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附 錄
The new high pressure cleaning the car
With the rapid development of industry, environment pollution is becoming more and more serious, the environmental protection question is already a global strategy. In order to adapt to the needs of the construction of urban environmental sanitation, clear in time the city, improve air quality, sanitation vehicles of development and development, has become an important topic of the set before us. The development of urbanization in our country, the increase of the road to the requirements of environmental protection and improve, which makes the sanitation car requirement increasingly, high pressure cleaning the car as a sanitation in vehicles, having to clean the road, guardrail and purify airy action, is one of the important urban environmental protection equipment. The current domestic production of high pressure cleaning car backward in technology, there are many problems; Foreign cleaning vehicle performance while is superior, but the price is expensive, need a lot of foreign exchange, it is not the solution to the problem. Therefore, the development of new high pressure cleaning cars has become China's urban environmental protection work important problem to be solved. It not only with independent intellectual property rights, and can improve the design level of our country special automobile, driving the sanitation vehicles in China to develop and manufacture independent design ability.
1 a general introduction
High pressure cleaning cars mainly by the power system, water system and hydraulic system, electronic control and manipulate system components. Power system for cleaning the car to walk and water pumps provide motivation. Water system mainly by the high pressure pump, water tank, valve, nozzle and other components, water through the pump pressure can improve after to 8 MP, form high pressure jet spraying to road, effectively flush the sand dust. Hydraulic system mainly by the hydraulic pump and motor and and valve set and other components, control vehicle to walk and injection action. Electric control part by sensors, SCM and main display control panel etc. In this paper the development of high pressure cleaning car main technical parameters are as follows:
The rating capacity; Engine output power 45 KW; The biggest water spray width is not less than 3 m; Spray work for vehicle speed 5 km/h; Spray water pressure is not less than 8 MP; Total number of nozzle 21; Water pump water largest amount 65 km/h.
2 power distribution and switching system
2.1 the basic principle of the power transmission and scheme selection
High pressure cleaning car according to the function of the realization of the divided into two kinds of state: a normal work is driving condition, high pressure cleaning the car and general at the same car, realize the transfer function; vehicle 2 it is watering operations state, the state in the vehicle with very low, the speed of the high pressure water spray homework, cleaning the road. Due to the high pressure cleaning the car need driving and driven two aspects of the pump power, so the dynamic how to provide design is to consider when the primary issue.
At home and abroad and usually use the power distribution solutions has two, one is to adopt double configuration of the engine power transmission system, is main engine vehicles not alter, transmission system will not do change, use a Taiwan independence in vehicles outside the system of power auxiliary engine drive hydraulic system for high pressure pump provide motivation.
The advantages of this scheme is simple in structure, the price is low, the disadvantage is as the vehicle in the water spray work driving the speed, low speed less than 10 km/h, this time the main engine can't work in the best working point, that power allocation is not reasonable, can produce fuel and power waste, and occupy the space of vice engine body, less the water storage volume, vice vehicle engine installation added new vibration noise sources, the influence the stability of the vehicle.
Another plan is to use the vehicle engine vehicle transmission system and hydraulic system provide the power, through the points with FenDongXiang action, in the transfer road, driven by the main engine FenDongXiang to driving axle differentials, high speed movement; vehicle In injection homework road, driven by the main engine FenDongXiang to hydraulic system, on the one hand, control operation speed, on the other hand, the drive pump water spray.
The scheme with the foregoing scheme, its advantage is compared, giving full play to the engine power, make the vehicle in the water spray operations can still working at high speed rating of the work of the state, not only save one engine, reduce the fuel consumption, and engine exhaust emission index is more advantageous to achieve urban environmental protection requirement. The vehicle structure more reasonable, vehicle weight of low, water storage space increases. To sum up, single engine configuration is a more reasonable configuration, so this paper power in the new, high pressure cleaning vehicle design, using a single engine design scheme.
2.2 power distribution
To ensure the high pressure pump provide of the injection pressure is constant, drive the hydraulic loop quantitative hydraulic pump must work in constant speed rating of the work of the state, water spray operations vehicle of the speed and the road of injection effect is also not to change about the amount of driving, so drive the variable pump will work in constant speed rating of the work of the state, the consumption of driving power also for setting value. Thus, when the engine power to homework for setting value.
