| The stacker-reclaimer is a modern industrial bulk material handling equipment. It is widelyused in place of terminals, ports, storage coal plants, power plants, bulk material storagestacker operation. Stacker-reclaimer of a power plant air-cooled unit project is largeequipment that used for bulk handling in circular stockyard. Circular stockyard is amaterial storage system that closed by a hemispherical steel frame dome. The core of thematerial storage system is the stacker-reclaimer which located in the center of circularstockyard. The stockyardhas a number of significant advantagessuch as smallfootprint, highdegree of automation,not subject to weather conditions and environmental features. With thegradual increase in awareness of environmental protection, more and more attention has beenpaid to the new styleof stockyard. Most people believethat the stacker-reclaimerwould havea better future. The design of the circular stacker-reclaimer is mainlybased on the layout ofrelated foreign equipments. The designers combined with the specific circumstances of thestockyard and then work out the initial structural design. In order to ensure the rationalityand reliabilityof the design, some performance check are necessary includingstiffness check,strength and dynamic characteristics check. So that we could optimal the initial and reducethe designcost.PRO/ENGINEER, a large parametric design software, has been considered as a newstandard of the world's machinery CAE field. Its integratedMECHANICAmodule is an FEManalysis module that integrated static analysis, buckling analysis, contact analysis, modalanalysis, fatigue analysis. The module works based on the non-traditional adaptive P-methodwhich could calculate the stress distribution of high stress gradient region accurately and itcould convergeautomatically.Our analysisis based on theplatform of PRO/ENGINEER。Wecreate the three-dimensional model of the circular stacker-reclaimer according to the designdrawings offered by designers. And then create parameter-driven model for the combinedconditions. The FEM model of main structure is modeled by plate elements. Rods, bracings,hoardings are modeled by beam elements. The articulated position, slewing ring and wire rope hoist system are simulated by the combination of bar elements and beam elements. Sothat we couldreduce thecalculation scales.After compiled the batch files, computer could calculate three working conditionsincluding gravity only,normal operations, overloaded operations. Each condition are dividedinto six combinations of gesture accordingto theamplitude location of scraper arm(horizontal,upward41°,downward7.38°)and the stacker rotation(angle between180°and135°). Thecomprehensive analysis of calculation results are presented for each combination ofconditions. Initialoptimizationsuggestionsare offeredaccordingtothe linear static analysis.The stacker-reclaimeris not only subject to the static loadingduring the course of theirwork, but also to some impact loading and other external stimulus. So a model analysis isnecessary.The first ten natural frequencies and model shapes are obtainedby model analysis.The results could provide the basic informations for designers whilethey modify their designprograms.In order to improve the utilization of materials, combinedwith the results of the secondchapter of the structural static analysis, optimization for lightweight is also necessary.Optimization is mainly for the lightweight of stacker counterweight arm which has largestress surplusrelatively.Finally thematerialproperties have a betterapplication.According to the linear static analysis results of the stacker-reclaimer, the mainstructural stress is below180Mpa. The stress of stacker counterweight boom is below120Mpa which has large stress surplus. There are large stress regions in some cusp postionsand lap positions but the range of the region is reasonable.The maximum deflection of thescraper arm is-13.6mm and the value still comply with the design standards. The modalanalysis is based on FEM model of PRO/MECHANICA which could solve the functions byANSYS solver.Through modal analysis, the top ten modal shapes andtheir natural frequencyare obtained. According to the modal results and the external incentive analysis results, wecan draw a conclution that the external stimulus couldn't cause resonance destruction. Theoptimal design for stacker counterweight boom is necessary due to it has large stess surplus.The optimized model is3.4tons lighter then before. For the most parts, the stress ofoptimizedstructureis nearly140Mpa, but stillwithinthe allowablerange.The CAE analysis of the circular stacker-reclaimer could discover the defect during design process and improve the initial design program. This method could shorten thedevelopment cycles andreducethe development costs. |
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