Finite element and experimental analysis of pinion bracket-assembly of three gorges project ship lift

Abstract

The pinion bracket-assembly (PBA) is a major part of three gorges project (TGP) ship lift drive system. The static strength, fatigue strength and stress distribution of hinge pin of PBA were analyzed by ANSYS, and the structure of PBA was optimized. The results show that after the optimization, the maximum comprehensive stress is 259.59 MPa, the maximum fatigue cumulative damage of weld joints is 0.94 and the maximum vertical deformation of hinge pin is 0.14 mm. The elastic deformation, hydropneumatic spring cylinder (HSC) load response and the vibration characteristics of PBA were studied by the bearing test when PBA bore the load caused by different water level errors. The results indicate that when the water level of ship chamber ranges from 3.4 m to 3.6 m, the vertical elastic deformation of the pinion shaft is between −8.58 and 10.50 mm. When upward outage-load(1580 kN) is imposed by the test-rack, the vertical elastic deformation of the pinion shaft is 13.42 and 14.07 mm and HSC load response is 795.80–800.80 kN. In the process of imposing load on the pinion by the test-rack, the maximum vibration amplitude and acceleration of PBA internal components are 0.37° and 2.67 rad/s², respectively; the maximum impact on the pin caused by vibration is 19.89 kN; the pinion shaft vertical displacement and HSC load response do not fluctuate. There is a great difference between the frequency of meshing force of the pinion and the rack (1.06 Hz) and first-order natural frequency of PBA(8.41 Hz), thus PBA will not resonate. From all above, PBA meets the static strength and fatigue strength requirements. The vibration of PBA internal components has no effect on the vertical displacement of the pinion shaft, HSC load response and smooth operation of PBA. There is a liner relationship in the ratio of 2:1 between the thrust imposed by the test-rack and HSC load, thus HSC can limit the load imposed on the pinion.