2404 沖壓廢料自動輸送裝置設計,沖壓,廢料,廢物,自動,輸送,裝置,設計 附件 3：邵陽學院畢業(yè)設計（論文）任務書年級專業(yè) 2004 級機制?？茖I(yè) 學生姓名 尹婷 學 號 0430817055課題名稱 沖 壓 廢 料 自 動 輸 送 裝 置 設 計設計(論文)起止時間 2007 年 3 月 20 日至 2007 年 6 月 9 日課題類型 工程設計 課題性質(zhì) 真實一、課題設計（研究）的目的和主要內(nèi)容研究目的：綜合機械制造專業(yè)所學課程的理論和實踐知識，進行一次實際解決問題的設計，培養(yǎng)學生獨立解決設計和制造上理論與實際問題的能力, 提高學生資料查閱和靈活使用軟件語言的能力。完成工廠沖壓廢料自動輸送裝置的設計。主要內(nèi)容：設計出一臺適應不同模具尺寸的沖壓廢料自動輸送裝置，使用一臺馬達同時驅動多條輸送帶，解決了一臺馬達驅動一條輸送帶所帶來的橫向空間不夠的問題。使廢料收集更方便、安全。提高生產(chǎn)效率。二、基本要求1、必須獨立完成畢業(yè)設計工作。2、完成裝備圖、主要部件圖、重要的零件圖、皮帶運輸機的電氣原理圖。3、按學院畢業(yè)設計的書寫格式要求，撰寫設計說明書，畢業(yè)設計說明書不少于 30000 字。4、應完成 3000-5000 個文字的與畢業(yè)設計有關的外文資料翻譯, 譯文要求準確,文字流暢。注：1、此表由指導教師填寫，經(jīng)各系、教研室主任審批，指導教師、學生簽字后生效；2、此表 1 式 3 份，學生、指導教師、教研室各 1 份。三、課題研究已具備的條件（包括實驗室、主要儀器設備、參考資料）1、實習工廠沖壓設備。2、邵陽學院圖書館相關資料：如主要參考資料：《沖壓設備》 ， 《機械設計手冊》 ， 《機械設計》， 《機床電氣控制原理》, 期刊雜志《模具工業(yè)》 、 《沖壓技術》 、 《沖壓工藝》 、中國沖壓件網(wǎng)、沖壓廢料處理網(wǎng)。3、課題前期的調(diào)查、研究工作四、設計（論文）進度安排2 月 20 日～3 月 20 日：調(diào)研、資料準備、確定方案、繪制草圖；3 月 21 日～4 月 21 日：完成裝配圖、部件圖、零件圖；4 月 22 日～5 月 22 日：編寫設計說明書；5 月 23 日～6 月 10 日：校對、總結、準備答辯。五、教研室審批意見教研室主任（簽字） 年 月 日六、系審批意見系主任（簽字） 單位（公章） 年 月 日指導教師（簽字）： 學生（簽字）：邵 陽 學 院畢業(yè)設計（論文）開題報告書課 題 名 稱 沖壓廢料自動輸送裝置 學 生 姓 名 尹 婷 學 號 0430817055 系 、 專 業(yè) 機 械 與 能 源 工 程 系 機 械 制 造 工 藝 與 設 備 指 導 教 師 陳 志 剛 2007 年 3 月 20 日一、課題的來源、目的意義（包括應用前景） 、國內(nèi)外現(xiàn)狀及水平課題來源：目前還有很多工廠的沖壓廢料清除方式都是最原始的人工清掃，機箱裝載。手工生產(chǎn)線需停機清掃，自動生產(chǎn)線雖不停機，但清掃時極不安全。同時手工清掃廢料及目前廢料收集方式使整個生產(chǎn)現(xiàn)場顯得零亂。廢料滿地散落，場地不清潔，人工清除廢料勢必停機作業(yè)，影響生產(chǎn)效率。目的：通過綜合運用所學的知識，在老師的指導下解決實際工程問題，培養(yǎng)學生理論聯(lián)系實際的能力，良好的設計思想和工作作風。意義：本次設計是要求解決實際的工程問題，不僅要求掌握具有相當?shù)膶I(yè)知識，還可以鍛煉獨立解決問題的能力，提高查閱設計手冊的能力，熟悉相關的國家標準的國際標準，更加熟練操作繪圖軟件繪制工程圖。最重要的是能讓我們學到的理論知識運用到實踐中，提高實踐能力。使我們的設計更具實用性，能為社會發(fā)展貢獻自己的一份微薄之力。本次設計還能讓我們更多的接觸社會，了解社會的發(fā)展態(tài)勢和國內(nèi)外的研究現(xiàn)狀，為自己以后的發(fā)展奠定基礎。應用前景：本課題就針對模具墊腳高度、間距及位置不一，夾模器的干涉，如何從模下自動清除廢料等問題，設計一種適應性強，效率高，安全可靠的廢料自動輸送裝置。應用相當?shù)膹V泛。國內(nèi)外現(xiàn)狀及水平：在沖壓作業(yè)中，沖壓機械設備、模具、作業(yè)方式對安全影響很大。實現(xiàn)沖壓機械化和廢料收集自動化，能大幅度提高沖壓設備的利用率和勞動生產(chǎn)率并保證人身安全。但是，沖壓作業(yè)的動作頻率高，又多數(shù)是薄板加工，所以保證沖壓機械化和廢料收集自動化的可靠性在技術上實現(xiàn)的難度較大。沖壓廢料的收集常常需要停機工作，既影響生產(chǎn)，又極不安全。目前，國內(nèi)、外研究的輸送裝置往往只針對一種沖壓產(chǎn)品，當遇到模具墊腳高度、間距及位置不一，夾模器的干涉等問題時， ，從模下自動清除廢料非常困難，本課題著重解決以上問題，設計制造完成以后，將在國內(nèi)得到廣泛地應用。二、課題研究的主要內(nèi)容、研究方法或工程技術方案和準備采取的措施課題研究的主要內(nèi)容：沖壓廢料自動輸送裝置的設計，包括：設計出一臺適應不同模具尺寸的沖壓廢料自動輸送裝置，使用一臺馬達同時驅動多條輸送帶，解決了一臺馬達驅動一條輸送帶所帶來的橫向空間不夠的問題。使廢料收集更方便、安全。提高生產(chǎn)效率。工程技術方案和準備采取的措施：1、使用一臺馬達同時驅動多條輸送帶，解決了一臺馬達驅動一條輸送帶所帶來的橫向空間不夠的問題；2、輸送帶橫向位置可任意調(diào)整，以適應不同的墊腳位置。3、一種輸送帶寬度可適應一定范圍的墊腳間距，輸送帶可任意組合，以適應不同的模具尺寸。4、換模時可方便地移動輸送帶，且各皮帶整體及單位皮帶伸入模具下的深度可調(diào)，適應不同的模具尺寸。5、換線時，可方便地更換輸送帶。6、超薄皮帶可越過夾模器或壓板地阻擋，更好地利用空間。7、本次設計全面滿足用戶要求的各項標準、規(guī)范要求，同時參考國際標準，對產(chǎn)品進行全面的優(yōu)化設計。三、現(xiàn)有基礎和具備的條件通過大學四年的學習，本人已經(jīng)掌握了基本的專業(yè)知識，對本課題的相關學科有一定的了解，具有了相關的理論基礎。學校還組織進行了各種課程設計，積累了一定的經(jīng)驗，對本次設計將會有很大的幫助。學校提供了大量的相關資料、技術支持以及實驗設備和實驗場地。學院圖書館收藏了許多有關專業(yè)方面的知識書籍和周刊，并且提供了網(wǎng)絡化的機房，可以在中國期刊網(wǎng)、維普網(wǎng)、萬方數(shù)據(jù)庫、超星數(shù)字圖書館等網(wǎng)站查閱有關資料。對目前工廠的各種沖壓設備的廢料輸送的調(diào)查及論證，一些非自動的沖壓廢料輸送裝置的運用，運輸機械的調(diào)研和在實際中的應用?，F(xiàn)具有的一些參考資料如：（1） 、 《機械設計手冊》（2） 、 《鏈傳動》（3） 、 《連續(xù)運輸機》（4） 、 《機械設計》（5） 、 《沖壓設備》（6） 、 《輸送機設計手冊》（7） 、 《電工技術》（8） 、 《機床電氣控制原理》除了以上的資料，還有沖壓機自動輸送裝置的一些圖樣及其相關的資料、AUTOCAD 繪圖軟件、OFFICE 辦公軟件等。四、總的工作任務，進度安排以及預期結果總的工作任務：總裝配圖的繪制和主要零件圖的繪制；說明書的編寫（２～３萬字） ；翻譯相關英文資料 1 篇。進度安排：2 月 20 日～3 月 20 日：調(diào)研、資料準備、確定方案、繪制草圖3 月 21 日～4 月 21 日：完成裝備圖、部件圖、零件圖4 月 22 日～5 月 22 日：編寫設計說明書5 月 23 日～6 月 10 日：校對、總結、準備答辯預期結果：完成 1 篇相關英文資料的翻譯。完成對輸送機的結構和功能分析，確定總體方案設計，并繪制出裝配圖。完成電動機、輸送裝置設計計算和零部件圖的繪制，撰寫詳細的設計說明書。我希望能提前完成任務，并且把錯誤降低到最低點，使本設計具有相當?shù)膶嵱眯?。五、指導教師審查意見指導教師（簽名? 