2.3 new single axis FenDongXiang design
FenDongXiang power distribution is the core of the system, the traditional thought of design FenDongXiang usually adopts two to three axis structure of power distribution. This paper introduces the design of new light high-pressure cleaning vehicle USES the chassis is isuzu NKR55LLA light chassis, with traditional structure of the FenDongXiang sizes too large, can't meet the size requirement. According to the characteristics of the power distribution system, independent design and development of the single shaft driving, the FenDongXiang greatly reduced the FenDongXiang size, make body structure more compact.
3 hydraulic system
The hydraulic control system is watering operations every action when the key to meeting, and the main variable pump, the quantitative pump, the drive motors, hydraulic cylinder, cooler, integrated control valves piece, filter etc. From the function of the realization of the perspective, hydraulic system by hydraulic motor drive travel system and hydraulic pressure motor drive water spray system two sub-systems.
3.1 hydraulic motor drive driving system
The variable pump, hydraulic motor and the corresponding hydraulic loop hydraulic subsystem, a walk for the system for oil pump, and quantitative pump coaxial connected. This system consists of integrated control valves to realize the control of hydraulic pump and hydraulic system. The variable pump and motor selection, according to the basic power to determine the value.
3.2 hydraulic motor drive water spray system
Hydraulic motor drive water spray system by quantitative pump, quantitative hydraulic motor, water pump, relief valve, cooler, filter and hydraulic cylinder and stacked valves group etc. For the hydraulic cylinder and stacked valves group together, for the control of water spray frame lift, extendable such action. The hydraulic oil tank, passes through to return to cooler water.
4 water injection system
The water system is high pressure cleaning the car mainly by the core part high pressure water pump, water spray nozzle, frame, the spray gun and valve etc. Water tank flow of water out of the pump will improve after water pressure to 8 MP, form high pressure jet spraying to the road. The high pressure pump rational selection of engine efficiency, the best utilization, best flush efficiency have important influence, need according to the design requirements and engine parameters, such as to determine the high-pressure pump power, speed and the parameters such as pump pressure at work. Water system design of the main problems including the following two aspects.
4.1 the telescopic multi-degree-of-freedom water spray frame
Water spray frame is injection system of actuators, installed in high pressure cleaning car head, high pressure water spray nozzle in the frame. To increase the width of the jet wash, design the new hydraulic control expansion institutions. Work, install a nozzle two of the rear protruding from the front of the car, and the nozzle into a straight line, and the high pressure water jet to; After completion of work, back to the nozzle tube retract side. Water spray frame from ground level also controlled by hydraulic system, also designs of the mechanical structure, highly fine-tuning height adjustment to trace.
4.2 water spray system parameters optimization
High pressure cleaning the car is the purpose of the quality of the road surface cleaning out clean, so, how to improve the cleaning effect, water conservation is design to consider when important question, also is the past studies the problem of no point to consider. The effect of road surface cleaning and many parameters. Including injection height, the shape of the nozzle, injection pressure, injection Angle, jet width, nozzle diffusion Angle, distance of the nozzle. Through a lot of the theoretical and experimental research, to determine the height of the injection pressure injection, jet Angle, the width of the jet, the nozzle of the diffusion Angle of pavement, wash the best results, the wash rate in above, clean unit area of the pavement, the consumption of water and energy, reached the best matching value.
5 electronic control and operation system design
Electronic control system to realize the working state of the vehicle display, monitoring, alarm and control etc. Function. Mainly includes the instrument shows system, dashboard, the hydraulic oil drive speed dial, hydraulic oil temperature display, hydraulic display, water tank water of the display and alarm, PenShuiGuan working status display, hydraulic system running time records, and other functions, the whole system USES modular design, the control panel integrated in driving indoor proper place, facilitate the operator control operation.
The water tank of the monitoring and forecast of electric control system is the important link, must be strictly controlled. Tank water after cooler for hydraulic oil after cooling to enter high pressure pump and so have a water tank must be reserved to the amount of water. In the the design of the magnetic levitation type level sensor, accurately measure the level of height. Control system mainly including operation box, the power switch handle, oil, left, pedal drove speed, PenShuiGuan right control handle, water spray handle adjustable control handle to and fro and speed of the pedals. The design of the control system, the arrangement of the operation box, structure, the handle position, fully considered the man-machine engineering requirements, easy to control.
