreliability,thereliability

7、constraintstheinherentreliability,highreliability,theuseisrelativelylow,theactualworkingreliabilityofbrakeisstillnothigh.2 制動器的故障模式分析Failuremodeanalysisof2brake提升機制動器的故障，是指制動器未能達到設(shè)計規(guī)定的要求（如制動力矩不足或制動減速度超限），因而完不成規(guī)定的制動任務或完成得不好。盤式制動器有許多故障，但并不是所有故障都會造成嚴重后果，僅是其中一些故障會影響制動器功能或造成事故損失。因此，在分析制動器故障的同時，還需要對故障的影響或

8、后果進行評價，這稱為故障模式和影響分析。制動系統(tǒng)中包括功能件、組件和零件。所謂功能件，是指由幾個到幾百個零部件組成的，具有獨立功能的子系統(tǒng)，例如液壓站、盤閘、控制臺；組件是由兩個以上的零部件構(gòu)成的并在子系統(tǒng)中保持特定功能的部件，如電磁閥、電液調(diào)壓裝置；零件是指無法繼續(xù)分解的具有設(shè)計規(guī)定的單個部件。一般情況下，零件故障都可能導致制動器的故障。在運行過程中，規(guī)定時間內(nèi)無法啟動，預定時間內(nèi)無法停車，制動能力降級或受阻。顯然，制動力矩不足等故障將直接引發(fā)制動器致命性故障，應倍加注意。近年在實際使用中，已多次發(fā)生盤式制動器剎不住車引發(fā)的“放大滑”事故，造成很大的經(jīng)濟損失。根據(jù)上述可靠性的論述，制動器的固

9、有可靠性和使用可靠性的串聯(lián)乘積，正體現(xiàn)了制動器的工作可靠性。Hoistfault,isreferstothebrakefailedtomeetthedesignrequirements(suchasbraketorqueorinsufficientbrakingdecelerationlimit),sodon'tfinishbrakingmandateordonotgood.Discbrakehasmanyfaults,butnotallthefaultwillcauseseriousconsequences,isonlysomeofthesefaultsaffectbrakefunc

10、tionorcauselossofaccident.Therefore,intheanalysisofbrakefailureatthesametime,alsoneedtoassesstheimpactoffailureorconsequences,thisiscalledafailuremodesandeffectsanalysis.Includingfunctionalparts,componentsandparts,brakesystem.Theso-calledfunctionalparts,isdefinedbyseveraltohundredsofcomponents,subsy

11、stemshaveindependentfunctions,suchashydraulicstation,discbrake,theconsole;componentistomaintainspecificfunctionsinthesubsystemcomponentsconsistsoftwoormorepartsand,suchaselectromagneticvalve,electro-hydraulicpressureregulatingdevice;thepartsareunabletocontinuewiththedesignrequirementsofasinglecompon

12、entdecomposition.Ingeneral,partsfaultmayleadtobrakefailure.Intheprocessofoperation,couldnotbestartedwithinthestipulatedtime,unabletostoptime,brakingcapacitydegradationorblocked.Obviously,thebrakingtorqueisinsufficientfailurewilldirectlyleadtobrakefatalfault,whichshouldbepaidattentionto.Inrecentyears

13、,inactualuse,hasbeenrepeatedlyoccurrenceofdiscbrakenotbrakecartriggeredthe"amplifyingslide"accident,whichcausedgreateconomicloss.Accordingtothereliabilityofseriesproduct,theinherentreliabilityandreliabilityofbrake,reflectsthereliabilityofbrake.3 制動器工作可靠評定The3brakereliabilityevaluation制動裝置各

14、單元之間常常表現(xiàn)為鋼塑土工格柵串聯(lián)關(guān)系，只有液壓站的動力部分是冷儲備關(guān)系，而多副盤形閘的制動力矩則是表決狀態(tài)關(guān)系（或簡化為并聯(lián)關(guān)系），這些復雜的功能關(guān)系使制動裝置的可靠性評定比較復雜。在實際工作中，制動裝置可靠性評定分為現(xiàn)場可靠性評定和理論可靠性評定。現(xiàn)場可靠性評定是通過收集現(xiàn)場運行提升機的壽命數(shù)據(jù)，對制動器的mtbf、入和壽命分布等參數(shù)進行估計；理論可靠性評定則是依據(jù)可靠性計算方法，對制動器關(guān)鍵單元的可靠性做分析計算。顯然，現(xiàn)場可靠性評定具有全面性，方法簡單；而理論可靠性評定則過于抽象，但卻具有指導意義。Betweeneachunitbrakingequipmentoftenappearto

