基于数据记录仪的掘进机载荷谱测定与分析方法研究

发布时间：2018-01-02 23:37

本文关键词：基于数据记录仪的掘进机载荷谱测定与分析方法研究　出处：《中国矿业大学(北京)》2017年博士论文　论文类型：学位论文

【摘要】：随着采煤机械化程度的不断提高,对工作面的推进速度提出更高的要求。掘进机械是实现快速掘进,保证矿井实现高产高效的重要装备。而载荷谱是掘进机结构设计与改进的重要依据。在煤巷掘进过程中快速、准确、有效的测取实际工况下的掘进机载荷,是保证煤矿安全高效生产的一项重要任务。但受井下环境的恶劣性和复杂性的制约,使得基于井下实际工况的载荷谱测取技术难度大,国内外相关研究报道较少。研究结果表明,经实际测取的载荷经过编制后形成的载荷谱可以用于疲劳试验或结构设计。其主要分为两类,连续谱和离散谱。离散谱由各级载荷及其频次按某种方法排序而成,连续谱由载荷历程直接表示。若用于疲劳实验,连续谱能更加真实地再现载荷历程,然而实验要求高、代价昂贵;而离散谱由于将载荷分为不同等级,可有效降低成本。而载荷谱的表示方式一般分为两种:在幅值域频域中加以描述。在机械试验中,用得最多的是载荷幅值分布特性,一般是先将载荷信号离散化,使其变成载荷数据序列,然后从中找出载荷变化的幅值大小并进行计数处理。因此,井下实测载荷信号的测定与分析技术一直以来都是众多学者关注的课题和研究方向。目前,各个领域普遍采用的载荷谱编制理论有三种:循环计数法、载荷-时间历程再造、疲劳损伤理论。但是由于煤巷特定的工作环境以及煤矿对载荷测试系统和仪器装备的特殊要求,给载荷的测取和编制带来了技术瓶颈大,干扰因素多,数据采集和资料解释难度大等诸多难题。这也使得现有载荷谱编制方法存在着一定的缺陷。分析总结众多载荷谱测取与编制的原理之后,提出了基于大容量数据记录仪的掘进机载荷谱的测定与分析方法。该方法以石家庄煤矿机械厂生产的EBZ160型掘进机为实验样机,加装整套传感检测系统,以煤矿井下采集的数据为基础,分析并研究了掘进机关键部件的载荷。本论文围绕数据记录仪存储的掘进机运行和状态信息展开研究,详细分析了掘进机工作过程中的受载荷情况,根据截割头的受力建立了受载模型,结合数据得出其三向力和阻力矩的大小,分析了单周期下的载荷—时间历程;根据压力变送器所测取的油路压力,通过分析控制油路和油缸结构,研究了单周期下回转油缸和升降油缸的载荷—时间历程,统计了时域和幅值域特征值,通过雨流计数编制了载荷谱并扩展成为工作载荷谱,提出了实测载荷信号测定与编制分析方法。本文主要研究成果和结论如下:(1)研究了掘进机载荷测试方法并构建了测试系统井下实测机型为EBZ-160二代掘进机,服役地点为冀中能源邢东矿的1100南部采区集中运料巷和1100南部采区集中运输巷,巷道断面为梯形。确定并搭建掘进机载荷实测系统,基于自主研发的“数据记录仪”监测掘进机的各种状态信息和控制信息,如电机的各相电流,液压油的油温油压,截割臂的摆动角度等,这些信息由PLC发出或由传感器反馈至PLC的寄存器中,再通过RS232串口通信传送到大容量固态硬盘中。通过建立掘进机运行信息数据库,分析了掘进机工作状态情况,进行了载荷谱的测定与分析,为悬臂式掘进机的结构优化提供必要的实测数据支持。该测试系统采用BYD-60型矿用隔爆型压力变送器测取油压信号;利用“数据记录仪”采集YBUD-200/110-4/8(1140)隔爆型双速三相异步截割电动机电流数值I、工作电压U,估算截割电机功率和转矩值;选取W18LD型双路测速传感器测截割臂空间水平角度,选取GUC360矿用倾角传感器测截割臂空间垂直角度;掘进机在工作时整机振动强烈,尤其是截割部和回转台部分,利用本安型振动加速度传感器记录振动信号。利用掘进机电控箱记录测取的状态信号和控制信号,用PLC记录掘进机工作时的控制信号和开关量等信号,这类信号可以用来辅助判断掘进机的截割工况和掘进机位姿等信息。(2)雨流计数法编制掘进机油缸载荷谱掘进机截割头水平截割煤壁时,通过一对同步升降油缸完成;截割头垂直截割煤壁时,通过一对回转液压缸完成。所以升降、回转液压缸的压力是实时变化的,急需开展液压缸方面的载荷研究。首先解算截割臂位姿,其次实现回转、升降液压缸压力信号数据换算,结合油缸的结构尺寸及连接方式得出其载荷计算公式。提出了截割周期判定和数据选择的四条标准,并通过该四条判定依据选出数据后对其进行处理,在时域和幅值域上进行了统计和简单分析,通过雨流计数法编制了载荷谱,并扩展为工作载荷谱,这些数据对掘进机油缸的改进和动态性能及工作可靠性的提高有很大帮助。(3)雨流计数法编制掘进机截割头载荷谱截割头是掘进机的直接受载部分,截割电机是驱动截割头的直接动力源。多年来许多科研工作者对截割头进行了结构分析、模拟仿真和优化设计,然而都不能得到其在工作时的真实载荷数据。本文首先通过“数据记录仪”中截割电机的功率和转矩两个载荷相关参数,从时域分析、概率密度两方面进行分析研究;然后建立截割头受载力学模型,结合井下数据记录仪实测数据推导其载荷历程、通过对载荷信号的计数处理和累积频次图的扩展得到载荷谱,这些为掘进机截割电机井下实际工作情况分析和截割头的分析改进提供了依据。(4)研究掘进机不同截割工况对掘进机载荷影响掘进机工作环境复杂,截割煤、夹矸、岩石时掘进机的载荷变化明显,机身振动情况也变化剧烈;同样在截割头转速和截割臂摆速变化时,掘进机截割部受到的载荷也是不相同的,所以研究不同截割工况下的载荷变化是研究掘进机载荷的一个重要方面,主要有以下内容:研究不同硬度煤岩、截割头转速变化、截割臂摆速变化时在掘进机截割时对其载荷的影响;掘进机工作时截割臂需要根据要求在空间变换位姿来完成截割任务,不同位姿下完成同样的截割动作时,截割电机的功率和升降、回转液压缸的压力也是不同的,确定掘进机受载最大的一种位姿的载荷参数作为掘进机设计和改进的依据。(5)研究掘进机回转台应力应变及疲劳强度回转台是掘进机的重要组成部分,它连接机架、支撑截割臂,实现截割头的钻进掏槽、扫落煤岩、截割臂的升降、回转等各项运动,并承受来自截割头的复杂多变的冲击载荷。这些载荷的落脚点均设在回转台机构上,并通过它传递到机架上去。因此回转台设计是否合理直接影响掘进机的工作性能和可靠性,所以对回转台的应力应变、模态、疲劳强度进行分析。根据截割部受力合成原理,将截割煤岩巷作业中每一状态拆分为升降挤压破碎、回转挤压破碎和截割头转动截割分析再受力合成。利用ADAMS虚拟样机技术建立截割部及回转台的虚拟样机动力学仿真模型,选取截割头处于下段、中段和上段的左中右端各三组位置进行受力分析研究并进行回转台静态有限元分析,获取对应的应力云图。对自由状态下的回转台进行模态分析,确定回转台前6阶模态振型。因EBZ160掘进机回转台为大型低合金钢铸件,其材质为ZG35Cr Mo,建立回转台SN曲线,并运用AWE对回转台进行疲劳分析。
