ZL50 裝載機(jī)驅(qū)動橋設(shè)計與優(yōu)化含5張CAD圖
ZL50 裝載機(jī)驅(qū)動橋設(shè)計與優(yōu)化含5張CAD圖,ZL50,裝載機(jī)驅(qū)動橋設(shè)計與優(yōu)化含5張CAD圖,裝載,驅(qū)動,設(shè)計,優(yōu)化,CAD
Loader
A loader is a type of construction equipment (engineering vehicle) machinery that is primarily used to "load" material into another type of machinery (dump truck, conveyor belt, rail-car, etc.).Loaders are used mainly for uploading materials into trucks, laying pipe, clearing rubble, and digging. A loader is not the most efficient machine for digging as it cannot dig very deep below the level of its wheels, like a backhoe can. Their deep bucket can usually store about 3-6 cubic meters of earth. The front loader's bucket capacity is much bigger than a bucket capacity of a backhoe loader. Loaders are not classified as earthmoving machinery, as their primary purpose is other than earthmoving.
Unlike most bulldozers, most loaders are wheeled and not tracked, although track loaders are common. They are successful where sharp edged materials in construction debris would damage 2 rubber wheels, or where the ground is soft and muddy. Wheels provide better mobility and speed and do not damage paved roads as much as tracks, but provide less traction.
Unlike standard tractors fitted with a front bucket, many large loaders do not use automotive steering mechanisms. Instead, they steer by a hydraulically actuated pivot point set exactly between the front and rear axles. This is referred to as "articulated steering" and allows the front axle to be solid, allowing it to carry greater weight. Articulated steering provides better maneuverability for a given wheelbase. Since the front wheels and attachment rotate on the same axis, the operator is able to "steer" his load in an arc after positioning the machine, which can be useful.
The loader assembly may be a removable attachment or permanently mounted. Often the bucket can be replaced with other devices or tools--for example, many can mount forks to lift heavy pallets or shipping containers, and a hydraulically-opening "clamshell" bucket allows a loader to act as a light dozer or scraper.
In construction areas loaders are also used to transport building materials - such as bricks,
pipe, metal bars, and digging tools - over short distances.Loaders are also used for snow removal, using their bucket or a snowbasket, but usually using a snowplow attachment. They
clear snow from streets, highways and parking lots. They sometimes load snow into dump trucks for transport.
Front loaders gained popularity during the last two decades, especially in urban engineering projects and small earthmoving works. Many engineering vehicle manufacturers offer a wide range of loaders, the most notable are those of John Deere, Caterpillar, Case, Volvo, Komatsu and Liebherr.
The following we will introduce Carter 938G Series II Wheel Loader.
Engine
The 938G II provides more power, excellent fuel economy, and reduced maintenance.
Turbocharged, ATAAC. Turbocharging packs dense air into the cylinders for more complete combustion and lower emissions. Air-to-air aftercooling (ATAAC) provides a separate cooling system for intake manifold air. The ATAAC system reduces smoke and emissions by providingcooler inlet air for more efficient combustion.
Constant Net Horsepower. The 938G II’s electronic engine is integrated with an on-demand cooling fan. The engine compensates for varying fan loads and provides constant net horsepower, regardless of operating conditions. A consistent level of “working” horsepower is provided and fuel consumption is reduced.
Oil Change Intervals. The engine oil change interval is increased to
500 hours (with CH-4 oil), reducing costs and downtime
Powerful Performance. The 3126B ATAAC engine delivers net power of 119 kW (160 hp), and meets EPA Tier 2 emissions standards. Its advanced system keeps fuel at low pressure in the fuel lines until it is injected into the cylinder. Fuel pressure is created hydraulically in response to a signal from the ADEM III? Electronic Control Module.
Electronic Control Module. The Advanced Diesel Engine Module (ADEM III) fuel system is
a proprietary electronic control module, which provides improved engine response and fuel efficiency,plus advanced diagnostics and reduced emissions. Altitude capability is increased to 3050 meters (10,000 feet) without derating. ADEM III allows full electronic integration
of the engine and transmission for maximum power train efficiency.