6 general structure design
On the structure, the vehicle including chassis (with cab), water tank, hydraulic oil tank, water pump, FenDongXiang, water spray rack large components. Water pump and hydraulic pressure tank parallel is decorated in the cabin and water tank, or so between both sides put hinged door outside using, open convenient, convenient in maintenance inspection. Water tank use stainless steel structure, outside the oval with decoration side wai and skirt edge. FenDongXiang arrangement in the chassis and the hydraulic oil tank in water pump, transmission and the second transmission shaft between. Vehicle used Unigraphics software for 3 d software entities, and USES the design of the vehicle assembly function of virtual assembly.
7 conclusion
The development of new high pressure cleaning car, in order to improve the effect of washing and energy saving as the core, using a single engine the configuration of the power distribution way, give full play to the water spray operations of engine power, improving the pressure of spray water; And the pavement flush the influence on the effect of parameters are optimized. The power distribution system, hydraulic system, water system, electronic control and control system, overall structure are studied. In the bodywork, single axis FenDongXiang development and research aspects such as road flush effect for several patents. This paper developed new high pressure cleaning car, prototype test each index, through to reserve requirements. High pressure cleaning the development of the new car, for the country's high performance high-pressure cleaning the car independent development and played a good role.
新型高壓清洗車
隨著工業(yè)的迅猛發(fā)展，環(huán)境污染顯得越來越嚴(yán)重，環(huán)保問題已是一個(gè)全球的戰(zhàn)略問題。為適應(yīng)城市環(huán)境衛(wèi)生建設(shè)的需要，及時(shí)清理城市路面，改善空氣質(zhì)量，環(huán)衛(wèi)車輛的開發(fā)和發(fā)展，已成為擺在我們面前的重要課題。我國城市化的發(fā)展，道路的增加及對環(huán)保要求的提高，使得對環(huán)衛(wèi)車的需求日益增加，高壓清洗車作為環(huán)衛(wèi)車輛中的一種，具有清洗道路、護(hù)欄和凈化空氣的作用，是城市環(huán)保的一種重要設(shè)備 。目前國內(nèi)生產(chǎn)的高壓清洗車技術(shù)落后，存在許多問題；國外的清洗車性能雖然優(yōu)越，但價(jià)格昂貴，需要大量的外匯，終究不是解決問題的辦法。為此，開發(fā)新型的高壓清洗車已成為我國城市環(huán)保工作中需要解決的重要問題。它不但具有自主知識(shí)產(chǎn)權(quán)，而且可以提高我國專用車的設(shè)計(jì)水平，帶動(dòng)我國環(huán)衛(wèi)車輛的自主設(shè)計(jì)開發(fā)及制造能力。
1 總體介紹
高壓清洗車主要由動(dòng)力系統(tǒng)、水系統(tǒng)、液壓系統(tǒng)、電控及操縱系統(tǒng)等部分組成。動(dòng)力系統(tǒng)為清洗車的行走和水泵提供動(dòng)力。水系統(tǒng)主要由高壓水泵、水箱、閥、噴嘴等組成，水流經(jīng)水泵后壓力可以提高到8MP，形成高壓射流噴射到路面，有效地沖洗路面的灰塵砂粒。液壓系統(tǒng)主要由液壓泵、馬達(dá)和和閥組等組成，控制車輛的行走和噴射動(dòng)作。電控部分主要由傳感器、單片機(jī)及顯示控制面板等組成 。本文開發(fā)的高壓清洗車主要技術(shù)參數(shù)如下：
額定容量 ；發(fā)動(dòng)機(jī)輸出功率 45KW；最大噴水寬度不小于3m；噴射工作時(shí)車輛行駛速度為 5km/h；噴射水壓不小于8MP；噴嘴總數(shù) 21 個(gè)；水泵最大噴水量 65km/h。
2動(dòng)力分配及切換系統(tǒng)
2.1動(dòng)力傳動(dòng)的基本原理及方案選擇
高壓清洗車根據(jù)其實(shí)現(xiàn)的功能分為兩種工作狀態(tài)：一是正常行駛狀態(tài)，此時(shí)高壓清洗車和一般的車一樣，實(shí)現(xiàn)車輛的轉(zhuǎn)移功能；二是噴水作業(yè)狀態(tài)，在此狀態(tài)下，車輛以很低的速度進(jìn)行高壓噴水作業(yè)，清洗路面。由于高壓清洗車需要行駛和驅(qū)動(dòng)水泵兩方面的動(dòng)力，所以該動(dòng)力如何提供是設(shè)計(jì)時(shí)需要考慮的首要問題。
目前國內(nèi)外通常使用的動(dòng)力分配方案有兩種，一是采用雙發(fā)動(dòng)機(jī)配置的動(dòng)力傳動(dòng)系統(tǒng)，即車輛主發(fā)動(dòng)機(jī)不作改動(dòng)，傳動(dòng)系統(tǒng)也不作改動(dòng)，使用一臺(tái)獨(dú)立于車輛動(dòng)力系統(tǒng)之外的輔助發(fā)動(dòng)機(jī)驅(qū)動(dòng)液壓系統(tǒng)為高壓水泵提供動(dòng)力。
該方案的優(yōu)點(diǎn)是結(jié)構(gòu)簡單，價(jià)格較低，缺點(diǎn)是由于車輛在噴水工作時(shí)低速行駛，其速度小于10km/h，此時(shí)主發(fā)動(dòng)機(jī)不能工作在最佳工作點(diǎn)，使功率分配不合理，會(huì)產(chǎn)生燃料和功率的浪費(fèi)，同時(shí)副發(fā)動(dòng)機(jī)占據(jù)車身的空間，相對減少了車輛的蓄水體積，副發(fā)動(dòng)機(jī)的安裝增加了新的振動(dòng)噪聲源，影響整車的穩(wěn)定性。
另外一種方案是采用車用主發(fā)動(dòng)機(jī)為車輛傳動(dòng)系統(tǒng)和液壓系統(tǒng)提供動(dòng)力，通過分動(dòng)箱的分動(dòng)作用，在轉(zhuǎn)移行駛時(shí)，動(dòng)力由主發(fā)動(dòng)機(jī)經(jīng)分動(dòng)箱到后橋差速器，車輛高速運(yùn)動(dòng)；在噴射作業(yè)行駛時(shí)，動(dòng)力由主發(fā)動(dòng)機(jī)經(jīng)分動(dòng)箱傳到液壓系統(tǒng)，一方面控制作業(yè)行駛速度，另一方面驅(qū)動(dòng)水泵噴水。
