裝配圖ZL05裝載機(jī)總體及其工作裝置設(shè)計(jì),裝配,zl05,裝載,總體,整體,及其,工作,裝置,設(shè)計(jì) 本科生畢業(yè)設(shè)計(jì)（論文） 開(kāi)題報(bào)告 學(xué)生姓名：李鑫 學(xué) 號(hào)：14020926 班 級(jí)：140209 專 業(yè)：機(jī)械工程及自動(dòng)化 指導(dǎo)教師：李 風(fēng) 畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告 一、課題介紹 1.課題名稱： ZL05微型輪式裝載機(jī)總體設(shè)計(jì) 2.課題背景： ⑴ 設(shè)計(jì)課題的意義 ZL系列輪式裝載機(jī)是一種高效率的工程機(jī)械，具有結(jié)構(gòu)先進(jìn)，性能可靠，機(jī)動(dòng)性強(qiáng)，操縱方便等優(yōu)點(diǎn)。廣泛應(yīng)用于礦山，建筑工地，道路修建，水利工程，港口，貨場(chǎng)，電站以及其他工業(yè)部門(mén)，進(jìn)行裝載、推土、鏟挖、起重、牽引等多種作業(yè)。對(duì)加快工程建設(shè)速度減輕勞動(dòng)強(qiáng)度提高工程質(zhì)量降低工程成本都發(fā)揮著重要作用，因此近幾年來(lái)無(wú)論在國(guó)內(nèi)還是國(guó)外裝載機(jī)品種和產(chǎn)量都得到迅速發(fā)展，成為工程機(jī)械的主導(dǎo)產(chǎn)品之一。 為適應(yīng)工程施工，市政建設(shè)及農(nóng)用水利工地的砂石、灰土等各種散裝物料的裝運(yùn)需要，提出設(shè)計(jì)小型輪式裝載機(jī)的任務(wù)。 ⑵ 設(shè)計(jì)課題的目的 輪式裝載機(jī)總體設(shè)計(jì)是機(jī)械制造，機(jī)械設(shè)計(jì)和機(jī)械電子（機(jī)電一體化）等專業(yè)的一個(gè)重要的教學(xué)環(huán)節(jié)，是學(xué)完技術(shù)基礎(chǔ)課及有關(guān)專業(yè)課以后的一次專業(yè)課程內(nèi)容的綜合設(shè)計(jì)。通過(guò)設(shè)計(jì)提高學(xué)生的機(jī)構(gòu)分析與綜合的能力，機(jī)械構(gòu)造設(shè)計(jì)的能力，機(jī)電一體化系統(tǒng)設(shè)計(jì)能力，掌握實(shí)踐生產(chǎn)過(guò)程自動(dòng)化的設(shè)計(jì)方法。通過(guò)設(shè)計(jì)把有關(guān)課程（機(jī)械原理，機(jī)械設(shè)計(jì)，理論力學(xué)，材料力學(xué)，液壓與氣動(dòng)技術(shù)，工程材料，材料成型，自動(dòng)控制理論，測(cè)試技術(shù)，數(shù)控技術(shù)，微型計(jì)算機(jī)原理及應(yīng)用，自動(dòng)機(jī)械設(shè)計(jì)等）中所獲得的理論知識(shí)在實(shí)際中綜合的加以運(yùn)用，使這些知識(shí)得到鞏固和發(fā)展，并使理論知識(shí)和生產(chǎn)密切的結(jié)合起來(lái)。 輪式裝載機(jī)總體設(shè)計(jì)是機(jī)械設(shè)計(jì)及機(jī)械制造專業(yè)和機(jī)械電子專業(yè)的學(xué)生一次比較完整的整機(jī)設(shè)計(jì)。通過(guò)設(shè)計(jì)，培養(yǎng)學(xué)生獨(dú)立的機(jī)械整機(jī)設(shè)計(jì)的能力，樹(shù)立正確的設(shè)計(jì)思想，掌握機(jī)械產(chǎn)品設(shè)計(jì)的基本方法和步驟。通過(guò)設(shè)計(jì)使學(xué)生能熟練的應(yīng)用有關(guān)參考資料，計(jì)算圖表，手冊(cè)，圖冊(cè)和規(guī)范；熟悉有關(guān)國(guó)家標(biāo)準(zhǔn)，以完成一個(gè)工程技術(shù)人員在機(jī)械整體設(shè)計(jì)方面所必須具備的基礎(chǔ)技能訓(xùn)練。 ⑶ 輪式裝載機(jī)的發(fā)展現(xiàn)狀 1）國(guó)外輪式裝載機(jī)的發(fā)展現(xiàn)狀 1 新產(chǎn)品不斷推出 近年來(lái)，輪式裝載機(jī)以圍繞提高效率、降低成本為核心，繼續(xù)向大型化、微型化發(fā)展，不斷推出新產(chǎn)品，加速更新?lián)Q代。 卡特彼勒公司90年代初推出Cat966F輪式裝載機(jī)，時(shí)隔1年又推出Cat980F輪式裝載機(jī)，它增加了斗容和功率。改善了性能、提高了可靠性。不久又推出更大的Cat994輪式裝載機(jī)，根據(jù)物料體積質(zhì)量不同而選配l8～ 30m3的鏟斗，機(jī)重170t；裝有渦輪增壓后冷的Cat3516型柴油發(fā)動(dòng)機(jī)牽引力大、加速性能好；加長(zhǎng)的工作動(dòng)臂增加了卸載高度，能對(duì)載重量218t的大型自卸汽車(chē)裝載。 馬拉松?勒?qǐng)D爾勒(Marathon Letourneau)公司1990年和1994年在LI100的基礎(chǔ)上分別推出LI400和LI800型輪式裝載機(jī)。l998年9月在美國(guó)塔克癬(Tucson)召開(kāi)的Longding 2000年會(huì)上，該公司宣布正在開(kāi)發(fā)的斗容20．4m3的L1350型輪式裝載機(jī)將于21世紀(jì)初投放市場(chǎng)，供載重量150～200t自卸汽車(chē)裝載。 德雷塞(Dresser)公司90年代初推出4000型輪式裝載機(jī)，斗容10～30m3、機(jī)重151．8t，采用模塊結(jié)構(gòu)的傳動(dòng)系統(tǒng)，大功率、敏感按鈕控制的液壓系統(tǒng)．z型單搖臂工作裝置。優(yōu)化的整體結(jié)構(gòu)和濕式盤(pán)式制動(dòng)器，具有自動(dòng)調(diào)節(jié)和自動(dòng)密封性能。 目前，全世界約有400臺(tái)(功率大于750kw)大型輪式裝載機(jī)應(yīng)用在露天礦山和建筑工程，與大型自卸汽車(chē)配套使用。在發(fā)展大型輪式裝載機(jī)的同時(shí)，微型輪式裝載機(jī)以機(jī)動(dòng)靈活、效率高、多功能和價(jià)格低廉贏得市場(chǎng)，發(fā)展甚快。如：日本古河公司生產(chǎn)的FL30-1型輪式裝載機(jī)斗容0．34m3、機(jī)重2．3t；小松公司的WA30-1型斗容0．34rn3、柴油機(jī)功率20kW；豐田織機(jī)公司的斗容0．17m3、機(jī)重1t等這些微型裝載機(jī)適用于建筑工地和地下礦山挖溝、平地、堆料等。 2 新結(jié)構(gòu)不斷涌現(xiàn) 2．1 工作機(jī)構(gòu) 卡特技勒公司推出組合式八桿機(jī)構(gòu)。從地面到整個(gè)舉升高度范圍內(nèi)具有平行移動(dòng)的特點(diǎn)。它將快速連接器和塔架式機(jī)構(gòu)設(shè)計(jì)成整體式工作裝置，通過(guò)快速更換不同的輔助機(jī)構(gòu)完成裝卸、堆垛、掃雪、平地、清掃路面、推土、吊裝、搬運(yùn)和地表鉆孔等作業(yè)，實(shí)現(xiàn)一機(jī)多能，減少用戶設(shè)備投資。 德雷塞公司開(kāi)發(fā)Z型單臂工作機(jī)構(gòu)并與高壓液壓系統(tǒng)相結(jié)臺(tái)，為鏟斗提供更大的掘起力；縮短裝載工作循環(huán)，增加鏟斗裝滿系數(shù)，大幅度提高勞動(dòng)生產(chǎn)率。由于鉸點(diǎn)少、桿件少，便于維修保養(yǎng)，降低維修費(fèi)用。 2．2 傳動(dòng)機(jī)構(gòu) 以卡特彼勒公司為代表的輪式裝載機(jī)采用液力機(jī)械傳動(dòng)系統(tǒng)，其自動(dòng)動(dòng)力換檔變速箱自動(dòng)選擇檔位傳動(dòng)比，使換檔在變速箱最佳效率點(diǎn)進(jìn)行。該公司最近推出的STIC(轉(zhuǎn)向變速集成)系統(tǒng)，將轉(zhuǎn)向和換檔功能集成于一操縱手柄上，使操縱更加省力、輕便，換檔更加平穩(wěn)，可大幅度提高生產(chǎn)率。 以日本小松公司W(wǎng)A系列中小功率(小于125kW)為代表的輪式裝載機(jī)采用新型集中式結(jié)構(gòu)的驅(qū)動(dòng)橋。它將主傳動(dòng)制動(dòng)器和行星輪式終傳動(dòng)都集中在橋的中部，橋殼斷面變化連續(xù)、平緩，內(nèi)應(yīng)力分布臺(tái)理，從根本上防止因傳統(tǒng)結(jié)構(gòu)橋殼在輪邊支承軸段應(yīng)力集中斷裂。輪端采用浮動(dòng)密封結(jié)構(gòu)，安裝簡(jiǎn)便，有自動(dòng)補(bǔ)償功能，密封性能良好。該結(jié)構(gòu)設(shè)計(jì)合理、基本零件少、工藝性好、性能好、可靠性高。 馬拉松?勒?qǐng)D爾勒公司的輪式裝載機(jī)采用柴油機(jī)一發(fā)電機(jī)一電動(dòng)輪傳動(dòng)，比液力機(jī)械傳動(dòng)系統(tǒng)簡(jiǎn)單。在整個(gè)作業(yè)中柴油發(fā)動(dòng)機(jī)以恒定轉(zhuǎn)速運(yùn)轉(zhuǎn)，減少燃油消耗，延長(zhǎng)發(fā)動(dòng)機(jī)壽命；無(wú)變速箱、傳動(dòng)軸等許多部件，提高了傳動(dòng)效率，操作維修方便，費(fèi)用低；獨(dú)立電動(dòng)牽引馬達(dá)為固態(tài)控制，反應(yīng)迅速，減少車(chē)輪打滑和輪胎過(guò)渡磨損；設(shè)置了電動(dòng)緩行器，不用工作制動(dòng)停機(jī)，裝料對(duì)位準(zhǔn)確；整機(jī)重心低，行駛穩(wěn)定性好，可靠性高。 2．3 液壓系統(tǒng) 德雷塞公司輪式裝載機(jī)液壓系統(tǒng)用傳感器接受柴油機(jī)轉(zhuǎn)速信號(hào)，當(dāng)轉(zhuǎn)速下降時(shí)柱塞式變量泵便自動(dòng)增加轉(zhuǎn)向系統(tǒng)流量，以保持恒定的轉(zhuǎn)向速度，在最大挖掘工況時(shí)可減少流量，減慢液壓元件動(dòng)作，以保持液壓系統(tǒng)的動(dòng)力平衡，減少液壓系統(tǒng)熱損耗，節(jié)省功率。卡特彼勒輪式裝載機(jī)轉(zhuǎn)向液壓系統(tǒng)用負(fù)荷傳感式溢流閥，使液壓泵在負(fù)載決定壓力下溢流，降低系統(tǒng)壓力，提高了液壓元件壽命。