年 月 日 六、教研室審查意見教研室主任（簽名） 年 月 日 七、院（系）審查意見院（系）主任（簽名） 年 月 日 備 注1A Comparison of Soft Start Mechanisms for Mining Belt ConveyorsMichael L. Nave, P.E.CONSOL Inc.1800 Washington Road Pittsburgh, PA 15241 Belt Conveyors are an important method for transportation of bulk materials in the mining industry. The control of the application of the starting torque from the belt drive system to the belt fabric affects the performance, life cost, and reliability of the conveyor. This paper examines applications of each starting method within the coal mining industry.INTRODUCTIONThe force required to move a belt conveyor must be transmitted by the drive pulley via friction between the drive pulley and the belt fabric. In order to transmit power there must be a difference in the belt tension as it approaches and leaves the drive pulley. These conditions are true for steady state running, starting, and stopping. Traditionally, belt designs are based on static calculations of running forces. Since starting and stopping are not examined in detail, safety factors are applied to static loadings (Harrison, 1987). This paper will primarily address the starting or acceleration duty of the conveyor. The belt designer must control starting acceleration to prevent excessive tension in the belt fabric and forces in the belt drive system (Suttees, 1986). High acceleration forces can adversely affect the belt fabric, belt splices, drive pulleys, idler pulleys, shafts, bearings, speed reducers, and couplings. Uncontrolled acceleration forces can cause belt conveyor system performance problems with vertical curves, excessive belt take-up movement, loss of drive pulley friction, spillage of materials, and festooning of the belt fabric. The belt designer is confronted with two problems, The belt drive system must produce a minimum torque powerful enough to start the conveyor, and controlled such that the acceleration forces are within safe limits. Smooth starting of the conveyor can be accomplished by the use of drive torque control equipment, either mechanical or electrical, or a 2combination of the two (CEM, 1979).SOFT START MECHANISM EVALUATION CRITERIONWhat is the best belt conveyor drive system? The answer depends on many variables. The best system is one that provides acceptable control for starting, running, and stopping at a reasonable cost and with high reliability (Lewdly and Sugarcane, 1978). Belt Drive System For the purposes of this paper we will assume that belt conveyors are almost always driven by electrical prime movers (Goodyear Tire and Rubber, 1982). The belt "drive system" shall consist of multiple components including the electrical prime mover, the electrical motor starter with control system, the motor coupling, the speed reducer, the low speed coupling, the belt drive pulley, and the pulley brake or hold back (Cur, 1986). It is important that the belt designer examine the applicability of each system component to the particular application. For the purpose of this paper, we will assume that all drive system components are located in the fresh air, non-permissible, areas of the mine, or in non-hazardous, National Electrical Code, Article 500 explosion-proof, areas of the surface of the mine.Belt Drive Component Attributes Size.Certain drive components are available and practical in different size ranges. For this discussion, we will assume that belt drive systems range from fractional horsepower to multiples of thousands of horsepower. Small drive systems are often below 50 horsepower. Medium systems range from 50 to 1000 horsepower. Large systems can be considered above 1000 horsepower. Division of sizes into these groups is entirely arbitrary. Care must be taken to resist the temptation to over motor or under motor a belt flight to enhance standardization. An over motored drive results in poor efficiency and the