Optimization Design Of Drive System Of XDE400 Mine Electric Wheel Dump Wheel Edge Reducer

With the rapid development of China’s economy,the demand for coal,iron ore and other resources is increasing.As the core equipment of mining and transportation of mineral resources,mining electric wheel dump truck plays a decisive role in the transportation of large open-pit mines.As the transport vehicle with the largest load capacity in open-pit mine,its working environment is extremely harsh and the working conditions are complex and changeable.As the core component of mine dump truck,the quality of wheel reducer restricts the performance of the whole vehicle.Therefore,the key method to improve the performance of the whole vehicle on the basis of the existing structure is to optimize the structure of the important parts in the wheel reducer,which will be of great significance to improve the operation efficiency of the minin g electric wheel dump truck.Based on the project support of the national key research and development plan in 2019:"Key Technology and Application Demonstration of High Torque Hub Drive for Construction Machinery"sub-project"Key Technology for Dynamic Design of High Torque Hub Drive System,"this paper aims to provide theoretical guidance for the structural design and manufacturing of the system by optimizing the structure and studying the characteristics of the two major components（planetary gea r train and planet carrier）in the wheel reducer.The specific research contents are as follows:First,the design analysis and modeling of the gear transmission system of the wheel reducer of the mining electric wheel dump truck.According to the design requirements of the gear transmission system of the wheel reducer,the NGW planetary gear transmission form with the planetary carrier as the output component is finally selected.The three-dimensional model of the wheel reducer of the mining dump truck is established in Romax Designer.The planetary frame and the box are finite elementized,and the node connection and model condensation with other parts are carried out to complete the establishment of the rigid-flexible coupling model.The load spectrum analysis is carried out for the specific driving conditions of the mining dump truck,and the power flow of each working condition is analyzed.Secondly,multi-objective optimization of planetary gear train of wheel reducer based on hybrid algorithm.The mathematical modeling of the planetary gear train in the wheel reducer of XDE400 mining electric wheel dump truck is carried out.The number of teeth,modification coefficient,modulus,tooth width and meshing angle of gear pairs at all levels are taken as d esign variables.The objective function of the minimum volume and the highest transmission efficiency of the secondary planetary gear transmission mechanism is determined,and the constraint conditions are determined based on the design principle of planet ary gear transmission.GA algorithm,PSO algorithm and hybrid GA-PSO algorithm are used to solve the model respectively,and the iterative convergence effect diagrams of the three algorithms are obtained and compared.The optimization results show that the hybrid GA-PSO algorithm takes into account the advantages of GA algorithm and PSO algorithm.It not only avoids the local convergence premature phenomenon but also accelerates the convergence speed,which reflects the superiority of the algorithm.After o ptimization,the target volume is reduced by 11.36%,and the transmission efficiency is improved by 0.79%.Thirdly,multi-objective optimization of planetary carrier of wheel reducer based on memory strategy dynamic ion motion algorithm.Firstly,the rel iability sensitivity analysis of planetary carrier at all levels is carried out by drawing on the idea of subset simulation method.By introducing intermediate failure probability events,the small probability events of planetary carrier failure probabilit y are transformed into the product of several large probability events.The direct sampling method is used to simulate the stratified method of relevant sample points.The subset simulation method,Monte Carlo method and direct sampling method are combined to determine the minimum sum of the reliability sensitivity of the planet carrier failure probability with respect to the variance and correlation coefficient of each variable and the minimum volume of the planet carrier as the optimization target.The IM O algorithm and the I-IMO improved algorithm are used to solve them respectively.The results show that the improved I-IMO algorithm converges faster than the IMO algorithm,and does not fall into the local optimal solution.While ensuring that the failure probability of each stage of the planet carrier reaches 10^-5,the total volume is reduced by 3.9%.The modal analysis of the planet carrier before and after optimization is carried out,and the frequency point of resonance is determined.The resonance phe nomenon between the planet carrier and the planetary gear pair is avoided by optimization.Fourth,the micro-modification optimization and simulation research of the planetary gear of the wheel reducer.Based on the theory of gear modification and genetic algorithm,five different modification methods are used to comprehensively modify the secondary sun gear,and the optimal parameters of the secondary sun gear modification are selected from 1000 modification schemes.The results show that through reasonabl e modification,the transmission error of the secondary sun gear is reduced from 92.21μm to 18.18μm,the load per unit length is reduced from 6604N/mm to 2403N/mm,the maximum contact stress of the tooth surface is reduced from 2719MPa to 1668MPa,and the eccentric load is greatly improved.The surface vibration acceleration of the secondary planet carrier at 752.0Hz reaches a peak of 63.105m/s²,which is reduced to14.170m/s² after modification.At this frequency,the Y-direction deflection mode is analyzed,and the Y-direction offset is reduced from 3.13μm to 1.13μm.