工作裝置液壓系統(tǒng)采用舉升限位裝置和下放自動(dòng)定位裝置，避免了機(jī)械限位時(shí)液壓缸行程終了產(chǎn)生高壓和沖擊；裝設(shè)的蓄能器能吸收沖擊載荷，并對(duì)整機(jī)的縱向搖擺起阻尼作用；液壓缸導(dǎo)向套處有三重密封，防止泄漏和肪塵。 2．4 司機(jī)室 新型輪式裝載機(jī)司機(jī)室的設(shè)計(jì)充分考慮了人的生理需求，對(duì)儀表位置排列、操作手柄和踏板、司機(jī)座椅、能見(jiàn)度、防噪和隔振、溫度調(diào)節(jié)等均符臺(tái)人機(jī)工程學(xué)，使司機(jī)在舒適、輕松、安全環(huán)境下操作，提高工作效率。如卡特彼勒輪式裝載機(jī)的司機(jī)室設(shè)有微機(jī)監(jiān)控裝置和可調(diào)懸掛式座椅，先導(dǎo)液壓閥操縱鏟斗控制手柄及流量放大轉(zhuǎn)向系統(tǒng)等，使操作輕便、靈活，采用防滾翻保護(hù)結(jié)構(gòu)(ROPS)和落體撞擊保護(hù)結(jié)構(gòu)(FOPS)符臺(tái)ISO標(biāo)準(zhǔn)要求。 3自動(dòng)化水平不斷提高 微電子技術(shù)的突破性進(jìn)展為輪式裝載機(jī)自動(dòng)控制、狀態(tài)監(jiān)測(cè)及視線范圍內(nèi)遙控技術(shù)的發(fā)展創(chuàng)造了條件。柴油發(fā)動(dòng)機(jī)自動(dòng)控制噴油系統(tǒng)、變速箱自動(dòng)控制換檔、性能參數(shù)和狀態(tài)監(jiān)測(cè)均取得重大進(jìn)展，在視線內(nèi)遙控作業(yè)已進(jìn)入實(shí)用階段，從而改善了性能，提高了可靠性，縮短了停機(jī)時(shí)間，增加了生產(chǎn)能力，降低了燃油消耗，取得了更大的經(jīng)濟(jì)效益。 3．1 柴油發(fā)動(dòng)機(jī)自動(dòng)控制噴油系統(tǒng) 卡特彼勒Cat994D型裝載機(jī)采用了Cat3516B型柴油發(fā)動(dòng)機(jī)，裝有HEUI型電控噴油系統(tǒng)，根據(jù)外載荷有效控制功率和轉(zhuǎn)速，發(fā)動(dòng)機(jī)噴油泵隨調(diào)速器動(dòng)作，精確地對(duì)燃油進(jìn)行調(diào)節(jié)、加壓和供油，降低初始噴油速率，減少NO 和HC，噪聲小，燃油效率高。 3．2 變速箱自動(dòng)控制換檔 日本川崎重工公司的KLD97ZⅢ型輪式裝載機(jī)采用自動(dòng)控制換檔的變速箱，可按裝載機(jī)運(yùn)轉(zhuǎn)工況自動(dòng)選擇最佳檔位，用微機(jī)控制離臺(tái)器，從而簡(jiǎn)化操作、提高作業(yè)效率、減少?zèng)_擊，實(shí)現(xiàn)平穩(wěn)換檔；電子控制裝置、傳感器等使用可靠，一旦控制系統(tǒng)發(fā)生故障，可用手動(dòng)換檔，不影響工作。 3．3 設(shè)備狀態(tài)監(jiān)測(cè) 卡特彼勒開(kāi)發(fā)的電子監(jiān)控(EMS)系統(tǒng)對(duì)輪式裝載機(jī)主要系統(tǒng)出現(xiàn)故障或潛在問(wèn)題提出警告和顯示，有三種不同的警告級(jí)別和信號(hào)，每種信號(hào)表明系統(tǒng)的狀態(tài)和司機(jī)應(yīng)采取的適當(dāng)措施。 3．4 機(jī)載電子稱重系統(tǒng) 目前，許多大型輪式裝載機(jī)都裝設(shè)機(jī)載電子稱重系統(tǒng)，能清楚地顯示出需再裝的物料量，從而使心中有數(shù)，以防止過(guò)載或欠載，減少無(wú)效跑車(chē)次數(shù)，節(jié)省作業(yè)時(shí)間，提高生產(chǎn)效率。并可對(duì)質(zhì)量累計(jì)計(jì)算顯示儀表以彩色數(shù)碼顯示，清楚明了，校準(zhǔn)簡(jiǎn)便，誤差為±3％以內(nèi)。 2）國(guó)內(nèi)輪式裝載機(jī)的發(fā)展現(xiàn)狀 在今后相當(dāng)長(zhǎng)的時(shí)間內(nèi)，輪式裝載機(jī)仍將是工程建設(shè)機(jī)械中最重要的機(jī)種之一，國(guó)內(nèi)年需求量持續(xù)穩(wěn)定地保持在一較高水平，但國(guó)內(nèi)裝載機(jī)生產(chǎn)廠家也在急劇膨脹，競(jìng)爭(zhēng)更趨激烈，各生產(chǎn)廠家紛紛開(kāi)發(fā)新產(chǎn)品，來(lái)迎接市場(chǎng)的挑戰(zhàn)。 ①3t以下裝載機(jī) 3t以下產(chǎn)品主要以ZL10、ZL15、ZL16為代表，還有一些利用拖拉機(jī)底盤(pán)改裝的小型裝載機(jī)，主要與日益增多的農(nóng)用運(yùn)輸車(chē)輛配套使用。主要零部件均采用一般性能及質(zhì)量的發(fā)動(dòng)機(jī)、驅(qū)動(dòng)橋、變速箱、液壓件。技術(shù)較先進(jìn)的靜液壓傳動(dòng)產(chǎn)品，液壓件國(guó)內(nèi)不易配套，產(chǎn)品成本居高不下，制約了該類(lèi)產(chǎn)品在國(guó)內(nèi)的發(fā)展。 ②ZL30裝載機(jī) ZL30裝載機(jī)主要生產(chǎn)廠家有成工、常林、徐工、宜工、山工等。該產(chǎn)品零部件配置較零亂，生產(chǎn)廠家具有自制的橋箱，風(fēng)格各具特色，質(zhì)量及性能上相對(duì)穩(wěn)定，技術(shù)先進(jìn)性一般。徐工最近開(kāi)發(fā)的ZL30F裝載機(jī)，采用電換擋變速箱，使3t級(jí)裝載機(jī)技術(shù)上有了新的突破。 ③ZL40／ZL50裝載機(jī) ZL40／ZL50裝載機(jī)，主要裝載機(jī)生產(chǎn)廠家均擁有該產(chǎn)品。第一代產(chǎn)品幾十年來(lái)沿續(xù)至今，全國(guó)幾乎使用同一套圖紙，有些技術(shù)力量薄弱的廠家，仍把其當(dāng)作主導(dǎo)產(chǎn)品推向市場(chǎng)。第二、三代產(chǎn)品主要是對(duì)工作裝置進(jìn)行優(yōu)化，改變外觀造型。如柳工ZL40B／ZL50C、徐工ZL40E／ZL50E。第四代產(chǎn)品是在第三代的基礎(chǔ)上，進(jìn)一步優(yōu)化整機(jī)的性能及配置，電控箱、濕式制動(dòng)器等新技術(shù)得到應(yīng)用，并形成了各企業(yè)的專有技術(shù)及專利技術(shù)，使產(chǎn)品以嶄新的面貌推向市場(chǎng)。 ④ZL60及6t以上裝載機(jī) 6t以及6t以上的裝載機(jī)，這是國(guó)內(nèi)潛在市場(chǎng)最大的產(chǎn)品，1998年以前大多數(shù)生產(chǎn)廠家均開(kāi)發(fā)了ZL60裝載機(jī)，但由于受傳動(dòng)件的制約，ZL60裝載機(jī)沒(méi)能成功地推向市場(chǎng)。在1999年北京國(guó)際工程機(jī)械博覽會(huì)上，各廠家推出了新一代ZL60裝載機(jī)，多數(shù)廠家選擇柳州ZF合資生產(chǎn)的箱或橋，液壓元件也有新配置，發(fā)動(dòng)機(jī)可選用斯太爾或上柴6121(Cat3306)，整機(jī)可靠性得到很大提高，給國(guó)內(nèi)大噸位裝載機(jī)帶來(lái)發(fā)展機(jī)遇。 ⑷ 產(chǎn)品在生產(chǎn)中的作用及使用范圍 ZL05裝載機(jī)是一種單橋驅(qū)動(dòng)、整體車(chē)架、機(jī)械傳動(dòng)的小型裝載機(jī)。該機(jī)適用于市政工程、城市環(huán)衛(wèi)、公路養(yǎng)護(hù)、車(chē)站碼頭、中小煤礦等單位裝載松散物料。可與翻斗車(chē)、輕型汽車(chē)、中小型拖拉機(jī)和農(nóng)用汽車(chē)配套使用，可明顯提高工作效率，降低工人勞動(dòng)強(qiáng)度，而且使用、維修簡(jiǎn)單、方便，價(jià)格低廉。 3.工作內(nèi)容和要求： ⑴題目的內(nèi)容 ①總體參數(shù)的確定，總體布置。 ②工作裝置及液壓系統(tǒng)設(shè)計(jì)。 ③典型零部件設(shè)計(jì)、選取。 ④整機(jī)合理性分析。 ⑵工作量 ①譯文6000字。 ②開(kāi)題報(bào)告。 ③說(shuō)明書(shū)20000字。 ④4張A0圖。 ⑤讀參考文獻(xiàn)15篇以上。 ⑥程序設(shè)計(jì)及典型零件工藝分析。 4.課題的重點(diǎn)和難點(diǎn)： ⅠZL05輪式裝載機(jī)的結(jié)構(gòu)組成 ①傳動(dòng)系統(tǒng)。 ②工作液壓系統(tǒng)。 ③工作裝置。 該機(jī)工作裝置由鏟斗、動(dòng)臂、搖臂和拉桿構(gòu)成，安裝在車(chē)架的支架上。 ④其他。 （1）該機(jī)采用了增加前橋橋荷和整機(jī)配重的措施，明顯地增加了前輪的附著力。 （2）與全液壓裝載機(jī)相比，該機(jī)結(jié)構(gòu)簡(jiǎn)單，操作容易，維修方便、價(jià)格低廉。 ⅡZL05輪式裝載機(jī)的主要技術(shù)參數(shù)： 額定裝載質(zhì)量(kg)： 500 額定斗容量(m3)： 0.25 最大卸載高度(mm)： 大于1900 相應(yīng)卸載距離(mm)： 大于800 軸距(mm)： 1540 輪距(mm)： 1150 最小離地間隙(mm)： 245 車(chē)速(km／h)： 前進(jìn)： V1=1.9, V2=4.4 V3=5.97, V4=7.1 V5=13.9, V6=22.2 后退： VR1=4.58 掘起力（KN）： 1100 最大牽引力（N）： 9000 發(fā)動(dòng)機(jī)額定功率(kW)： 15 機(jī)重（kg）： 1800 5.可能用到的主要知識(shí)和技能： 機(jī)械原理，機(jī)械設(shè)計(jì)，理論力學(xué)，材料力學(xué)，液壓與氣動(dòng)技術(shù)，工程材料，材料成型，自動(dòng)控制理論，測(cè)試技術(shù)，數(shù)控技術(shù)，微型計(jì)算機(jī)原理及應(yīng)用，自動(dòng)機(jī)械設(shè)計(jì)等本科期間學(xué)到的課程。 6.需要自學(xué)的知識(shí)和技能： SolidWorks,AUTOCAD,CATIA等繪圖仿真軟件。 二、 工作計(jì)劃 2006.02——2006.03 調(diào)研，譯文，開(kāi)題報(bào)告 2006.04.01——2006.04.15 總體布置及草圖 2006.04.15——2006.05.01 總體設(shè)計(jì)，總裝圖 2006.05.01——2006.05.15 零部件設(shè)計(jì)，說(shuō)明書(shū) 2006.05.15——2006.06.01 繪圖，論文 2006.06.01——2006.06.20 修改，完善圖紙、論文，準(zhǔn)備答辯 三、參考文獻(xiàn) [1] 劉慧斌，裝載機(jī)工作裝置優(yōu)化設(shè)計(jì)方法的研究，碩士，浙江大學(xué)，2000. [2] 吉林工業(yè)大學(xué)工程機(jī)械教研室.