Power Train
Advanced Caterpillar power train is reliable and fuel efficient.Electronic Power Shift Transmission.The electronic power shift transmission with automatic shift capability is a countershaft design built by Caterpillar. It is electronically controlled and allows full power shifts and directional changes. Fully modulated gear shifts contribute to operator comfort and increase component life.Electronic Clutch Pressure Control (ECPC). Senses input from both the transmission and the operator controls in the cab to modulate each individual clutch through a proportional electro-hydraulic valve. This results in smoother gear changes and improved shift quality. Energy is modulated into the clutches, resulting in longer clutch life.
Integrated Braking System. New for G Series II, IBS integrates downshifting and transmission neutralization into the left-hand brake pedal. IBS provides smooth, optimized transmission neutralizer performance with a greater range of adjustability. The Integrated Braking System also lowers owning and operating costs by reducing axle oil temperatures, which can extend service brake life.Easy Service. Daily transmission oil level check is done from the ground through a well-protected sight gauge.An oil sampling valve allows quick,clean access to the transmission for S?O?SSM oil analysis.
Cooling System
New G Series II cooling package reduces radiator plugging and improves fuel efficiency.
Reverse Flow. Air enters through the rear grill and exits out the top opening and side hood doors. Rear air flow picks up less debris from the ground, reducing plugging.
Improved System Access. The 938G II adds a swing-out grill, hydraulic oil cooler and air conditioner condenser for easier cleaning. Side panels open to allow access to both sides of all cores for cleaning. A heavy duty Airborne Debris Grill, with 4 mm perforations is available as an attachment.
On-Demand Fan. Electronically controlled, variable speed on-demand fan adjusts to meet the varying cooling requirements of the machine. Fan speed is determined by oil, coolant and inlet
manifold temperatures. In cooler operating conditions, average fan speed is reduced, resulting in less fuel consumption, lower noise levels and less radiator plugging.
Unit Core Radiator. New unit core radiator with square wave shaped fins.Lower fin density (6 fins per inch) allows debris to pass through more easily.
Environmental Features
Caterpillar cares about the environment and continues to develop innovative solutions.
Low Exhaust Emissions. The Cat 3126B ATAAC engine used in the 938G Series II is a low emission engine designed to meet Tier 2 emission regulations. It is electronically controlled, with air-to-air aftercooling for more efficient combustion and cleaner emissions.
Reduced Sound. The electronic on-demand fan automatically
regulates fan speed depending on cooling requirements. The fan draws less horsepower in cooler ambient temperatures, which reduces fuel consumption. Sound levels are also reduced when the fan slows down.There is additional insulation around the engine to reduce sound levels.
Environmental Fluids. Extended Life Coolant/Antifreeze with anti-foaming and anti-corrosion properties provide extended service intervals (up to 6000 hours) and requires less frequent fluid changes and disposals. Air conditioning refrigerant is CFC-free.
Operator Station
The ultimate in wheel loader operator comfort and efficiency.
1 Steering. Low effort hand metering unit steering. Tilt steering column helps fit the wheel to the operator. Load sensing steering directs power through the steering system only when needed. When not steering, more engine power is available to generate rimpull, breakout and lift forces.
2 Excellent Visibility. The front window provides remarkable forward and peripheral
viewing, including the machine wheels and bucket corners. Bonded glass in the windshield eliminates frame obstructions.The sloping hood provides excellent visibility to the rear of the machine.
3 Finger Tip Controls. New pilot-assisted hydraulic implement controls deliver comfortable, low-effort operation. Single lever joystick and lift lever F-N-R switch are available as attachments.
4 New Instrument Cluster. Gauges, status indicators and alert indicators are now centrally located. 3-level warning system monitors key functions. The system alerts the operator of immediate or impending problems with engine oil pressure, parking brake, fuel pressure,electrical system, brake oil pressure,hydraulic oil temperature, transmission filter bypass, engine inlet manifold temperature, primary steering oil pressure and the air inlet heater. LED warning indicators with no bulbs to replace.
5 Cab Access. Left and right side doors swing open 180 degrees and latch for optimal ventilation, visibility and communication to ground level. Left and right side sliding windows are available as an attachment. Full service platforms are provided on both sides of the machine for safety and easy maintenance access.
6 Floor Mounted Pedals. All pedals including the new electronic governor,are floor mounted for greater operator comfort. Left pedal incorporates the new Integrated Braking System that combines service brake, transmission neutralizer and downshift functions.
