采煤机截割传动系统故障诊断及可靠性分析

发布时间：2018-02-20 22:20

本文关键词： 采煤机截割系统可靠性分析截割系统动力学截割系统壳体　出处：《中国矿业大学》2015年博士论文　论文类型：学位论文

【摘要】：采煤机截割传动系统是采煤机完成综采任务的重要部件,其维护工作已成为采煤机维护工作的重中之重。随着综采工作面开采技术的要求越来越严格,人们对采煤机的质量要求越来越高,对采煤机截割传动系统的性能要求也越来越高,因此对采煤机截割传动系统的设计变得越来越重要。可靠性无疑是采煤机截割传动系统设计中的关键因素,因此通过对截割传动系统进行全面的可靠性评价分析,可以有效的控制故障的发生概率,提高采煤机截割传动系统可靠性。同时对采煤机可靠性分析,为采煤机故障的自诊断、预测、和自修复提供基础,对自动化智能采煤工作面的发展提供条件。论文针对需要降低采煤机截割传动系统运行风险的要求,提出了一套应用于采煤机截割传动系统的可靠性分析体系,并运用其对采煤机截割传动系统进行了可靠性应用分析。主要研究内容如下:(1)通过对采煤机的截割传动系统进行结构和功能原理分析,建立了采煤机截割传动系统的可靠性分析模型,并且基于相关可靠性分析标准,制定可靠性分析约定层次和分析流程,进而基于FMEA(故障模式影响分析)可靠性分析方法对采煤机截割传动系统进行了可靠性分析,建立了采煤机截割传动系统的故障模式库,并生成了分析报告。(2)在对比分析FMECA(故障模式影响及危害性分析)和FTA(故障树分析)两种可靠性分析方法的基础上,充分利用两种分析的方法的优点提出了将FMECA和FTA结合的FTF可靠性综合分析方法,并对正向、逆向FTF分析作比较分析。论文利用正向FTF分析方法,先对采煤机截割传动系统进行FMECA分析,根据分析的结果选择I、II类的事件中RPN值和危害度值排序较高的事件作为顶事件进行FTA分析,得到了故障发生原因组合以及危害重要度,进行优先排序得到了截割传动系统健康状态评价参数,提出了系统薄弱环节的改进措施。(3)齿轮故障可以通过齿轮啮合动力学参数表现出来,特别地,齿轮啮合刚度和轮齿啮合力对齿轮系统的故障比较敏感,所以研究齿轮动力学啮合参数是对齿轮系统进行精准故障诊断的基础。基于材料力学原理和能量原理建立了求解齿轮时变啮合刚度的理论模型,进一步建立了具有非等齿宽裂纹的齿轮时变啮合刚度理论模型模型。基于截割传动系统高速区是齿轮故障高发区,建立高速区齿轮9自由度动力学模型,基于此模型研究了高速区齿轮动态特性、冲击载荷对齿轮动态特性的影响,以及不同裂纹损伤程度对系统动态特性的影响,结果表明齿轮系统的损伤存在可通过时域信号分析诊断。(4)针对煤矿井下强噪声背景影响,及齿轮传动产生的非线性、非平稳振动信号,基于多传感器信息融合建立故障诊断模型,利用小波相关特征尺度熵提取故障特征信息,SOM神经网络进行单传感器识别,最后利用D-S证据理论进行多传感器融合诊断。解决了强噪声背景下准确识别故障类型,消除识别不确定等关键问题。(5)通过ANSYS对截割系统壳体的有限元分析,找到了截割系统壳体结构的主要应力集中部位,合理优化加强筋结构,从而提高了截割系统壳体的设计可靠性。基于特种铸钢材料的提高采煤机截割系统壳体综合机械强度的研究,设计采煤机截割系统壳体合理和稳定的铸造工艺,根据铸件力学性能需要和金属液的充型能力选材和确定成分,有利于降低铸造难度,铸造出铸件健全和综合机械性能较高的大功率截割系统壳体。壳体验收检验表明,壳体加工路线安排和机加工工艺设计满足加工精度要求。在井下工业应用期间,截割系统壳体使用性能保持良好状态,壳体综合力学性能满足大功率采煤机使用要求。(6)通过分析截割传动系统高低速密封件的密封机理以及目前使用中存在的问题,研制了浮动油封试验装置,并根据试验装置和截割系统加载试验对不同厂家的密封件性能进行了对比,筛选出了产品性能优越的密封件和最佳装配间隙,提出了改进截割传动系统高低速密封可靠性的措施和密封件损坏检测方法及维护措施。文章最后对论文的工作进行了总结,并对相关的研究技术进行了展望。
[Abstract]:Shearer cutting drive system is an important part of coal mining machine to complete the mining task, the maintenance work has become a priority among priorities of shearer maintenance work. With the mining technology of fully mechanized mining face of the increasingly stringent requirements, people on the quality of the coal mining machine is more and more high, the performance of shearer cutting drive system requirements more and more is also high, so the design of shearer cutting drive system becomes more and more important. The reliability is the key factors in the design of shearer cutting drive system, so the cutting drive system to conduct a comprehensive evaluation of the reliability analysis, the probability of failure can be controlled effectively, improve the shearer the reliability of transmission system. At the same time analysis of shearer reliability prediction, self diagnosis, fault shearer, and provide the basis for self repair, provide conditions for the development of the automatic intelligent coal face theory. Aiming at the need to reduce the shearer running risk transmission system requirements, proposed a set of application in system reliability analysis of shearer cutting drive system, and the use of the shearer cutting drive system for the application of reliability analysis. The main contents are as follows: (1) analyze the structure and function of the principle of shearer cutting drive system, established reliability analysis model of shearer cutting drive system, and analyze the related standard based on reliability, reliability analysis and hierarchical analysis to develop contract process, on the basis of FMEA (failure mode and effect analysis) of the reliability analysis method of reliability analysis of shearer cutting drive system, fault pattern library the establishment of the shearer cutting drive system, and generate analysis report. (2) in the comparative analysis of FMECA (failure mode effects and criticality analysis) and FTA (fault tree Two) analysis method of reliability analysis, taking full advantage of two methods for the analysis of the comprehensive reliability analysis of FTF method