輪式裝載機(jī)設(shè)計(jì).北京：中國(guó)建筑工業(yè)出版社，1982. [3] 李建成.礦山裝載機(jī)設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1989. [4] 高夢(mèng)熊.地下裝載機(jī)結(jié)構(gòu)設(shè)計(jì)與使用.北京：北京冶金工業(yè)出版社，1987. [5] 王國(guó)彪，楊力夫.裝載機(jī)工作裝置優(yōu)化設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1996. [6] 機(jī)械設(shè)計(jì)手冊(cè)聯(lián)合編寫(xiě)組.機(jī)械設(shè)計(jì)手冊(cè).北京：化學(xué)工業(yè)出版社，1982. [7] 房斌，張文中，胡其穎.ZL05裝載機(jī).徐州：徐州工程機(jī)械集團(tuán)公司，1997. [8] 趙昱東.國(guó)外輪式裝載機(jī)的新進(jìn)展. 馬鞍山：馬鞍山礦研究院，2000. 8 本科生畢業(yè)設(shè)計(jì)（論文） 開(kāi)題報(bào)告 學(xué)生姓名：李鑫 學(xué) 號(hào)：14020926 班 級(jí)：140209 專 業(yè)：機(jī)械工程及自動(dòng)化 指導(dǎo)教師：李 風(fēng) 畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告 一、課題介紹 1.課題名稱： ZL05微型輪式裝載機(jī)總體設(shè)計(jì) 2.課題背景： ⑴ 設(shè)計(jì)課題的意義 ZL系列輪式裝載機(jī)是一種高效率的工程機(jī)械，具有結(jié)構(gòu)先進(jìn)，性能可靠，機(jī)動(dòng)性強(qiáng)，操縱方便等優(yōu)點(diǎn)。廣泛應(yīng)用于礦山，建筑工地，道路修建，水利工程，港口，貨場(chǎng)，電站以及其他工業(yè)部門(mén)，進(jìn)行裝載、推土、鏟挖、起重、牽引等多種作業(yè)。對(duì)加快工程建設(shè)速度減輕勞動(dòng)強(qiáng)度提高工程質(zhì)量降低工程成本都發(fā)揮著重要作用，因此近幾年來(lái)無(wú)論在國(guó)內(nèi)還是國(guó)外裝載機(jī)品種和產(chǎn)量都得到迅速發(fā)展，成為工程機(jī)械的主導(dǎo)產(chǎn)品之一。 為適應(yīng)工程施工，市政建設(shè)及農(nóng)用水利工地的砂石、灰土等各種散裝物料的裝運(yùn)需要，提出設(shè)計(jì)小型輪式裝載機(jī)的任務(wù)。 ⑵ 設(shè)計(jì)課題的目的 輪式裝載機(jī)總體設(shè)計(jì)是機(jī)械制造，機(jī)械設(shè)計(jì)和機(jī)械電子（機(jī)電一體化）等專業(yè)的一個(gè)重要的教學(xué)環(huán)節(jié)，是學(xué)完技術(shù)基礎(chǔ)課及有關(guān)專業(yè)課以后的一次專業(yè)課程內(nèi)容的綜合設(shè)計(jì)。通過(guò)設(shè)計(jì)提高學(xué)生的機(jī)構(gòu)分析與綜合的能力，機(jī)械構(gòu)造設(shè)計(jì)的能力，機(jī)電一體化系統(tǒng)設(shè)計(jì)能力，掌握實(shí)踐生產(chǎn)過(guò)程自動(dòng)化的設(shè)計(jì)方法。通過(guò)設(shè)計(jì)把有關(guān)課程（機(jī)械原理，機(jī)械設(shè)計(jì)，理論力學(xué)，材料力學(xué)，液壓與氣動(dòng)技術(shù)，工程材料，材料成型，自動(dòng)控制理論，測(cè)試技術(shù)，數(shù)控技術(shù)，微型計(jì)算機(jī)原理及應(yīng)用，自動(dòng)機(jī)械設(shè)計(jì)等）中所獲得的理論知識(shí)在實(shí)際中綜合的加以運(yùn)用，使這些知識(shí)得到鞏固和發(fā)展，并使理論知識(shí)和生產(chǎn)密切的結(jié)合起來(lái)。 輪式裝載機(jī)總體設(shè)計(jì)是機(jī)械設(shè)計(jì)及機(jī)械制造專業(yè)和機(jī)械電子專業(yè)的學(xué)生一次比較完整的整機(jī)設(shè)計(jì)。通過(guò)設(shè)計(jì)，培養(yǎng)學(xué)生獨(dú)立的機(jī)械整機(jī)設(shè)計(jì)的能力，樹(shù)立正確的設(shè)計(jì)思想，掌握機(jī)械產(chǎn)品設(shè)計(jì)的基本方法和步驟。通過(guò)設(shè)計(jì)使學(xué)生能熟練的應(yīng)用有關(guān)參考資料，計(jì)算圖表，手冊(cè)，圖冊(cè)和規(guī)范；熟悉有關(guān)國(guó)家標(biāo)準(zhǔn)，以完成一個(gè)工程技術(shù)人員在機(jī)械整體設(shè)計(jì)方面所必須具備的基礎(chǔ)技能訓(xùn)練。 ⑶ 輪式裝載機(jī)的發(fā)展現(xiàn)狀 1）國(guó)外輪式裝載機(jī)的發(fā)展現(xiàn)狀 1 新產(chǎn)品不斷推出 近年來(lái)，輪式裝載機(jī)以圍繞提高效率、降低成本為核心，繼續(xù)向大型化、微型化發(fā)展，不斷推出新產(chǎn)品，加速更新?lián)Q代。 卡特彼勒公司90年代初推出Cat966F輪式裝載機(jī)，時(shí)隔1年又推出Cat980F輪式裝載機(jī)，它增加了斗容和功率。改善了性能、提高了可靠性。不久又推出更大的Cat994輪式裝載機(jī)，根據(jù)物料體積質(zhì)量不同而選配l8～ 30m3的鏟斗，機(jī)重170t；裝有渦輪增壓后冷的Cat3516型柴油發(fā)動(dòng)機(jī)牽引力大、加速性能好；加長(zhǎng)的工作動(dòng)臂增加了卸載高度，能對(duì)載重量218t的大型自卸汽車(chē)裝載。 馬拉松?勒?qǐng)D爾勒(Marathon Letourneau)公司1990年和1994年在LI100的基礎(chǔ)上分別推出LI400和LI800型輪式裝載機(jī)。l998年9月在美國(guó)塔克癬(Tucson)召開(kāi)的Longding 2000年會(huì)上，該公司宣布正在開(kāi)發(fā)的斗容20．4m3的L1350型輪式裝載機(jī)將于21世紀(jì)初投放市場(chǎng)，供載重量150～200t自卸汽車(chē)裝載。 德雷塞(Dresser)公司90年代初推出4000型輪式裝載機(jī)，斗容10～30m3、機(jī)重151．8t，采用模塊結(jié)構(gòu)的傳動(dòng)系統(tǒng)，大功率、敏感按鈕控制的液壓系統(tǒng)．z型單搖臂工作裝置。優(yōu)化的整體結(jié)構(gòu)和濕式盤(pán)式制動(dòng)器，具有自動(dòng)調(diào)節(jié)和自動(dòng)密封性能。 目前，全世界約有400臺(tái)(功率大于750kw)大型輪式裝載機(jī)應(yīng)用在露天礦山和建筑工程，與大型自卸汽車(chē)配套使用。在發(fā)展大型輪式裝載機(jī)的同時(shí)，微型輪式裝載機(jī)以機(jī)動(dòng)靈活、效率高、多功能和價(jià)格低廉贏得市場(chǎng)，發(fā)展甚快。如：日本古河公司生產(chǎn)的FL30-1型輪式裝載機(jī)斗容0．34m3、機(jī)重2．3t；小松公司的WA30-1型斗容0．34rn3、柴油機(jī)功率20kW；豐田織機(jī)公司的斗容0．17m3、機(jī)重1t等這些微型裝載機(jī)適用于建筑工地和地下礦山挖溝、平地、堆料等。 2 新結(jié)構(gòu)不斷涌現(xiàn) 2．1 工作機(jī)構(gòu) 卡特技勒公司推出組合式八桿機(jī)構(gòu)。從地面到整個(gè)舉升高度范圍內(nèi)具有平行移動(dòng)的特點(diǎn)。它將快速連接器和塔架式機(jī)構(gòu)設(shè)計(jì)成整體式工作裝置，通過(guò)快速更換不同的輔助機(jī)構(gòu)完成裝卸、堆垛、掃雪、平地、清掃路面、推土、吊裝、搬運(yùn)和地表鉆孔等作業(yè)，實(shí)現(xiàn)一機(jī)多能，減少用戶設(shè)備投資。 德雷塞公司開(kāi)發(fā)Z型單臂工作機(jī)構(gòu)并與高壓液壓系統(tǒng)相結(jié)臺(tái)，為鏟斗提供更大的掘起力；縮短裝載工作循環(huán)，增加鏟斗裝滿系數(shù)，大幅度提高勞動(dòng)生產(chǎn)率。由于鉸點(diǎn)少、桿件少，便于維修保養(yǎng)，降低維修費(fèi)用。 2．2 傳動(dòng)機(jī)構(gòu) 以卡特彼勒公司為代表的輪式裝載機(jī)采用液力機(jī)械傳動(dòng)系統(tǒng)，其自動(dòng)動(dòng)力換檔變速箱自動(dòng)選擇檔位傳動(dòng)比，使換檔在變速箱最佳效率點(diǎn)進(jìn)行。該公司最近推出的STIC(轉(zhuǎn)向變速集成)系統(tǒng)，將轉(zhuǎn)向和換檔功能集成于一操縱手柄上，使操縱更加省力、輕便，換檔更加平穩(wěn)，可大幅度提高生產(chǎn)率。 以日本小松公司W(wǎng)A系列中小功率(小于125kW)為代表的輪式裝載機(jī)采用新型集中式結(jié)構(gòu)的驅(qū)動(dòng)橋。它將主傳動(dòng)制動(dòng)器和行星輪式終傳動(dòng)都集中在橋的中部，橋殼斷面變化連續(xù)、平緩，內(nèi)應(yīng)力分布臺(tái)理，從根本上防止因傳統(tǒng)結(jié)構(gòu)橋殼在輪邊支承軸段應(yīng)力集中斷裂。輪端采用浮動(dòng)密封結(jié)構(gòu)，安裝簡(jiǎn)便，有自動(dòng)補(bǔ)償功能，密封性能良好。該結(jié)構(gòu)設(shè)計(jì)合理、基本零件少、工藝性好、性能好、可靠性高。 馬拉松?勒?qǐng)D爾勒公司的輪式裝載機(jī)采用柴油機(jī)一發(fā)電機(jī)一電動(dòng)輪傳動(dòng)，比液力機(jī)械傳動(dòng)系統(tǒng)簡(jiǎn)單。