15、beconnectedinseries,onlythepowerofhydraulicstationiscoldreserves,andbrakemomentmultiplediscbrakeisvotingstaterelations(orsimplifiedparallel),thesecomplexfunctionrelationshipsenablereliabilityevaluationofcomplexbrakedevice.Inactualwork,brakingdevicereliabilityassessmentisdividedintofieldreliabilityev

16、aluationandtheoryofreliabilityevaluation.Fieldreliabilityassessmentisthroughthecollectionofsiteoperationpromotionlifedatamachine,thebrakesontheMTBF,入andlifedistributionparameters;reliabilityassessmentisbasedonthetheoryofreliabilitycalculationmethodofreliabilityanalysisandcalculationonthebrake,dokeyu

17、nit.Obviously,thesceneiscomprehensive,reliabilityevaluationmethodissimple;andthetheoryofreliabilityassessmentistooabstract,butithasguidingsignificance4 制動器維護可靠性評定The4brakemaintenancereliabilityevaluation我們從實踐中可以體會到，維護良好的制動器一般情況下都能夠發(fā)揮應有的功能，而維護不善的制動器則往往潛伏事故隱患。從制動器的故障模式分析不難看到，保證制動器的固有可靠性的主要維護工作包括:制動閘瓦和

18、閘盤間隙的調(diào)整；閘盤污染控制；液壓站油壓值整定及殘壓限制。在以上三項維護工作中，若有一項維護工作未做好，都會影響制動器的固有可靠性發(fā)揮。因此，維護可靠性是這三項單元可靠性的串聯(lián)組合，即閘瓦同步貼閘可靠性、閘盤污染可靠性和液壓站殘壓可靠性三者的乘積。除渣機貼閘可靠性是指制動器所有制動閘同步貼閘的能力；若貼閘同步能力差，則制動力矩達不到設(shè)計值，固有可靠性保障能力差。閘盤污染可靠性是指污染閘盤和閘瓦摩擦制動力矩不減值的能力；殘壓可靠性則是指液壓站殘壓不超過規(guī)定值的能力。由于當前維護工作和結(jié)構(gòu)設(shè)計中對閘盤污染都給予高度重視，所以發(fā)生非人為污染的概率非常小。殘壓可靠性和液壓系統(tǒng)故障和電液閥調(diào)整、閥彈簧的

19、抗疲勞能力有關(guān)。因此，維護可靠性的重點在于閘瓦間隙調(diào)整而影響的貼閘可靠性。Wecanseefromthepracticeexperience,themaintenanceofgoodbrakegeneralcanplayitsfunction,andpoormaintenanceofbrakeisoftenlatenthiddendangerofaccident.Fromthefailuremodeanalysisofbrakeisnotdifficulttosee,toensurethemaintenanceoftheinherentreliabilityofbrakeincludes:br

20、akeshoesandbrakediscclearanceadjustmentofthebrakedisc;pollutioncontrol;oilpressurevaluesettingandresidualpressurelimitofhydraulicstation.Intheabovethreemaintenancework,ifthereisamaintenanceworknotdone,willinfluencetheinherentreliabilityofbrake.Therefore,tomaintainthereliabilityofseriescombinationoft

21、hethreeunitreliability,isaproductofthebrakeshoe,brakediscbrakereliabilityofsynchronouswithpollutionreliabilityandhydraulicstationresidualpressureandreliabilityofthethree.Stickgatereliabilityreferstotheabilityofallbrakebrakesynchronousstickgate;iftheattachedbrakesynchronousabilityispoor,thenthebraket

22、orqueislessthanthedesignvalue,reliabilityguaranteecapabilityinherentdifference.Brakediscpollutionreliabilityreferstoabilityofpollutionbrakediscandbrakeshoefrictionbrakingtorqueisnotimpaired;residualvoltagereliabilityreferstothehydraulicstationresidualvoltagedoesnotexceedthecapacityofthespecifiedvalue.Duetothecurrentmaintenanceworkandstructuredesignofbrakediscpollutionhavepaidmuchattentionto,soartificialpol