potential for high torques, while an under motored drive could result in destructive overspending on regeneration, or overheating with shortened motor life (Lords, et al., 1978).Torque Control. Belt designers try to limit the starting torque to no more than 150% of 3the running torque (CEMA, 1979; Goodyear, 1982). The limit on the applied starting torque is often the limit of rating of the belt carcass, belt splice, pulley lagging, or shaft deflections. On larger belts and belts with optimized sized components, torque limits of 110% through 125% are common (Elberton, 1986). In addition to a torque limit, the belt starter may be required to limit torque increments that would stretch belting and cause traveling waves. An ideal starting control system would apply a pretension torque to the belt at rest up to the point of breakaway, or movement of the entire belt, then a torque equal to the movement requirements of the belt with load plus a constant torque to accelerate the inertia of the system components from rest to final running speed. This would minimize system transient forces and belt stretch (Shultz, 1992). Different drive systems exhibit varying ability to control the application of torques to the belt at rest and at different speeds. Also, the conveyor itself exhibits two extremes of loading. An empty belt normally presents the smallest required torque for breakaway and acceleration, while a fully loaded belt presents the highest required torque. A mining drive system must be capable of scaling the applied torque from a 2/1 ratio for a horizontal simple belt arrangement, to a 10/1 ranges for an inclined or complex belt profile.Thermal Rating. During starting and running, each drive system may dissipate waste heat. The waste heat may be liberated in the electrical motor, the electrical controls,, the couplings, the speed reducer, or the belt braking system. The thermal load of each start Is dependent on the amount of belt load and the duration of the start. The designer must fulfill the application requirements for repeated starts after running the conveyor at full load. Typical mining belt starting duties vary from 3 to 10 starts per hour equally spaced, or 2 to 4 starts in succession. Repeated starting may require the dreading or over sizing of system components. There is a direct relationship between thermal rating for repeated starts and costs. Variable Speed. Some belt drive systems are suitable for controlling the starting torque and speed, but only run at constant speed. 4Some belt applications would require a drive system capable of running for extended periods at less than full speed. This is useful when the drive load must be shared with other drives, the belt is used as a process feeder for rate control of the conveyed material, the belt speed is optimized for the haulage rate, the belt is used at slower speeds to transport men or materials, or the belt is run a slow inspection or inching speed for maintenance purposes (Hager, 1991). The variable speed belt drive will require a control system based on some algorithm to regulate operating speed. Regeneration or Overhauling Load. Some belt profiles present the potential for overhauling loads where the belt system supplies energy to the drive system. Not all drive systems have the ability to accept regenerated energy from the load. Some drives can accept energy from the load and return it to the power line for use by other loads. Other drives accept energy from the load and dissipate it into designated dynamic or mechanical braking elements. Some belt profiles switch from motoring to regeneration during operation. Can the drive system accept regenerated