[Abstract]:With the continuous improvement of mining mechanization, speed put forward higher requirements to promote the working face. The tunneling machine is fast driving, to guarantee the realization of important equipment for high yield and high efficiency. And the load spectrum is an important basis for the design and improvement of boring machine structure. Accurate in coal roadway in the process of rapid, effective measure the tunneling machine load under practical conditions, is an important task to ensure safe and efficient production of coal mine. But restricted by the harsh and complex underground environment, the load spectrum of the actual working conditions underground measuring technical difficulty based on the related research at home and abroad are reported. The results show that, by taking the actual load after the formation of the compilation of load spectrum can be used for fatigue testing or structural design. It is mainly divided into two categories, continuous spectrum and discrete spectrum. The discrete spectrum by the frequency and load levels in a certain way and sort, The continuous spectrum is directly represented by the load history. If used in the fatigue test, the continuous spectrum can more accurately reproduce the load history, however the demand is high, expensive; and discrete spectrum due to the load is divided into different levels, can effectively reduce the cost. And the load spectrum representation is generally divided into two types: described in amplitude domain in the frequency domain. The mechanical test, the most used is the amplitude distribution characteristics of load, the load is generally the first to discrete signals, so that it becomes a load data sequence, count and then find out the change in the magnitude of the load from. And because of this, and analysis technology has been the topic and research direction of many scholars on Determination of underground measured load signals. At present, widely used in various fields of the load spectrum compiling theory has three kinds: the cycle count and re load time history, fatigue damage theory. But due to the coal roadway. The coal mine working environment and the special requirements on load testing system and equipment, to load test and preparation of bring the technical bottleneck, many interference factors, data acquisition and data interpretation difficult and many other problems. It also makes the existing load spectrum compilation method has certain defects. Analyzed and summarized many load spectrum with the establishment of the measuring principle, is proposed for the determination of airborne tunneling of large capacity data recorder and analysis method based on the load spectrum. This method is based on the EBZ160 tunneling machine in Shijiazhuang coal mine machinery factory production of the prototype, with the whole set of sensing and detecting system of coal mine based on data collection, analysis and Research on the load key parts of roadheader. This paper focuses on the data logger storage tunneling machine running state and information research, detailed analysis of the load condition of roadheader working process, According to the force of cutting head was established by the load model, combined with the data obtained from the force and the moment of resistance size, analyzes the load time course of single period; according to the measured oil pressure transmitter pressure, through the analysis of the control circuit and the cylinder structure, the load time course of single week period and lift cylinder, statistical time domain and amplitude domain feature values, counting programmed load spectrum and load spectrum expansion become through rain flow, the actual load signal analysis method for the determination and preparation. The main research