在整個(gè)作業(yè)中柴油發(fā)動(dòng)機(jī)以恒定轉(zhuǎn)速運(yùn)轉(zhuǎn)，減少燃油消耗，延長(zhǎng)發(fā)動(dòng)機(jī)壽命；無(wú)變速箱、傳動(dòng)軸等許多部件，提高了傳動(dòng)效率，操作維修方便，費(fèi)用低；獨(dú)立電動(dòng)牽引馬達(dá)為固態(tài)控制，反應(yīng)迅速，減少車(chē)輪打滑和輪胎過(guò)渡磨損；設(shè)置了電動(dòng)緩行器，不用工作制動(dòng)停機(jī)，裝料對(duì)位準(zhǔn)確；整機(jī)重心低，行駛穩(wěn)定性好，可靠性高。 2．3 液壓系統(tǒng) 德雷塞公司輪式裝載機(jī)液壓系統(tǒng)用傳感器接受柴油機(jī)轉(zhuǎn)速信號(hào)，當(dāng)轉(zhuǎn)速下降時(shí)柱塞式變量泵便自動(dòng)增加轉(zhuǎn)向系統(tǒng)流量，以保持恒定的轉(zhuǎn)向速度，在最大挖掘工況時(shí)可減少流量，減慢液壓元件動(dòng)作，以保持液壓系統(tǒng)的動(dòng)力平衡，減少液壓系統(tǒng)熱損耗，節(jié)省功率?？ㄌ乇死蛰喪窖b載機(jī)轉(zhuǎn)向液壓系統(tǒng)用負(fù)荷傳感式溢流閥，使液壓泵在負(fù)載決定壓力下溢流，降低系統(tǒng)壓力，提高了液壓元件壽命。工作裝置液壓系統(tǒng)采用舉升限位裝置和下放自動(dòng)定位裝置，避免了機(jī)械限位時(shí)液壓缸行程終了產(chǎn)生高壓和沖擊；裝設(shè)的蓄能器能吸收沖擊載荷，并對(duì)整機(jī)的縱向搖擺起阻尼作用；液壓缸導(dǎo)向套處有三重密封，防止泄漏和肪塵。 2．4 司機(jī)室 新型輪式裝載機(jī)司機(jī)室的設(shè)計(jì)充分考慮了人的生理需求，對(duì)儀表位置排列、操作手柄和踏板、司機(jī)座椅、能見(jiàn)度、防噪和隔振、溫度調(diào)節(jié)等均符臺(tái)人機(jī)工程學(xué)，使司機(jī)在舒適、輕松、安全環(huán)境下操作，提高工作效率。如卡特彼勒輪式裝載機(jī)的司機(jī)室設(shè)有微機(jī)監(jiān)控裝置和可調(diào)懸掛式座椅，先導(dǎo)液壓閥操縱鏟斗控制手柄及流量放大轉(zhuǎn)向系統(tǒng)等，使操作輕便、靈活，采用防滾翻保護(hù)結(jié)構(gòu)(ROPS)和落體撞擊保護(hù)結(jié)構(gòu)(FOPS)符臺(tái)ISO標(biāo)準(zhǔn)要求。 3自動(dòng)化水平不斷提高 微電子技術(shù)的突破性進(jìn)展為輪式裝載機(jī)自動(dòng)控制、狀態(tài)監(jiān)測(cè)及視線范圍內(nèi)遙控技術(shù)的發(fā)展創(chuàng)造了條件。柴油發(fā)動(dòng)機(jī)自動(dòng)控制噴油系統(tǒng)、變速箱自動(dòng)控制換檔、性能參數(shù)和狀態(tài)監(jiān)測(cè)均取得重大進(jìn)展，在視線內(nèi)遙控作業(yè)已進(jìn)入實(shí)用階段，從而改善了性能，提高了可靠性，縮短了停機(jī)時(shí)間，增加了生產(chǎn)能力，降低了燃油消耗，取得了更大的經(jīng)濟(jì)效益。 3．1 柴油發(fā)動(dòng)機(jī)自動(dòng)控制噴油系統(tǒng) 卡特彼勒Cat994D型裝載機(jī)采用了Cat3516B型柴油發(fā)動(dòng)機(jī)，裝有HEUI型電控噴油系統(tǒng)，根據(jù)外載荷有效控制功率和轉(zhuǎn)速，發(fā)動(dòng)機(jī)噴油泵隨調(diào)速器動(dòng)作，精確地對(duì)燃油進(jìn)行調(diào)節(jié)、加壓和供油，降低初始噴油速率，減少NO 和HC，噪聲小，燃油效率高。 3．2 變速箱自動(dòng)控制換檔 日本川崎重工公司的KLD97ZⅢ型輪式裝載機(jī)采用自動(dòng)控制換檔的變速箱，可按裝載機(jī)運(yùn)轉(zhuǎn)工況自動(dòng)選擇最佳檔位，用微機(jī)控制離臺(tái)器，從而簡(jiǎn)化操作、提高作業(yè)效率、減少?zèng)_擊，實(shí)現(xiàn)平穩(wěn)換檔；電子控制裝置、傳感器等使用可靠，一旦控制系統(tǒng)發(fā)生故障，可用手動(dòng)換檔，不影響工作。 3．3 設(shè)備狀態(tài)監(jiān)測(cè) 卡特彼勒開(kāi)發(fā)的電子監(jiān)控(EMS)系統(tǒng)對(duì)輪式裝載機(jī)主要系統(tǒng)出現(xiàn)故障或潛在問(wèn)題提出警告和顯示，有三種不同的警告級(jí)別和信號(hào)，每種信號(hào)表明系統(tǒng)的狀態(tài)和司機(jī)應(yīng)采取的適當(dāng)措施。 3．4 機(jī)載電子稱重系統(tǒng) 目前，許多大型輪式裝載機(jī)都裝設(shè)機(jī)載電子稱重系統(tǒng)，能清楚地顯示出需再裝的物料量，從而使心中有數(shù)，以防止過(guò)載或欠載，減少無(wú)效跑車(chē)次數(shù)，節(jié)省作業(yè)時(shí)間，提高生產(chǎn)效率。并可對(duì)質(zhì)量累計(jì)計(jì)算顯示儀表以彩色數(shù)碼顯示，清楚明了，校準(zhǔn)簡(jiǎn)便，誤差為±3％以內(nèi)。 2）國(guó)內(nèi)輪式裝載機(jī)的發(fā)展現(xiàn)狀 在今后相當(dāng)長(zhǎng)的時(shí)間內(nèi)，輪式裝載機(jī)仍將是工程建設(shè)機(jī)械中最重要的機(jī)種之一，國(guó)內(nèi)年需求量持續(xù)穩(wěn)定地保持在一較高水平，但國(guó)內(nèi)裝載機(jī)生產(chǎn)廠家也在急劇膨脹，競(jìng)爭(zhēng)更趨激烈，各生產(chǎn)廠家紛紛開(kāi)發(fā)新產(chǎn)品，來(lái)迎接市場(chǎng)的挑戰(zhàn)。 ①3t以下裝載機(jī) 3t以下產(chǎn)品主要以ZL10、ZL15、ZL16為代表，還有一些利用拖拉機(jī)底盤(pán)改裝的小型裝載機(jī)，主要與日益增多的農(nóng)用運(yùn)輸車(chē)輛配套使用。主要零部件均采用一般性能及質(zhì)量的發(fā)動(dòng)機(jī)、驅(qū)動(dòng)橋、變速箱、液壓件。技術(shù)較先進(jìn)的靜液壓傳動(dòng)產(chǎn)品，液壓件國(guó)內(nèi)不易配套，產(chǎn)品成本居高不下，制約了該類(lèi)產(chǎn)品在國(guó)內(nèi)的發(fā)展。 ②ZL30裝載機(jī) ZL30裝載機(jī)主要生產(chǎn)廠家有成工、常林、徐工、宜工、山工等。該產(chǎn)品零部件配置較零亂，生產(chǎn)廠家具有自制的橋箱，風(fēng)格各具特色，質(zhì)量及性能上相對(duì)穩(wěn)定，技術(shù)先進(jìn)性一般。徐工最近開(kāi)發(fā)的ZL30F裝載機(jī)，采用電換擋變速箱，使3t級(jí)裝載機(jī)技術(shù)上有了新的突破。 ③ZL40／ZL50裝載機(jī) ZL40／ZL50裝載機(jī)，主要裝載機(jī)生產(chǎn)廠家均擁有該產(chǎn)品。第一代產(chǎn)品幾十年來(lái)沿續(xù)至今，全國(guó)幾乎使用同一套圖紙，有些技術(shù)力量薄弱的廠家，仍把其當(dāng)作主導(dǎo)產(chǎn)品推向市場(chǎng)。第二、三代產(chǎn)品主要是對(duì)工作裝置進(jìn)行優(yōu)化，改變外觀造型。如柳工ZL40B／ZL50C、徐工ZL40E／ZL50E。第四代產(chǎn)品是在第三代的基礎(chǔ)上，進(jìn)一步優(yōu)化整機(jī)的性能及配置，電控箱、濕式制動(dòng)器等新技術(shù)得到應(yīng)用，并形成了各企業(yè)的專有技術(shù)及專利技術(shù)，使產(chǎn)品以嶄新的面貌推向市場(chǎng)。 ④ZL60及6t以上裝載機(jī) 6t以及6t以上的裝載機(jī)，這是國(guó)內(nèi)潛在市場(chǎng)最大的產(chǎn)品，1998年以前大多數(shù)生產(chǎn)廠家均開(kāi)發(fā)了ZL60裝載機(jī)，但由于受傳動(dòng)件的制約，ZL60裝載機(jī)沒(méi)能成功地推向市場(chǎng)。在1999年北京國(guó)際工程機(jī)械博覽會(huì)上，各廠家推出了新一代ZL60裝載機(jī)，多數(shù)廠家選擇柳州ZF合資生產(chǎn)的箱或橋，液壓元件也有新配置，發(fā)動(dòng)機(jī)可選用斯太爾或上柴6121(Cat3306)，整機(jī)可靠性得到很大提高，給國(guó)內(nèi)大噸位裝載機(jī)帶來(lái)發(fā)展機(jī)遇。 ⑷ 產(chǎn)品在生產(chǎn)中的作用及使用范圍 ZL05裝載機(jī)是一種單橋驅(qū)動(dòng)、整體車(chē)架、機(jī)械傳動(dòng)的小型裝載機(jī)。該機(jī)適用于市政工程、城市環(huán)衛(wèi)、公路養(yǎng)護(hù)、車(chē)站碼頭、中小煤礦等單位裝載松散物料?？膳c翻斗車(chē)、輕型汽車(chē)、中小型拖拉機(jī)和農(nóng)用汽車(chē)配套使用，可明顯提高工作效率，降低工人勞動(dòng)強(qiáng)度，而且使用、維修簡(jiǎn)單、方便，價(jià)格低廉。 3.工作內(nèi)容和要求： ⑴題目的內(nèi)容 ①總體參數(shù)的確定，總體布置。 ②工作裝置及液壓系統(tǒng)設(shè)計(jì)。 ③典型零部件設(shè)計(jì)、選取。 ④整機(jī)合理性分析。 ⑵工作量 ①譯文6000字。 ②開(kāi)題報(bào)告。 ③說(shuō)明書(shū)20000字。 ④4張A0圖。 ⑤讀參考文獻(xiàn)15篇以上。 ⑥程序設(shè)計(jì)及典型零件工藝分析。 4.課題的重點(diǎn)和難點(diǎn)： ⅠZL05輪式裝載機(jī)的結(jié)構(gòu)組成 ①傳動(dòng)系統(tǒng)。 ②工作液壓系統(tǒng)。 ③工作裝置。 該機(jī)工作裝置由鏟斗、動(dòng)臂、搖臂和拉桿構(gòu)成，安裝在車(chē)架的支架上。 ④其他。 （1）該機(jī)采用了增加前橋橋荷和整機(jī)配重的措施，明顯地增加了前輪的附著力。 （2）與全液壓裝載機(jī)相比，該機(jī)結(jié)構(gòu)簡(jiǎn)單，操作容易，維修方便、價(jià)格低廉。 ⅡZL05輪式裝載機(jī)的主要技術(shù)參數(shù)： 額定裝載質(zhì)量(kg)： 500 額定斗容量(m3)： 0.25 最大卸載高度(mm)： 大于1900 相應(yīng)卸載距離(mm)： 大于800 軸距(mm)： 1540 輪距(mm)： 1150 最小離地間隙(mm)： 245 車(chē)速(km／h)： 前進(jìn)： V1=1.9, V2=4.4 V3=5.97, V4=7.1 V5=13.9, V6=22.2 后退： VR1=4.58 掘起力（KN）： 1100 最大牽引力（N）： 9000 發(fā)動(dòng)機(jī)額定功率(kW)： 15 機(jī)重（kg）： 1800 5.