FMECA and FTA combination, and the positive and reverse FTF analysis were compared and analyzed. The positive analysis method of FTF, the first FMECA analysis of transmission system of shearer. According to the results of the analysis I, and criticality values higher ranking events as the top event was analyzed by FTA RPN II value in the event of the failure reason and harm of combination of importance, prioritize the health status evaluation of cutting parameters of transmission system, the improvement measures are put forward. (the weak links of the system 3) gear fault by gear meshing dynamic parameters show, in particular, the gear meshing stiffness and meshing forces of the gear system fault is more sensitive, so the research of gear meshing dynamics The parameter is the basis for the accurate fault diagnosis of gear system. The principle of material mechanics and energy based on the principle of solving gear established theoretical model of time-varying stiffness meshing, further established with non equal tooth width of crack gear time-varying stiffness model meshing theory model. High speed cutting drive system based on region is a high incidence of gear fault the establishment of high speed gear, 9 degree of freedom dynamics model, based on this model to study the dynamic characteristics of high speed gear, impact load on the dynamic characteristics of gear, and different crack damage degree of the effect on system dynamic property, results show that the gear system can damage diagnosis by time-domain signal. (4) because of the influence of coal mine under the strong background noise, nonlinear and gear transmission the nonstationary vibration signal, multi sensor information fusion based fault diagnosis model based on using small wave. Sign scale entropy for fault feature extraction, SOM neural network for single sensor, finally using D-S evidence theory to fuse multi-sensor diagnosis. It solved the strong background noise to accurately identify the fault types, eliminate the identification of key issues of uncertainty. (5) by using ANSYS finite element analysis of the shell of the cutting system, find the section the cutting system shell structure of the main stress concentration position, optimize rib structure, thus improves the reliability of the design and cutting system of housing. Housing research comprehensive mechanical strength cutting special steel material to improve the system of Shearer Based on casting process design of shearer cutting system shell is reasonable and stable, according to the filling ability the mechanical properties of castings and metal material to liquid and determine the composition, to reduce the difficulty of casting, casting and casting and improve the comprehensive mechanical properties of high power cutting system The shell shell. Acceptance test shows that the design process of shell processing route arrangement and meet the requirements of precision machining. During the underground industrial application, cut cut system to maintain a good state of housing performance, comprehensive mechanical properties can meet the shell of large power shearer requirements. (6) transmission system of high speed sealing mechanism and problems there are currently used in cutting through the analysis section, the development of floating seal test device, and compared according to the seal performance of different test device and cutting system loading test, screened the best seal and assembly clearance of superior product performance, put forward the improvement of cutting drive system of high speed sealing reliability measure and seal damage detection method and maintenance measures. Finally, the research work was summarized, and the related research technology was prospected.

【学位授予单位】：中国矿业大学
【学位级别】：博士
【学位授予年份】：2015
【分类号】：TD421.6

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