results of this paper are as follows: (1) and the conclusion of TBM construction and load test method the test system for the measurement models for the two generation of EBZ-160 roadheader, service location for Jizhong energy Xingdong Mine 1100 Southern mining area concentrated material transport lane and 1100 Southern Mining Area transportation lane, the roadway section is trapezoidal. Identify and take Construction of tunneling machine load measurement system, based on independent research and development of "data recorder" monitoring tunneling machine state information and control information, such as the motor phase current, oil temperature and oil pressure of the hydraulic oil, cutting arm swing angle, the information issued by PLC or by the sensor feedback to the PLC register, and then through the RS232 serial communication sent to the large capacity solid state disk. Through the establishment of TBM operation information database, analysis of the tunneling machine working state, the determination and analysis of the load spectrum, the measured data provide necessary support for the structural optimization of roadheader. The test system uses BYD-60 type flameproof pressure transmitter measuring the pressure signal; using "data recorder" (1140) acquisition of YBUD-200/110-4/8 flameproof three-phase asynchronous motor current numerical cutting I, voltage U, cutting machine and electric power estimation Torque value; select W18LD type dual speed sensor to measure the cutting arm space level, select the GUC360 mine cutting arm angle sensor measuring vertical space angle; boring machine at work when the vibration is strong, especially the cuttingdepartment and rotary table, the use of intrinsically safe vibration acceleration sensor vibration signal. Using electromechanical driving record state signal and control signal control box records measured, recorded by PLC tunneler control signals and switch signals, these signals can be used to help judge the roadheader cutting condition and boring machine position information. (2) the rain flow counting method preparation of oil cylinder driving load spectrum of roadheader the cutting head horizontal cutting coal wall, through a pair of synchronous lifting cylinder; cutting head vertical cutting coal wall, through a pair of rotary hydraulic cylinder lifting rotary hydraulic cylinder. So, the pressure is real-time change, urgent need To carry out the load on the hydraulic cylinder. The calculation of cutting arm position, then the rotary, lifting hydraulic cylinder pressure signal data conversion, combined with the structure size of cylinder and the calculation formula of the load connection. Put forward four standard cutting cycle and data selection, and through the four decision based on the selected data after the treatment, the simple statistics and analysis in time domain and amplitude domain, the load spectrum by rain flow counting method, and the expansion of the load spectrum is of great help to the data of cylinder boring machine and improvement of dynamic performance and reliability improvement. (3) the rain flow counting method for cutting head load spectrum of cutting head of roadheader is directly affected by the load, the cutting motor is the direct driving power of the cutting head. Many researchers have made analysis on the structure