可能用到的主要知識(shí)和技能： 機(jī)械原理，機(jī)械設(shè)計(jì)，理論力學(xué)，材料力學(xué)，液壓與氣動(dòng)技術(shù)，工程材料，材料成型，自動(dòng)控制理論，測(cè)試技術(shù)，數(shù)控技術(shù)，微型計(jì)算機(jī)原理及應(yīng)用，自動(dòng)機(jī)械設(shè)計(jì)等本科期間學(xué)到的課程。 6.需要自學(xué)的知識(shí)和技能： SolidWorks,AUTOCAD,CATIA等繪圖仿真軟件。 二、 工作計(jì)劃 2006.02——2006.03 調(diào)研，譯文，開(kāi)題報(bào)告 2006.04.01——2006.04.15 總體布置及草圖 2006.04.15——2006.05.01 總體設(shè)計(jì)，總裝圖 2006.05.01——2006.05.15 零部件設(shè)計(jì)，說(shuō)明書(shū) 2006.05.15——2006.06.01 繪圖，論文 2006.06.01——2006.06.20 修改，完善圖紙、論文，準(zhǔn)備答辯 三、參考文獻(xiàn) [1] 劉慧斌，裝載機(jī)工作裝置優(yōu)化設(shè)計(jì)方法的研究，碩士，浙江大學(xué)，2000. [2] 吉林工業(yè)大學(xué)工程機(jī)械教研室.輪式裝載機(jī)設(shè)計(jì).北京：中國(guó)建筑工業(yè)出版社，1982. [3] 李建成.礦山裝載機(jī)設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1989. [4] 高夢(mèng)熊.地下裝載機(jī)結(jié)構(gòu)設(shè)計(jì)與使用.北京：北京冶金工業(yè)出版社，1987. [5] 王國(guó)彪，楊力夫.裝載機(jī)工作裝置優(yōu)化設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1996. [6] 機(jī)械設(shè)計(jì)手冊(cè)聯(lián)合編寫(xiě)組.機(jī)械設(shè)計(jì)手冊(cè).北京：化學(xué)工業(yè)出版社，1982. [7] 房斌，張文中，胡其穎.ZL05裝載機(jī).徐州：徐州工程機(jī)械集團(tuán)公司，1997. [8] 趙昱東.國(guó)外輪式裝載機(jī)的新進(jìn)展. 馬鞍山：馬鞍山礦研究院，2000. 8 Aspects to improve cabin comfort of wheel loaders and excavators according to operators Abstract Comfort plays an increasingly important role in interior design of earth moving equipment. Although research has been conducted on vehicle interiors of wheel loa- ders and excavators, hardly any information is known about the operator’s opinion. In this study a questionnaire was completed by machine operators to get their opinion about aspects which need to be improved in order to design a more comfortable vehi- cle interior. The results show that almost half of the operators rate the comfort of th- eir cabin‘‘a(chǎn)verage’’ or ‘‘poor’’. According to the operators, cab comfort of wheel loaders can be increased by improving seat comfort. Besides improving seat comfort, cabin comfort of excavators can be improved by changing the cab design (including dimensions, ingress/egress), view, reliability, and climate control. Keywords: Cabin comfort; Operators’ opinion; Earth moving equipment. 1. Introduction Comfort plays an increasingly important role in vehicle design. As machine operators of earth moving equipment often spend long hours in their vehicle— some- times even more than 8 h a day—comfort is a major issue in interior design of these machines.Operating earth-moving machinery is not a physically heavy job and can be sustained for long periods.Nevertheless, operating such a machine appears to be a risk factor for musculoskeletal disorders, especially when the task is not interrupted by other working activities or breaks. Zimmerman et al. (1997) showed that the main problems of earth-moving machinery operators concern physical complaints in the neck/ shoulder and low back region, general fatigue and feelings of discomfort. This might be attributed to a combination of static load during prolonged sitting— frequ- ently in awkward postures—exposure to whole body vibrations, and handling and steering the machine(Zimmerman et al., 1997; Tola et al., 1988; de Looze et al., 2000). A comfortable well-designed vehicle interior may reduce awkward postures and provide an environment that stimulates optimal operator performance. Based on a literature review about musculoskeletal disorders and their risk factors, Zimmerman et al. (1997) made four recommendations for reducing work-related musculoskeletal disorders among operators: minimizing of magnitude and frequency of vibration rea- ching the operator; locating controls optimally to minimize reach distances, trunk ?exion and trunk rotation; providing maximum operator visibility from an upright supported seated posture; and taking regular breaks to minimize the effects of sus- tained postures. Improvements of cab comfort are very often based on reducing the risk factors for work-related musculoskeletal disorders (Zimmerman et al., 1997; Attebrant et al., 1997). Only a few studies have mentioned aspects which operators wishto see improved. Nakada (1997) describes the desirability ranking for dump trucks and wheel loaders given by product creators, designers, design engineers, operators and young people. Nakada, (1997) shows that much design attention has been paid to instrument panel/monitors and meters and the operator seat. Unfor- tunately, the operators’ opinions cannot be distinguished in Nakada’s study (1997). However, in order to design a comfortable vehicle interior, the opinion of the operators is important as they are the end-users of the machines. Their user expe- rience may be of great help designing a more comfortable vehicle interior. The aim of the current study is to ?nd aspects mentioned by wheel loader and excavator ope- rators, which can be used to improve the comfort of vehicle interiors in the future. In this article we describe the results of a questionnaire given to 273 machine operators. They were asked their opinion about their current machine, their future demands and aspects they considered important to work well with the machine. This allowed us to identify aspects that need improvement in machine design. 