energy of a certain magnitude for the application? Does the drive system have to control or modulate the amount of retarding force during overhauling? Does the overhauling occur when running and starting? Maintenance and Supporting Systems. Each drive system will require periodic preventative maintenance. Replaceable items would include motor brushes, bearings, brake pads, dissipation resistors, oils, and cooling water. If the drive system is conservatively engineered and operated, the lower stress on consumables will result in lower maintenance costs. Some drives require supporting systems such as circulating oil for lubrication, cooling air or water, environmental dust filtering, or computer instrumentation. The maintenance of the supporting systems can affect the reliability of the drive system.Cost. The drive designer will examine the cost of each drive system. The total cost is the sum of the first capital cost to acquire the drive, the cost to install and commission the drive, the cost to operate the drive, and the cost to maintain the drive. The cost for power to operate the drive may vary widely 5with different locations. The designer strives to meet all system performance requirements at lowest total cost. Often more than one drive system may satisfy all system performance criterions at competitive costs.Complexity. The preferred drive arrangement is the simplest, such as a single motor driving through a single head pulley. However, mechanical, economic, and functional requirements often necessitate the use of complex drives. The belt designer must balance the need for sophistication against the problems that accompany complex systems. Complex systems require additional design engineering for successful deployment. An often-overlooked cost in a complex system is the cost of training onsite personnel, or the cost of downtime as a result of insufficient training.SOFT START DRIVE CONTROL LOGICEach drive system will require a control system to regulate the starting mechanism. The most common type of control used on smaller to medium sized drives with simple profiles is termed "Open Loop Acceleration Control". In open loop, the control system is previously configured to sequence the starting mechanism in a prescribed manner, usually based on time. In open loop control, drive-operating parameters such as current, torque, or speed do not influence sequence operation. This method presumes that the control designer has adequately modeled drive system performance on the conveyor. For larger or more complex belts, "Closed Loop" or "Feedback" control may he utilized. In closed loop control, during starting, the control system monitors via sensors drive operating parameters such as current level of the motor, speed of the belt, or force on the belt, and modifies the starting sequence to control, limit, or optimize one or wore parameters. Closed loop control systems modify the starting applied force between an empty and fully loaded conveyor. The constants in the mathematical model related to the measured variable versus the system drive response are termed the tuning constants. These constants must be properly adjusted for successful application to each conveyor. The most common schemes for closed loop 6control of conveyor starts are tachometer feedback for speed control and load cell force or drive force feedback for torque control. On some complex systems, It is desirable to have the closed loop control system adjust itself for various encountered conveyor conditions. This is termed "Adaptive Control". These extremes can involve vast variations in loadings, temperature of the belting, location of the loading on