該方案與前述方案相比較，其優(yōu)點(diǎn)在于，充分發(fā)揮了發(fā)動(dòng)機(jī)的功率，使車輛在噴水作業(yè)時(shí)仍可以工作在高轉(zhuǎn)速的額定工作狀態(tài)，不但節(jié)省了一臺(tái)發(fā)動(dòng)機(jī)，降低了燃油消耗，同時(shí)發(fā)動(dòng)機(jī)尾氣排放指標(biāo)更有利于達(dá)到城市環(huán)保要求。整車的結(jié)構(gòu)更加合理，車輛的自重較低，蓄水空間相應(yīng)增加。綜上所述，單發(fā)動(dòng)機(jī)配置是一種更為合理的動(dòng)力配置方案，所以本文在新型高壓清洗車的設(shè)計(jì)中，采用了單發(fā)動(dòng)機(jī)的設(shè)計(jì)方案。
2.2功率的合理分配
為保證高壓水泵提供的噴射壓力恒定，驅(qū)動(dòng)該液壓回路的定量液壓泵必須工作在恒轉(zhuǎn)速的額定工作狀態(tài)，噴水作業(yè)時(shí)車輛的行駛速度與路面的噴射效果有關(guān)，也是不可改變的量，所以驅(qū)動(dòng)行駛的變量泵也要工作在恒轉(zhuǎn)速的額定工作狀態(tài)，行駛消耗的功率也為定值。因而，作業(yè)時(shí)需要的發(fā)動(dòng)機(jī)功率為定值。
2.3新型單軸分動(dòng)箱的設(shè)計(jì)
分動(dòng)箱是動(dòng)力分配系統(tǒng)的核心部分，傳統(tǒng)思想設(shè)計(jì)的分動(dòng)箱通常采用二到三軸結(jié)構(gòu)進(jìn)行動(dòng)力分配。本文設(shè)計(jì)的新型輕型高壓清洗車采用的底盤是五十鈴NKR55LLA 輕型底盤，用傳統(tǒng)結(jié)構(gòu)的分動(dòng)箱尺寸偏大，無法滿足尺寸要求。根據(jù)動(dòng)力分配系統(tǒng)的特點(diǎn)，自主設(shè)計(jì)開發(fā)了單軸傳動(dòng)的分動(dòng)箱，大大減小了分動(dòng)箱的尺寸，使車身結(jié)構(gòu)更加緊湊。
3液壓系統(tǒng)
液壓控制系統(tǒng)是噴水作業(yè)時(shí)各個(gè)動(dòng)作得以實(shí)現(xiàn)的關(guān)鍵，主要由變量泵、定量泵、驅(qū)動(dòng)馬達(dá)、液壓缸、冷卻器、集成控制閥塊、過濾器等組成。從實(shí)現(xiàn)的功能上來看，液壓系統(tǒng)由液壓馬達(dá)驅(qū)動(dòng)行走系統(tǒng)和液壓馬達(dá)驅(qū)動(dòng)噴水系統(tǒng)兩個(gè)子系統(tǒng)組成。
3.1液壓馬達(dá)驅(qū)動(dòng)行駛系統(tǒng)
變量泵 、液壓馬達(dá) 和相應(yīng)的液壓回路構(gòu)成了液壓行走子系統(tǒng)， 為系統(tǒng)的補(bǔ)油泵，與定量泵同軸連接。該系統(tǒng)由集成控制閥塊實(shí)現(xiàn)對油路和液壓泵的控制。變量泵及馬達(dá)的選型，基本根據(jù)前述的功率值來確定。
3.2液壓馬達(dá)驅(qū)動(dòng)噴水系統(tǒng)
液壓馬達(dá)驅(qū)動(dòng)噴水系統(tǒng)由定量泵 、定量液壓馬達(dá) 、水泵 、溢流閥、冷卻器、過濾器和液壓缸及疊加閥組 等組成。 為液壓缸和疊加閥組共同組成，用于控制噴水架的升降、伸縮等動(dòng)作。液壓油返回油箱時(shí)，經(jīng)過水冷卻器冷卻。
4水噴射系統(tǒng)
水系統(tǒng)是高壓清洗車的核心部分 主要由高壓水泵、噴水架、噴嘴、噴槍及閥等組成。水箱流出的水經(jīng)水泵后將水壓提高到8MP ，形成高壓射流噴射到路面。高壓泵的合理選取，對發(fā)動(dòng)機(jī)效率的最佳利用、最佳沖洗效率都有重要的影響，需要根據(jù)設(shè)計(jì)要求及發(fā)動(dòng)機(jī)參數(shù)等來確定高壓泵的功率、工作轉(zhuǎn)速和泵壓等參數(shù)。水系統(tǒng)設(shè)計(jì)中的主要問題包括以下兩個(gè)方面。
4.1伸縮式多自由度噴水架