2. Method 2.1. Subjects A convenience sample was obtained through approaching operators visiting Ba- uma (the world’s largest exhibition for construction equipment). Most of the parti- cipants were wheel loader operators (n = 61) and excavator operators (n=212). The others (n = 65) were operators of several construction machines (e.g., mobile cranes, dozers, tower cranes, off-road trucks). Only the results for wheel loader and excava- tor operators are presented in this article, as they account for 18% and 62.7% of the total number of respondents respectively. Figs. 1 and 2 show a typical wheel loader and excavator. 2.2. Questionnaire Data were collected by means of a questionnaire which was completed during an interview. The questionnaire was divided into three parts: (1) characteristics of the population, (2) evaluation of the current machine being operated, and (3) future de- mands on earthmoving machinery. In the ?rst part we asked the operator’s age, years of experience as operator, the kind of machinery being operated and its age. In the se- cond part of the questionnaire, operators evaluated their machine by rating overall comfort and their opinion of speci?c parts of the machine on a four-point scale (very good, good, average, poor). Finally, two open questions asked about the operator’s f- uture demands: what improvements would make the machine more comfortable and what aspects are the most important to work well with the machine. 2.3. Data analysis Data were sorted by machine type, after which the responses of wheel loader operators and excavator operators were separately analyzed. Within these groups, operators of older machinery (≥4 years old) were separated from operators of newer machinery (〈4 years old). In addition, the categories ‘‘very good’’ and‘‘good’’ were combined (‘‘very good/good’’) and the categories ‘‘a(chǎn)verage’’ and ‘‘poor’’ were com- bined(‘‘a(chǎn)verage/poor’’). Frequency tables were made of the operators opinions about overall machine comfort and about their opinions about speci?c parts of their machines. Chi-square was calculated between age of machine and overall comfort and between age of ma- chine and the operators’ opinion of speci?c parts of the machine. We assumed that if fewer than 80% of the operators rated a part of the machine ‘‘good/very good’’, im- provement of this part could contribute to a more comfortable vehicle interior. In part three of the questionnaire, the operators indicated aspects to improve machine com- fort and aspects they found necessary to work well with the machine. We classi?ed these aspects into categories and calculated the percentage responses. 3. Results 3.1. Characteristics of the population Both the wheel loader operators (mean age: 36.5±9.4 years) and the excavator operators (mean age: 36.3±9.3 years) who participated in this study, were experien- ced with a mean of 12.3 (±8.1) and 13.4 (±9.2) years of service, respectively. Half of the operators operate machines less than 4 years old (53% of the wheel loader and 50% of the excavator operators). 3.2. Evaluation of current machine 57.4% of wheel loader operators and 55.9% of the excavator operators rated the overall cabin comfort‘‘good/very good’’. It shows that operators of newer machinery (<4 years old) rated the overall cab comfort as ‘‘good/very good’’ more often than operators of older machines (≥4 years old). This was found both among wheel load- ers (χ2(1)=8.5,p<0.04) and among excavators (χ2(1)=23.0,p<0.001).Seventy-eight percent of the operators driving wheel loaders less than 4 years old, rated the comfort of their machine as ‘‘good/very good’’.With excavator operators this ?gure was 81%. These results show that during recent years the experienced cab comfort of excavat- ors and wheel loaders has improved.It illustrates the opinion of the operators about speci?c parts of the machines less than 4 years old.Fewer aspects of wheel loaders are rated‘‘a(chǎn)verage/poor’’ by more than 20% of the operators, than excavators. Com- mon aspects which can contribute to increase of cab comfort are dashboard and dis- plays, adjustability of seats and controls, vibration and damping, noise reduction, and seat comfort. Excavator operators would also like to see improvement of climate co- ntrol, improved machine appearance, and better cab dimensions (including interior space, ingress/egress),view, and reliability. 