the profile, or multiple drive options on the conveyor. There are three common adaptive methods. The first involves decisions made before the start, or 'Restart Conditioning'. If the control system could know that the belt is empty, it would reduce initial force and lengthen the application of acceleration force to full speed. If the belt is loaded, the control system would apply pretension forces under stall for less time and supply sufficient torque to adequately accelerate the belt in a timely manner. Since the belt only became loaded during previous running by loading the drive, the average drive current can be sampled when running and retained in a first-in-first-out buffer memory that reflects the belt conveyance time. Then at shutdown the FIFO average may be use4 to precondition some open loop and closed loop set points for the next start. The second method involves decisions that are based on drive observations that occur during initial starting or "Motion Proving'. This usually involves a comparison In time of the drive current or force versus the belt speed. if the drive current or force required early in the sequence is low and motion is initiated, the belt must be unloaded. If the drive current or force required is high and motion is slow in starting, the conveyor must be loaded. This decision can be divided in zones and used to modify the middle and finish of the start sequence control. The third method involves a comparison of the belt speed versus time for this start against historical limits of belt acceleration, or 'Acceleration Envelope Monitoring'. At start, the belt speed is measured versus time. This is compared with two limiting belt speed curves that are retained in control system memory. The first curve profiles the empty belt when accelerated, and the second one the fully loaded belt. Thus, if the current speed versus time is lower than the loaded profile, it may indicate that the belt is overloaded, 7impeded, or drive malfunction. If the current speed versus time is higher than the empty profile, it may indicate a broken belt, coupling, or drive malfunction. In either case, the current start is aborted and an alarm issued.CONCLUSIONThe best belt starting system is one that provides acceptable performance under all belt load Conditions at a reasonable cost with high reliability. No one starting system meets all needs. The belt designer must define the starting system attributes that are required for each belt. In general, the AC induction motor with full voltage starting is confined to small belts with simple profiles. The AC induction motor with reduced voltage SCR starting is the base case mining starter for underground belts from small to medium sizes. With recent improvements, the AC motor with fixed fill fluid couplings is the base case for medium to large conveyors with simple profiles. The Wound Rotor Induction Motor drive is the traditional choice for medium to large belts with repeated starting duty or complex profiles that require precise torque control. The DC motor drive, Variable Fill Hydrokinetic drive, and the Variable Mechanical Transmission drive compete for application on belts with extreme profiles or variable speed at running requirements. The choice is dependent on location environment, competitive price, operating energy losses, speed response, and user familiarity. AC Variable Frequency drive and Brush less DC applications are limited to small to medium sized belts that require precise speed control due to higher present costs and complexity. However, with continuing competitive and technical improvements, the use of synthesized waveform electronic drives will expand.