铸铁镶铜闸门优化设计 制造及自动化研究-research on optimum design, manufacture and automation of cast iron copper gate.docxVIP

铸铁镶铜闸门优化 铸铁镶铜闸门优化 设 计、制造及自动化 研 究 万方数据 万方数据 摘 要 本文在收集国内外有关闸门资料的基础上，并以闸门的结构优化、降低制造成本 和提高可靠性为研究主线，着重研究了城市氧化沟污水处理工艺中使用数量很大的设 备——铸铁镶铜闸门的结构优化、制造和自动化控制等问题。 长期以来，国内的闸门设计通常是由设计人员凭经验或类比法进行设计。本文利 用 ANSYS 软件对铸铁闸门门体建立了三维有限元模型，对闸门门体的应力与应变作了 三维有限元计算，得出该闸门在静水压下的变形及应力分布规律，并对闸门结构进行 了优化设计。结果表明用三维有限元设计方法能使闸门重量大大减轻。 至目前为止，闸门仍然没有标准化和系列化，导致在售后维修中极大不便，也导 致国内闸门制造效率低和成本较高。本文对闸门的关键零部件进行了系列化和标准化 设计；同时开发了闸门楔块刨加工、楔座群钻和螺杆旋风铣削等工艺装备，大大提高 了生产效率、保证了零件精度和易损件的互换性。另外解决了一个关键工艺，利用钎 焊技术在闸门上钎焊铜圈，使贵重金属铜的使用量大大减少。 针对运用传统闸门启闭机电器控制落后状况，自主开发了一套基于 PLC 的闸门自 动控制系统，实现了自动检测闸门开度、闸前水位、并实时记录过闸流量和自动报警， 能监控两台闸门交替运行，达到自动控制的目的。 上述部分创新论点已在公开发表的论文（《光学技术》核心刊物，EI 收录，第一 作者）和国际会议论文中阐述。 关键词：速闭启闭机、三维有限元方法、群钻、旋风铣削、自动监控系统 10 Abstract On the basis of collecting the domestic and international data about cast-iron bronze-inlaid gates, the study has been launched from the aspects of the design, manufacturing and control automatically. The gate has widely been used in the area of oxidized ditch technology. The study focuses on structure optimization, how to lessen the cost of the gates and enhance its reliability and so on. Conventionally, the gate is designed in terms of the designer’s experience and analogy method. With software of ANSYS, the three-dimensional finite element model of the gate body is established to calculate its deformation and stress. By calculation, the distributing law of deformation and stress under static water pressure is obtained. Then the structure of the gate’s body is optimal designed. The results show that three-dimensional finite element method can reduce the gate weight remarkably. At present, those gates have not been standardized and serialized. This leads to be very inconvenient in maintaining, inefficient manufacturing and high cost. The key part is standardized and serialized in the paper. We developed a series of process fixture such as the fixture of plane process, the fixture of common screw and so on. These fixtures can enhance manufacturing efficiency, precision and interchange-ability of maintenan