3.3. Future demands The participants generated 467 items desired to improve the machine’s comfort. We classi?ed these aspects into 15 categories (see Table 2). It shows which features should be improved according to the operators. Seat comfort, climate control and ac- cessories are often mentioned for both wheel loaders (20%, 12%,15%, resp.) and ex- cavators (21%, 19%, 12%, resp.).Excavator operators also mention cab design (inc- luding dimensions, ingress/egress; 19%). The aspects considered most important to work well with the machine are sum- marized . Machine performance is by far the most important issue if we look at the averages. Other aspects like view and reliability play less important roles. 4. Discussion The aim of the current study was to ?nd aspects mentioned by wheel loader and excavator operators which can be used to improve the comfort of vehicle interiors in future. In order to ?nd these aspects, we asked questions about three issues. ?about comfort of speci?c aspects of the cab (rating on a four-point scale); ?about aspects necessary to improve the cab comfort (open question); ?about aspects important to work well with the machine (open question). Excavator and wheel loader operators mentioned improved seat comfort, clim- ate control and accessories as ways to increase cab comfort. Excavator operators also mentioned cab design (including dimensions, ingress/egress). These aspects were al- so rated as‘‘a(chǎn)verage/poor’’ by more than 20% of the operators (except accessories be- cause this was not an item in the second part of the questionnaire). Other aspects wh- ich can be taken into account with cab design are those which operators mention as most important aspects to work well with the machine. Especially when these aspects are also rated as ‘‘a(chǎn)verage/poor’’ by more than 20% of the operators, they need spec- ial attention.Improving these aspects have priority in designing a more comfortable cab. In our study, we collected our data among visitors to the Bauma exhibition in 2001. The advantage of this collection method is that it is possible to reach a large group of operators within a short period of time, at the same time getting a large re- sponse, which would normally be very dif?cult. A disadvantage might be that the va- st majority of respondents were German which could mean that the results have a li- mited validity among operators in other countries. The German operators may have other ideas about cab comfort than operators, who work in other countries. The de- mands of the operators on their machine depend on the working environment (e.g., climate, landscape, dust) and their tasks (e.g., driving off road, driving on the main road), which can be different between countries. Besides, the operators based their opinion on their current machine. It is possible that in Germany certain brands are overrepresented compared to other countries and that the operator’s opinion might vary according to the brand. The most common brands would therefore in?uence the results of our study as many operators use one of these machines (Excavators: brand A 22.6%, brand B 22.2%;Wheel loaders: brand A 21.3%, brand B 18%, brand C 11.5 %). Since we used a short questionnaire to collect the data, no detailed information could be asked. The goal of our study was to get a global view on the operators’ opi- nion. The open questions gave the operators the opportunity to think open-minded which may render valuable information. Open questions are less suitable for data an- alysis, because we needed to categorize answers. Inevitably information is lost in this process, but the goal of obtaining a global view was nevertheless achieved. Our results show that seat comfort, climate control, accessories (for wheel load- ers and excavators) and cab design (including dimensions, ingress/egress), view, and reliability (for excavators only) are the aspects which can improve cab comfort. All these aspects are rated‘‘a(chǎn)verage/poor’’ by more than 20% of the operators and they a- re also mentioned as aspects which need improvement in order to increase cab com- fort. In our opinion designers should give priority to these items when redesigning cabs. It is interesting that operators did not mention vibration as an aspect which can improve comfort, as it was ranked high on the list of machine parts rated ‘‘a(chǎn)verage/p- oor’’. Besides, whole body vibration is a serious health hazard (Houtman et al., 200 1). It is possible that the operators did not mention vibration because they may see vibration as an engine property or an inevitable consequence of working on earth- moving equipment. Operators