7 Generous Storage Space.Compartments for lunchbox, coolers
and cups.
8 Seat Options. The standard cloth and vinyl seat adjusts 6 ways. A new Caterpillar Contour
air suspension seat (attachment) provides increased operator comfort with 6-way adjustment and automotive-style lumbar support.
9 Electronic Autoshift Control. Set for manual or one of two fully automatic shifting modes.
10 Ride Control System Switch.Attachment that reduces fore and aft pitch for a smoother, more comfortable ride. Allows the selection of three different modes: Off – always off service. On – always in service.Auto – the system is automatically actuated when the
machine travels at a speed greater than 9 km (6 mph).
11 Transmission Neutralizer Lockout Switch. Rocker switch that locks out the neutralizer. Defaults back to neutralizer “on” upon machine start up.
裝載機(jī)
裝載機(jī)是一種主要用于向另一種機(jī)械（自卸車、輸送皮帶、鐵路運(yùn)輸車輛等）“裝載”物料的建設(shè)機(jī)械（工程車輛）設(shè)備。裝載機(jī)主要用于向卡車裝載物料，以及鋪設(shè)管道、清理碎石和挖土等工作。作為挖土作業(yè)裝載機(jī)不是最有效的機(jī)械，與挖掘機(jī)不同，裝載機(jī)不適用于輪胎支承面以下較深處的挖掘作業(yè)。裝載機(jī)的深底鏟斗一般可裝載3～6立方米的土壤。鏟斗前置裝載機(jī)的斗容量遠(yuǎn)大于挖掘裝載機(jī)的斗容量。裝載機(jī)不屬于鏟土運(yùn)輸機(jī)械，因其主要用途并非土方運(yùn)輸。
盡管履帶式裝載機(jī)是普遍的，但與大多數(shù)推土機(jī)不同，大多數(shù)裝載機(jī)是輪式的而并非履帶式。履帶式裝載機(jī)適用于棱角銳利的建筑材料會破壞橡膠輪胎的場合，或者在松軟泥濘道路上的作業(yè)。輪式裝載機(jī)具有良好的機(jī)動性和較高的工作速度，并且不像履帶那樣破壞鋪裝路面，但其所能提供的牽引力較小。
與安裝前置鏟斗的標(biāo)準(zhǔn)拖拉機(jī)不同，許多大型裝載機(jī)不使用汽車轉(zhuǎn)向機(jī)構(gòu)。取而代之，它們通過液壓驅(qū)動的安裝于前、后橋之間的轉(zhuǎn)向鉸接裝置轉(zhuǎn)向。這種轉(zhuǎn)向稱為“鉸接轉(zhuǎn)向”，它可使前橋固定，并使其承受更大的重量。對于一定的軸距鉸接轉(zhuǎn)向提供了較好的機(jī)動性。由于前輪與工作裝置繞同一車軸旋轉(zhuǎn)，駕駛員在使機(jī)械定位后可使鏟斗沿弧線“轉(zhuǎn)向”，這一點(diǎn)是實用的。
裝載機(jī)的工作裝置可以是更換式的或者是固定安裝。鏟斗常?？捎闷渌b置或工具更換，例如，許多裝載機(jī)可以安裝叉車工裝提升重型貨物或者裝運(yùn)集裝箱，裝備液壓開啟式“蛤殼”型鏟斗可以使裝載機(jī)像推土機(jī)或鏟運(yùn)機(jī)一樣作業(yè)。
