SAE R-419-2014 Heavy-Duty Wheeled Vehicles Design Theory Calculations (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf

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1、Heavy-Duty Wheeled VehiclesOther SAE books of interest: Advanced Hybrid Powertrains for Commercial Vehicles By Haoran Hu, Rudy Smaling, and Simon Baseley(Product Code: R-396) Motor Truck Engineering Handbook, Fourth Edition By James Fitch(Product Code: R-125) Riding on AirA History of Air Suspension

2、 By Jack Gieck(Product Code: R-235) For more information or to order a book, contact: SAE International 400 Commonwealth Drive Warrendale, PA 15096-0001 USA Phone: 877-606-7323 (U.S. and Canada only) or 724-776-4970 (outside U.S. and Canada) Fax: 724-776-0790; Email: CustomerServicesae.org; Website:

3、 books.sae.orgWarrendale, Pennsylvania, USA By Boris N. Belousov and Sergei D. Popov Heavy-Duty Wheeled Vehicles: Design, Theory, Calculations Copyright 2014 SAE International eISBN: 978-0-7680-8068-1 Copyright 2014 SAE International. All rights reserved. No part of this publication may be reproduce

4、d, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE. For permission and licensing requests, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: 724-772-4028;

5、 fax: 724-772-9765. ISBN 978-0-7680-7723-0 SAE Order Number R-419 DOI 10.4271/R-419 Translated from Russian to English by Leonid Schukin. Information contained in this work has been obtained by SAE International from sources believed to be reliable. However, neither SAE International nor its authors

6、 guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SAE International and its au

7、thors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. To purchase bulk quantities, please contact: SAE Customer Service E-mail: CustomerServicesae.or

8、g Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-0790 Visit the SAE Bookstore at bOOkS.SAE.Org 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerServicesae.org Phone: 877-606-7323 (inside USA and Canada)724-776-4970 (outside USA) Fax: 724-776-07

9、90 Library of Congress Cataloging-in-Publication Data Belousov, Boris N.Heavy-duty wheeled vehicles : design, theory, calculations / Boris N. Belousov, Sergei D. Popov.pages cmISBN 978-0-7680-7723-01. Trucks-Design and construction. 2. Four-wheel drive vehicles-Design and construction. I. Popov, Ser

10、gei D. II. Title. TL230.B382 2013629.224-dc232013021860v Dedication In memory of Professors P .V . Aksyonov, N.F. Bocharov, G.A. Smirnov, and Yu.V . Pirkovskyvii Table of Contents Preface xi Acknowledgments xiii Symbols used xxi Enterprises and institutions . xxiii Part I Evolut Ion of h Ea vy-duty

11、wh EEl Ed v Eh Icl Es Chapter 1 History of HDWVs .3 1.1 General design-layout solutions .3 1.2 Hydromechanical transmissions (HMT) .13 1.3 Electric transmissions (ETs) .17 1.4 Hydrostatic transmissions (HSTs) 22 1.5 Steering systems 34 Chapter 2 Multi-support vehicles .37 2.1 Overview 37 2.2 Transmi

12、ssion 42 2.3 Supports .43 2.4 Steering system .47 Chapter 3 Heavy- and super-heavy-duty dumpers .53 3.1 Overview 53 3.2 Transmission 58 3.3 Undercarriage 65 3.4 Steering system .68 3.5 Brake system 70 3.6 Cabin .72 3.7 Dumpers made by MoAZ 72 Chapter 4 Evolution of the multi-axle chassis .75 4.1 His

13、tory and evolution of the multi-axle chassis for monocargoes 75 4.2 Hovercrafts 80 4.3 General design and layout solutions .86 4.4 Designs of special wheeled chassis in the 1980s 87viii Part II o v Er v IEw of hd wv s Chapter 5 HD WV general design methods . 99 5.1 General provisions 99 5.2 Hierarch

14、ical structure of SWC as a complex technical system 103 5.3 Process of forming the appearance of SWCs 112 5.4 Structure of a HDWV mathematical model 129 5.5 HDWV appearance formation algorithm 131 5.6 Characteristics of the “Formation of HDWV Appearance” project stage 133 Chapter 6 Conditions and ar

15、eas for using HDWVs 135 6.1 Techno-economic feasibility for using HDWVs for cargo hauling 135 6.2 Conditions for using HDWVs .138 6.3 Basic requirements for traffic routes 143 Chapter 7 basic requirements for HDWV consumer properties . 149 7.1 General provisions 149 7.2 Traction-speed properties and

16、 fuel efficiency .150 7.3 Weight and dimensions 154 7.4 Maneuverability, ease of steering, and road passing ability.157 7.5 Safety 159 7.6 Ergonomics 166 Chapter 8 Main technical criteria and efficiency evaluation of HDWV solutions . 173 8.1 Analysis of technical criteria of vehicle excellence 173 8