might have the idea that vibration cannot be reduced by redesigning only the cab. It is,however, unclear why operators did not mention vibration. When comparing excavators and wheel loaders, improving seat comfort is an is- sue for both wheel loaders and excavators. Although seat comfort in excavators has been improved during recent years (see Table 1), improvements are still necessary. However,this is not easy as sitting comfort depends on many other factors more or less related to seat design: e.g., adjustability of seat and controls, vibration and dam- ping, and view. For example, a bad view from the cabin can result in awkward body postures, which reduces comfort in spite of a comfortable seat. Beyond the common aspect seat comfort, many differences exist between wheel loaders and excavators. One difference we found between the excavator and the wh- eel loader was that excavator cab design (including dimensions and ingress/egress) needs improvement. This difference may be explained by access and space. Firs- t,there is a difference in machine access with grips generally quite wide apart and steps to the cabin far from optimal, being either too high or too narrow. Operators could experience this as a problem. Secondly, there is a fundamental difference be- tween wheel loaders and excavators in the space available for the cab. With the pre- sent design, excavators have a limited width available for the cab as it must be posi- tioned between the boom and the left machine side, leaving approximately 1 m for the cab. Another difference is that improving view can increase the cab comfort of the excavator. View is a very important aspect to work well with the excavator. The boo- m of the excavator has a wide range of motion and the operator needs to see the bu- cket for the full range. A comfortable cab provides a clear view of the work place and the bucket, without necessitating awkward postures. In the introduction, we stated that comfort plays an important role in cab design. It is therefore interesting to ?nd that the operators did not mention comfort as one of the most important aspects to work well with the machine. They mentioned aspects such as the machine’s performance, reliability, view and operability. It seems that operators think ?rst about the basic requirements needed to perform their task and apparently do not see comfort as one of them. If we compare our results with the results of Nakada, (1997), in both studies the operator seat is ranked as important. Instrument panel, monitors and meters are also ranked as important in Nakada’s study. In our study vibration, dashboard and disp- lays are high on the list of parts rated as ‘‘a(chǎn)verage/poor’’ by more than 20% of the operators, but they are not seen as aspects that can improve cab comfort. Nakada’s study did not mention vibration at all. A reason for this may be that in our study, ex- perienced operators played a larger role than in Nakada’s and because that study was focused on interior design. An increase in cab comfort has been achieved during recent years. From Table 1 it seems that wheel loaders have made progress on fewer aspects than excavators. But in fact, the improvements of speci?c aspects of wheel loaders (i.e., machine’s ap- pearance, climate control, and view) were of such a high level that these aspects were rated as ‘‘a(chǎn)verage/poor’’ by fewer than 20% of the operators and are therefore not m- entioned in this table. However, 27.7% of the excavator operators and 25.0% of the wheel loader operators of machinery less than 4 years old rate the cabin’s comfort ‘‘a(chǎn)verage/ poor’’. These results show that improvement of cab comfort is still needed. In our study, we found some important aspects which can contribute to improvement of cab comfort. Unfortunately, these aspects do not represent detailed information, and we can not say how they should be changed to get a more comfortable cab. The- refore, further research is necessary to indicate speci?c improvements for each mac- hine individually. 5. Conclusion Operators do not mention cabin comfort as one of the most important aspects to work well with the machine, yet when asked about it almost half of the wheel loader and excavator operators rate their cabin’s comfort as ‘‘a(chǎn)verage/poor’’. Cab comfort of wheel loaders can be increased by improving seat comfort. Besides seat comfort, cab comfort of excavators can be improved by changing the cab design (including dimensions,ingress/egress), view, reliability, and climate control, according to the operators. Because we cannot say speci?cally how these aspects should be changed to get a more comfortable cab, further research is necessary to indicate speci?c impr- ovements for excavators and wheel loaders individually.