在各種建筑工地上裝載機(jī)也經(jīng)常用來近距離轉(zhuǎn)運(yùn)建筑材料，例如磚塊、管材、鋼筋、各種挖掘工具等。借助鏟斗或除雪鏟，裝載機(jī)也用于除雪作業(yè)，但通常使用除雪裝置。它們用來清除街道、公路和停車場上的積雪。有時用裝載機(jī)將積雪裝載到自卸車上進(jìn)行運(yùn)輸。
近20年來，特別是在城市建設(shè)工程和小型土方運(yùn)輸工程中，裝載機(jī)獲得了普遍的應(yīng)用。許多工程車輛制造商可生產(chǎn)多種類型的裝載機(jī)，其中最知名的有約翰迪爾、卡特彼勒、凱斯、沃爾沃、小松和利勃海爾等品牌。
下面我們將介紹卡特938GII系列輪式裝載機(jī)。
發(fā)動機(jī)
這個938GII提供更大的動力，優(yōu)良的燃油經(jīng)濟(jì)性，并減少維修。
渦輪增壓，ATAAC。渦輪增壓使包裹著更大密度的空氣進(jìn)入汽缸以便更完全的燃燒，更少的排放物。ATAAC提供了一個獨(dú)立的冷卻空氣進(jìn)氣系統(tǒng)。ATAAC系統(tǒng)通過冷卻進(jìn)氣空氣使更完全的燃燒從而減少煙氣的排放。
恒定的凈功率 :該938G II的電子引擎集成了可調(diào)節(jié)散熱風(fēng)扇。不管什么樣的工作條件，發(fā)動機(jī)風(fēng)扇補(bǔ)償了變化的負(fù)載，并提供恒定的凈馬力。一個恒定馬力的“工作”狀態(tài)被提供并且燃料消耗降低。
換油周期。該發(fā)動機(jī)機(jī)油更換間隔增加至 500小時（用CH - 4油），降低了成本和停機(jī)時間。該3126B ATAAC發(fā)動機(jī)提供119千瓦（160馬力）的凈功率，并符合美國環(huán)保署2級排放標(biāo)準(zhǔn)。其先進(jìn)的系統(tǒng)在燃料管線上保持低壓，直到它被注入氣缸。燃油壓力產(chǎn)生液壓從電子控制模塊中做出響應(yīng)信號。
電子控制模塊：先進(jìn)的柴油引擎模塊燃料系統(tǒng)是一種專有的電子控制模塊，它提供了改進(jìn)的發(fā)動機(jī)響應(yīng)和燃油效率，再加上先進(jìn)的診斷減少了排放量。爬坡能力提高到三千零五十零米（10,000英尺）。ADEM III 允許電子發(fā)動機(jī)一體化使傳動系傳輸效率最高。
傳動系統(tǒng)
卡特動力系統(tǒng)先進(jìn)可靠，省油。 電子式動力換擋變速器.電子式自動換擋變速箱自動換擋能力是一個被卡特彼勒建成的中間軸設(shè)計。它是電子控制，并允許全功率的變化和方向變化。充分調(diào)制換檔有助于提高操作員舒適性和元件壽命。
電子離合器壓力控制（ECPC）。來自傳動裝置和操作員在駕駛室控制的感官輸入通過各比例電動液壓閥來調(diào)制離合器。這就有了換檔順暢和改善換擋質(zhì)量這樣的結(jié)果。能源被調(diào)制到離合器中，使離合器的壽命較長。
綜合制動系統(tǒng)：新的G II系列，IBS集成低速變速器進(jìn)入左邊的剎車踏板。 IBS提供平穩(wěn)，更大范圍的可調(diào)節(jié)性能優(yōu)化的傳動裝置。綜合制動系統(tǒng)還能通過減少車軸油的溫度降低生產(chǎn)費(fèi)用，那可以延長制動器壽命成本。
便于維修：通過被防護(hù)的觀測計從接觸面檢查每日傳動油油位.一個油采樣閥門允許快速，清理傳動裝置進(jìn)口為獲得S?O?SSM油液分析。
冷卻系統(tǒng)
新的GII系列II散熱器冷卻封裝減少堵塞，提高燃油效率。
反向流動?？諝馔ㄟ^后部進(jìn)入，從頂口和側(cè)口排出。后方的氣流從地面帶來更少的污物，減少堵塞。
改進(jìn)的系統(tǒng)通道。938GII添加了個擺動刷，液壓油冷卻器和空調(diào)冷凝器更容易清洗。打開側(cè)板，允許磁芯的兩面都被清洗。重型機(jī)載碎片水箱護(hù)罩與4毫米齒孔，作為附件提供。