17、.2 Methods for assessing vehicle designs 183 8.3 Mathematical model of the SWCs representative route .186 8.4 Mathematical model of the SWCs motion .197 8.5 Comparing SWC mobility on different routes206 Part III f undam Entals of hdwv th Eory and d Es Ign Chapter 9 basic principles of HDWV general l

18、ayout . 213 9.1 Trends in overall layout .213 9.2 Fundamentals of modular designing .227 9.3 Theory for building HDWV families .233 9.4 Future transport-and-process wheeled vehicle 238 9.5 Weight equations of a multi-wheel vehicle and its elements .244 9.6 Calculating the weight of wheeled vehicles

19、.255ix Chapter 10 Power units of wheeled vehicles .267 10.1 General characterization of power units .267 10.2 Engine development trends 269 10.3 Fundamentals of HDWV engine designs .272 10.4 Features of mathematical modeling a diesel engine and gas-turbine power plants for HDWVs 282 10.5 State of th

20、ings with electrochemical engines 286 Chapter 11 Fundamental theory and calculation of power transmission from engine to wheeled mover . 291 11.1 General overview, classification, and requirements for transmissions .291 11.2 Trends in designs of mechanical transmissions306 11.3 Brakes-retarders of t

21、ransmission type 317 11.4 Main principles of power distribution in transmissions of modern and future HDWVs 319 11.5 Optimization of the power transfer to the wheeled mover 323 11.6 Promising electric transmissions 340 Chapter 12 Oscillations in a multi-axle wheeled chassis with resilient tires 351

22、12.1 Characteristics of vertical- and longitudinal-angular oscillations .351 12.2 Characteristics of lateral-angular oscillations .367 12.3 Frequency characteristics of oscillation velocities 369 12.4 Frequency characteristics of oscillation accelerations .370 12.5 Spectral analysis of oscillations

23、372 12.6 Spatial models of oscillations 376 12.7 Spatial model of oscillations in a multi-axle saddle road train 385 Chapter 13 Fundamental theory and design of springing systems in HDWV wheels 391 13.1 Function, classification, and requirements for wheel suspensions .391 13.2 Analysis and calculati

24、on process of wheel suspensions .394 13.3 Active and regulated suspensions and platform stabilization systems 401 13.4 Choice of damping and rigidity parameters for long-stroke suspensions .411 13.5 Designing long-stroke wheel suspensions for support-running modules (SRM) .421 13.6 Analysis of the r

25、esults of experimental trials on HDWV hydropneumatic suspensions .425 13.7 Designing and calculating suspensions .429 Chapter 14 Curvilinear motion of multi-axle wheel chassis 441 14.1 Terms and definitions .441 14.2 Equations of plane curvilinear motion in multi-link wheeled chassis 446 14.3 Motion

26、 stability of multi-axle wheeled chassis 462 14.4 Steady motion stability in multi-axle wheeled chassis475 14.5 Steady motion stability in a multi-axle wheeled chassis.480 14.6 Non-stationary motion stability in a multi-axle wheeled chassis 485x Chapter 15 Fundamental theory and design of HDWV steer

27、ing systems . 487 15.1 General provisions 487 15.2 Basic requirements for steering systems490 15.3 Initial data for StS calculation .491 15.4 Selection and mathematical justification of functionality of flexible StS 496 15.5 Study of turning ability, maneuverability, and motion of HDWVs with differe

28、nt StSs .501 15.6 General design of automated control systems for curvilinear motion .513 15.7 All-wheel steering system for a 1212 HDWV .526 r eferences .537 Index . 543 About the Authors .553xi Preface This book narrates the history of heavy-duty wheeled vehicles (HDVWs) and presents the basics of

29、 the design, theory, and calculation of their individual units and systems; as well as the peculiarities of common design solutions used. HDWVs are all-wheel-drive vehicles that have a load capacity of 25 tons or more and three or more axles. Such vehicles are used for transporting heavy, indivisibl

30、e, bulky cargos and as transport platforms for various technical equipment. HDWV designs have their own development requirements, which are associated with high loads, huge dimensions, and specific operation conditions. Naturally, the approaches to designing such vehicles differ from those used in d

31、esigning other multipurpose all-wheel-drive automobiles. Designers and manufacturers of HDWVs use a custom approach, such as designing a chassis for a particular purpose requested by the customer. The main elements of the chassis, namely, the undercarriage, the carrying system, the transmission type

32、 and composition, the engine, and resilient elements of the wheel suspension are flexible and vary. Other design variables include the number of axles and which are the driving and driven ones, and what size and type of tire are needed. Due to the individual character of the design process, design s

33、olutions are often different than those used to design passenger cars. Therefore, every positive and negative aspect of designing an HDWV deserves a thorough study for future use in designing new vehicles. An enormous contribution into the theory and practice of designing HDWVs was made by Professor