of the cutting head, simulation The simulation and optimization design, but can not get the job in the real load data. This paper uses the "data recorder" in cutting motor power and torque of two load parameters from time domain analysis, two aspects of probability density analysis; then a cutting head loading mechanics model, combining with the measured data the data logger derives its load history, through the counting process of load signals and extend the cumulative frequency graph obtained load spectrum, the cutting motor downhole actual working condition analysis and cutting head analysis provides a basis for improvement. (4) study on different cutting condition of boring machine boring machine load affect the environment roadheader is complex, cutting coal, gangue, load the roadheader changes the rock, vibration also changes sharply; in the same cutting head speed and cutting arm swing speed change, Load cutting by is not the same, so the study on different cutting conditions of cutting load change is an important aspect of load on the boring machine. The main contents are as follows: study the different hardness of coal rock, the cutting head speed change cutting arm swing speed change effect on the load in tunneling machine cutting work; when the roadheader cutting arm according to the requirements in the space transformation pose to finish cutting task, different position to accomplish the same cutting action, cutting motor power and lifting, rotating hydraulic cylinder pressure is different, is determined by the load parameters of roadheader the maximum load of a position as a boring machine design and improvement of the basis. (5) study of roadheader turret turret should stress strain and fatigue strength is an important part of the tunneling machine, it is attached to the frame, supporting the cutting arm, the cutting head drilling cutting, Saul Coal rock cutting, lifting the cutting arm, the rotary motion of the cutting head and suffer from complex impact loads. These loads are arranged on the rotary table goal mechanism, and through transfer it to the rack up. So the rotary table design is reasonable or not directly affect the performance and reliability of roadheader, so the stress and strain of the rotary table, modal analysis, fatigue strength. According to the cutting force synthesis principle, each state will split into lifting crushing cutting coal rock roadway work, rotary crushing and cutting head to rotate the cutting force analysis further synthesis. To establish the virtual prototype simulation model of cutting section and rotary table using ADAMS virtual prototype technology, selection of cutting head in the lower, middle and upper parts of the left and right ends of the three groups of position force analysis and rotary table static finite element analysis, obtain the corresponding The stress cloud diagram is used. Modal analysis of the rotary table in free state is carried out to determine the 6 mode vibration mode of the rotary table. Because the turntable of the EBZ160 roadheader is a large low alloy steel casting, and its material is ZG35Cr Mo. The SN curve of the turntable is established, and the fatigue analysis of the turntable is done by AWE.

【学位授予单位】：中国矿业大学(北京)
【学位级别】：博士
【学位授予年份】：2017
【分类号】：TD421.5

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