噴水架是噴射系統(tǒng)的執(zhí)行機(jī)構(gòu)，安裝在高壓清洗車頭部，高壓噴嘴安裝在噴水架上。為增加路面噴射沖洗的寬度，設(shè)計(jì)了新型液壓控制伸縮機(jī)構(gòu)。工作時(shí)，安裝有噴嘴的兩根后排管向外伸出，與車頭前方的主噴管成一直線，同時(shí)向路面噴射高壓水流；工作完成后，后排管縮回主噴管后側(cè)。噴水架的離地高度也由液壓系統(tǒng)控制，同時(shí)還設(shè)計(jì)了機(jī)械式高度微調(diào)結(jié)構(gòu)，對高度進(jìn)行微量調(diào)節(jié)。
4.2噴水系統(tǒng)參數(shù)的優(yōu)化
高壓清洗車的用途是清洗出優(yōu)質(zhì)清潔的路面，所以，如何提高路面清洗效果、節(jié)約用水是設(shè)計(jì)時(shí)需要考慮的重要問題，也是以往的研究沒有重點(diǎn)考慮的問題。路面清洗的效果和許多參數(shù)有關(guān)。包括噴射高度 、噴嘴的形狀、噴射的壓力、噴射角度 、射流寬度 、噴嘴擴(kuò)散角 、噴嘴間距等 。通過大量的理論和試驗(yàn)研究，確定了噴射高度噴射的壓力、噴射的角度、射流的寬度、噴嘴的擴(kuò)散角 時(shí)，對路面進(jìn)行沖洗的效果最佳，路面的洗凈率在 以上，清洗單位面積的路面所消耗的水量和能量，都達(dá)到了最佳匹配值。
5電控及操作系統(tǒng)設(shè)計(jì)
電控系統(tǒng)要實(shí)現(xiàn)車輛的工作狀態(tài)顯示、監(jiān)測、報(bào)警和控制等功能。主要包括儀表顯示系統(tǒng)、儀表盤、液壓油驅(qū)動(dòng)車速表盤、液壓油溫顯示、油壓顯示、水箱的水位顯示及報(bào)警、噴水管工作狀態(tài)顯示、液壓系統(tǒng)運(yùn)行時(shí)間記錄等功能，整個(gè)系統(tǒng)采用模塊化設(shè)計(jì)，控制面板集成在駕駛室內(nèi)適當(dāng)位置，便于操作者控制操作。
水箱水量的監(jiān)測和預(yù)報(bào)是電控系統(tǒng)的重要環(huán)節(jié)，必須嚴(yán)格控制。水箱內(nèi)的水經(jīng)過冷卻器為液壓油冷卻后才進(jìn)入高壓水泵，所以水箱內(nèi)必須有相當(dāng)?shù)念A(yù)留水量。設(shè)計(jì)時(shí)采用了磁浮式液位傳感器，準(zhǔn)確測定液位的高度。操控系統(tǒng)主要包括操縱箱，動(dòng)力切換手柄，油驅(qū)車速踏板，左、中、右噴水管伸縮控制手柄，噴水柄前后擺動(dòng)控制手柄和車速踏板。操控系統(tǒng)的設(shè)計(jì)，操縱箱的布置、結(jié)構(gòu)，各手柄的位置，充分考慮了人機(jī)工程學(xué)要求，便于操控。
6總體結(jié)構(gòu)設(shè)計(jì)
在結(jié)構(gòu)上，整車包括底盤（帶駕駛室）、水箱、液壓油箱、水泵、分動(dòng)箱、噴水架等大型組件。水泵和液壓油箱平行布置在駕駛室和水箱之間，左右兩側(cè)采用外擺鉸鏈?zhǔn)杰囬T，開啟方便，便于維修檢查。水箱采用不銹鋼橢圓形結(jié)構(gòu)，外面配有裝飾側(cè)圍及裙邊。分動(dòng)箱布置在底盤內(nèi)液壓油箱和水泵下部，變速器和第二傳動(dòng)軸之間。整車采用Unigraphics 軟件進(jìn)行三維實(shí)體設(shè)計(jì)，并采用其裝配功能進(jìn)行了整車的虛擬裝配。
7 結(jié)論
新型高壓清洗車的研制，以提高路面沖洗效果和節(jié)約能源為核心，采用了單發(fā)動(dòng)機(jī)配置的動(dòng)力分配方式，充分發(fā)揮噴水作業(yè)時(shí)發(fā)動(dòng)機(jī)的功率，提高了噴水壓力；并對路面沖洗效果的影響參數(shù)進(jìn)行了優(yōu)化。對動(dòng)力分配系統(tǒng)、液壓系統(tǒng)、水系統(tǒng)、電控及操縱系統(tǒng)、總體結(jié)構(gòu)等都進(jìn)行了深入的研究。在車身外形、單軸分動(dòng)箱的開發(fā)以及路面沖洗效果等研究方面申請了數(shù)項(xiàng)專利。本文研制的新型高壓清洗車，經(jīng)過樣車試驗(yàn)，各項(xiàng)指標(biāo)都達(dá)到了預(yù)定要求。新型高壓清洗車的研制，為我國高性能高壓清洗車的自主開發(fā)，起到了良好的推動(dòng)作用。