34、s N.F. Bocharov and G.A. Smirnov of the N.E. Bauman MSTU and Professors P.V. Aksyonov and Yu.V. Pirkovsky, who closely cooperated with MSTU. This book presents certain elements of updated theory, calculations, and related general design solutions. The concept of general design solutions, introduced

35、by Professor Aksyonov, comprises of the number and location of axles, steering and transmission system layout, and general vehicle layout principles. The authors hope that this book will be helpful for the engineers, technicians, and scientists involved in the motor industry; for those engaged in de

36、signing and building wheeled transportation vehicles; and for students and trainees at universities where specialists of respective branches of industry are trained. The authors will be grateful for any critical remarks and wishes expressed by the readers.xiii Acknowledgments The authors gratefully

37、acknowledge the following reviewers: G.I. Gladov S.B. Shukhmanxv Introduction Heavy-duty wheeled vehicles (HDWVs) are crucial for the economy and defense of any country. The Dictionary of Motor Transport by Yu.I. Egorov and A.N. Narbut defines this group of vehicles as those that can transport cargo

38、s of 25 tons or more. The Russian fleet of HDWVs includes quarry dumpers made by BelAZ and MoAZ; heavy-duty road trains for transporting long-sized cargoes weighing 50 tons or more and consisting of tow cars made by the Open Joint-Stock Company (OJSC), “Rusich,” KZKT, or MZKT and semi-trailers by Ch

39、MZAP or FGUP “Motor KB”; multi-axle special wheeled chassis (SWCs) made by OJSC “BAZ” and MZKT; and truck-mounted cranes built on foreign-made multi-axle chassis. Abroad, HDWVs include quarry dumpers, multi-support wheeled transportation vehicles, and multi-axle chassis vehicles that have truck-moun

40、ted cranes. One way to boost the efficiency of a truck is to increase its load capacity. That is why multi- axle and multi-support vehicles with 412 axles, more than 20 supports, over 100 wheels, and a load capacity of 500 tons or more have appeared since the middle of the twentieth century. Multi-

41、support vehicles can transport prefabricated modules of production shops, factories and plants, dockage facilities, and other structures of huge dimension and weight. Historically, vehicle designs have advanced by increasing the number of axles. To improve the adaptability of wheeled vehicles to poo

42、r roads, and because of legislatively established limits on load per axle, axles totaling three or more were successively added. Powerful hydraulic excavators placed increased demands on quarry transport. To fully benefit from the greater capabilities of such excavators, which are able to dig into a

43、ll types of rocks, new models of super-heavy-duty quarry dumpers were developed that can work with such excavators. The HDWVs class is essentially different from the class of general transportation automobiles. Like other complex machines, they have their own theory, which sets the general rules of

44、design and direction for further development and improvement. HDWV theory stems from the general automobile theory developed by the Academician E.A. Chudakov, which is based on the works by N.R. Brilling, V .I. Grinevetsky, N.E. Zhukovsky, G.V . Zimelyov, B.S. Falkevich, and others. It considers the

45、 general motion principles of mainly a two-axle vehicle with one driving axle. The general design theory of multi-axle HDWVs is based on the works of the following Soviet scientists and engineers: Ya.S. Ageikin, A.S. Antonov, D.A. Antonov, P .V . Aksyonov, N.F. Bocharov, M.S. Vysotsky, A.I. Grishkev

46、ich, V .P . Efimov, K.S. Kolesnikov, N.I. Korotonoshko, L.G. Krasnevsky, V .I. Medvedkov, Yu.V . Pirkovsky, V .F. Platonov, R.V . Rotenberg, V .M. Semyonov, G.A. Smirnov, Yu.A. Stepanov, B.L. Shaposhnik, V .E. Chvyalyov, Ya.S. Farobin, N.N. Yatsenko, and others. Currently, Russian and Belarusian sci

47、entists and engineers are in a leading position when it comes to addressing theoretical and practical problems of future and promising HDWVs. The fact that a HDWV has many systems and mechanisms that use different energy types (mechanic, hydraulic, and electric), leads to an essential increase in we

48、ight, a higher complexity of design, and problems in operation, maintenance, repair, etc. The need to design multi-axle HDWVs for the military, for transporting various weapons and combat vehicles, has caused another qualitative breakthrough in HDWV design and has given birth to radically new techni

49、cal solutions.xvi Introduction A special contribution to HDWV designs was made by the Belarusian school of machine- building. Belarus is home to motor industry giants such as BelAZ, MAZ, MoAZ, and MZKT. The achievements of Russian motor factoriesthe KZKT, ZIL, BAZ, and Motor KBalso deserve mention. Specialists at these enterprises have designed and madein cooperation with respective scientistsa number of modern transportation vehicles that have no equal abroad. The improvement of multi-axle vehicles and a broad introduction of road trains took place in parallel. Road trains