Study On Lightweight Design And Test For Boom Hoist Reducer In Ship-to-shore Crane

With the continuous development of the global economic integration,trade between countries is also getting closer and closer,which led to the development of the ship-to-shore container crane industry.With the continuous growth of container throughput,ship-to-shore crane is developing towards the large-scale,high-speed,and lightweight to meet the requirements of the high speed loading and unloading for port operation.In this paper,the boom hoist reducer is selected to be optimized.The lightweight of boom hoist reducer is researched to make the mechanism more compact and reduce the whole machinery room size and weight.It is significant to reduce weight of crane and improve the competitiveness of products.The gears,shafts and housing in reducer accounted for about 90% of the whole weight.Therefore,the lightweight optimization of boom hoist reducer is carried out from these three aspects.The calculated bending strength of gears is reduced by increasing the normal chordal dimensions of the tooth root critical section through pressure angle improvement,and nominal bending stress number is increased by shot peening treatment.The widths of gears are minimized to reduce the weight under the precondition of the same output torque with previous reducer.The safety factors of the shafts are properly distributed by shortening shaft length and increasing the diameter of shaft section matched to the gear.The stiffness of the input and output shafts withstanding external loads are checked.The housing multi-objective parameterization design is carried out to choose optimal project by selecting the Design Exploration module of ANSYS.Topological analysis is also applied to study the possibility of housing weight further reduction after optimization.The modal analysis of the final optimized housing shows that it meets the requirements for dynamic characteristics.The optimized prototype reducer is tested by the direct current bus electric closed loop test stand and results showed that its vibration,sound level and bearing temperature rise data meet the requirement.The optimized reducer weight is reduced from 6600 kg to5770kg,up to 12.58%,which has achieved the expectation weight reduction goal of more than 10%.