風(fēng)機(jī)。電控變速風(fēng)機(jī)調(diào)節(jié),以滿足需求的不同冷卻要求的機(jī)器。風(fēng)扇速度取決于油、冷卻介質(zhì)及進(jìn)口氣管的溫度。在較涼的操作條件下,平均風(fēng)速減小,導(dǎo)致更少的燃料消耗,降低噪音,更少的散熱器堵塞。
散熱器核心單元：新單元散熱器帶有方波成形散熱片.更低密度的散熱器散熱片讓核心碎片更容易通過。
環(huán)境特征
卡特注重環(huán)境和持續(xù)發(fā)展創(chuàng)意的解決方案。
低廢氣排放?？ㄌ?126B ATAAC引擎在938GII使用的是一種低排放發(fā)動機(jī)，以滿足二
級排放法規(guī)。它是電子控制，ATAAC為更有效率和更清潔的排放量。
降低聲音。風(fēng)扇自動調(diào)節(jié)需根據(jù)冷卻風(fēng)扇速度的要求。風(fēng)機(jī)吸收更少的馬力,從而降低環(huán)境溫度冷卻器的燃料消耗。當(dāng)風(fēng)機(jī)減緩時聲級也減小。又額外減少絕緣引擎周圍的聲音級別。
環(huán)境流體。冷卻劑/防凍劑具有抗起泡性和抗腐蝕性能提供延長服務(wù)時間間隔（6000小時），需要更少的頻繁的流體變化和處置?？照{(diào)制冷劑無氟。
操作員控制臺
在輪式裝載機(jī)操作者的舒適度和效率。
1操縱：手計量單位低受力轉(zhuǎn)向。適應(yīng)輪經(jīng)營者的傾斜轉(zhuǎn)向柱幫助。當(dāng)需要時負(fù)荷傳感轉(zhuǎn)向指向力量通過轉(zhuǎn)向系統(tǒng)。當(dāng)不轉(zhuǎn)向,更多的發(fā)動機(jī)功率是可用來產(chǎn)生邊緣拉力、抬升力。
2能見度極佳：前面的窗戶提供良好的前視和周邊的觀賞,包括機(jī)器的輪子和斗的角落。在擋風(fēng)玻璃上消除保稅玻璃框架障礙物。傾斜的引擎蓋,為尾部的機(jī)器提供了良好的能見度。
3指尖控制。新的試驗輔助液壓實行控制，提供舒適，省力的操作。單桿和升降桿操縱桿FNR的開關(guān)都作為附屬裝置提供。
4新的儀表盤。壓力表,狀況指標(biāo)和報警指標(biāo)是現(xiàn)在在中心。三級報警系統(tǒng)監(jiān)視器主要功能。該系統(tǒng)的警報的經(jīng)營人迫在眉睫的問題是立即用機(jī)油壓力、停車制動,燃油壓力、電力系統(tǒng)、剎車油壓力、液壓油溫度、傳輸、發(fā)動機(jī)進(jìn)氣歧管的過濾旁路溫度、轉(zhuǎn)向油壓和空氣進(jìn)口加熱器。LED燈泡警告指標(biāo)沒有替代的。
5駕駛室口：左，右側(cè)車門打開180度的擺動與優(yōu)化通風(fēng)，能見度和地面通信閂鎖。左，右側(cè)滑動窗口都作為附屬裝置提供。在機(jī)器的兩側(cè)為機(jī)器的安全和容易維修提供全面的服務(wù)。
6踏板：為適應(yīng)操作者的舒適度所有的踏板包括新的電子調(diào)速器被安裝。融合了全新整合的左踏板剎車制動系統(tǒng)包含了腳踏閘，傳動裝置，減速檔。
7寬松的空間.為便當(dāng)，冷飲器，杯子劃出隔間。
8座椅的選擇。標(biāo)準(zhǔn)的布和塑料基座椅調(diào)整6種方式。一個新的空氣懸浮座椅輪，可提高6路調(diào)整和汽車式腰部支撐的舒適性。
9電子自動變速控制。設(shè)置為手動或自動換擋的兩個完全模式之一。
10行駛控制系統(tǒng)開關(guān)：減小了縱長及校平器縱長節(jié)距便于更舒適的乘坐。允許在三種不同的模式選擇：關(guān)閉 - 始終關(guān)閉服務(wù)。開啟 - 總在服務(wù).自動 - 系統(tǒng)會自動啟動的當(dāng)機(jī)的速度超過9公里（6英里）或更大的速度。
11傳輸力合器和鎖定開關(guān)。蹺板開關(guān)，鎖定力合器。力合器回到默認(rèn)值，機(jī)器啟動起來。
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