液压锚杆钻机设计研究
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摘要
锚杆钻机是与锚杆支护施工相配套的关键设备之一,影响着支护质量的好坏与支护速度的快慢。采用旋转切削方式破岩钻孔的单体锚杆钻机是目前钻孔机具的主导产品。但机体笨重、可靠性低制约着它们进一步推广使用,迫切需要研制高性能的锚杆钻孔机具。针对这一状况,本论文开展了液压锚杆钻机的设计研究工作。
首先对锚杆钻机破岩机理进行了研究。论文系统分析研究了锚杆钻机破岩特点、在旋转切削作用下的岩石所表现出的物理性质与机械性质、以及影响旋转切削破岩钻进速度与效果的主要因素。
本论文提出了将非圆行星齿轮液压马达用于锚杆钻机,在对不同类型非圆行星齿轮液压马达的结构及性能分析的基础上,针对非圆行星齿轮液压马达设计时目标函数及约束条件较多、且设计变量为离散变量、有些参数相互关联而其影响关系不易直接看出的特点,采用了基于正交试验的鲁棒性设计方法对非圆行星齿轮液压马达进行优化设计。建立了非圆行星齿轮液压马达鲁棒性设计的数学模型,通过计算获得了各设计方案的质量特性数据,以信噪比为工具得到了符合设计要求的马达结构参数的组合,且在较宽松的工艺条件下即可使马达具有较强的鲁棒性。在鲁棒优化设计的基础上,完成了非圆行星齿轮液压马达以及新型液压锚杆钻机的产品设计,委托加工厂家试制了样机。
细长的锚杆钻具在旋转切削破岩钻孔过程中有着复杂的工况,受到复杂的外力,具有复杂的变形和运动学、动力学状态。论文利用有限元仿真软件ANSYS软件对锚杆钻具整体的静力学和动力学特性进行了更加精确、可靠地分析与研究。主要研究内容包括锚杆钻具有限元模型建立、边界条件确定、约束及载荷加载、钻具受力与变形特点分析以及钻具可能同时受到扭转振动、纵向振动和横向振动等激励的模态分析,为科学设计锚杆钻具及钻机、合理确定钻进参数和指导实际生产等提供了重要的参考。
论文在合理假设的基础上,建立了液压锚杆钻机静动态特性的数学模型,研究了其静动态特性,得到了其在额定负载条件下启动的速度特性方程、在正常工作条件下的负载特性方程以及马达输出转速对阶跃流量输入和阶跃负载输入的动态响应方程。通过试验确定了钻机特性数学模型中的参量值,得到了反映钻机静动态特性的试验曲线,并采用仿真软件MATLAB对其进行了仿真。仿真曲线与试验曲线具有较好的一致性,表明所建立的描述该锚杆钻机特性的物理模型、数学模型以及仿真模型的合理性,验证了理论分析研究的正确性。通过井下实钻试验,表明了该液压锚杆钻机设计合理,具有结构紧凑、重量轻、钻孔速度快、操作方便、可靠性高等特点,完全能满足煤矿现场的使用要求。
Roofbolter is one of the key equipments for the construction of bolt support, which influences support quality and support speed. The monomer roofbolter by rotary cutting breaking rock, has become the main trend of the production and development of drilling machines for bolt support Heavy machine body and low reliability is one of the main common factors restricting them further spreading use. It is urgently necessary to develop a kind of roofbolter with high performance. According to the existing problem, hydraulic roofbolter is designed and researched in this dissertation.
Firstly, the breaking rock mechanism of roofbolter is studied. This dissertation systematically analyses the breaking rock characteristics, the physical and mechanical property of rock while rotary cutting, and some factors influencing drilling rate and effectiveness of rotary cutting breaking rock.
This paper puts forward applying non-circular planetary gear hydraulic motor to roofbolter, and analyzes the structures and performances of different types of non-circular planetary gear motors. On the basis of studying on the non-circular planetary gear mechanism and movement, the design formula and constraint condition of pitch curve is theoretically derived. There are many objective functions and design variables to optimally design a non-circular planetary gear motor, the design variables are discrete, some parameters are interdependent and the influence relation among them can not be seen clearly, so the robust optimization design method based on orthogonal test is adopted to design a non-circular planetary gear motor. The mathematical model of robust optimization design for a non-circular planetary gear motor is established. Quality characteristic datum of various design schemes are obtained by computing. By means of signal-to-noise ratio, combination of motor structure parameters to meet design requirements is gained. All these ensure the motor to have a strong robustness under a more loose process condition. Based on robust optimization design for the motor, product design of the non-circular planetary gear motor and the new hydraulic roofbolter is carried out, trial production is performed by a manufacturer.
While rotary cutting rock, the slender drilling tool for roofbolter bears rather complicated working conditions and outside force. It has complicated deformation, kinematics and dynamics status. This paper analyzes and researches the statics and dynamics characteristics of drilling tool using finite element analysis simulation software ANSYS more accurately and reliably, which mainly includes foundation of finite element model for drilling tool, determination of boundary conditions, setting of restrictions and load, analysis of force-bearing and deformation characteristics, modal analysis including torsional vibration, longitudinal vibration and transverse vibration. The research results can provide important reference for scientifically designing drilling tool and roofbolter, reasonably determining drilling parameters and directing practical production.
The mathematical model of static and dynamic characteristic of the hydraulic roofbolter is established on the basis of reasonable hypothesis. After studying, the velocity characteristic equation of rated load starting, the load characteristic equation of normal work and the dynamic characteristic equations which are the response of speed output to input of step flow and the response of speed output to input of step load are obtained. By experiment, parameter values in the mathematical model and test curves related to the characteristic of hydraulic roofbolter are gained. The simulation is carried out with MATLAB and the simulation curves are in good consistency with test curves. The results show that physical model, mathematical model and simulation model of roofbolter’s characteristic are reasonable. It verifies the accuracy of theoretical analysis research. Underground practical drilling test has indicated that the roofbolter possesses the features of reasonable design, compact structure, light weight, fast drilling rate, easy operation and high reliability, which can completely meet the demands of application.
首先对锚杆钻机破岩机理进行了研究。论文系统分析研究了锚杆钻机破岩特点、在旋转切削作用下的岩石所表现出的物理性质与机械性质、以及影响旋转切削破岩钻进速度与效果的主要因素。
本论文提出了将非圆行星齿轮液压马达用于锚杆钻机,在对不同类型非圆行星齿轮液压马达的结构及性能分析的基础上,针对非圆行星齿轮液压马达设计时目标函数及约束条件较多、且设计变量为离散变量、有些参数相互关联而其影响关系不易直接看出的特点,采用了基于正交试验的鲁棒性设计方法对非圆行星齿轮液压马达进行优化设计。建立了非圆行星齿轮液压马达鲁棒性设计的数学模型,通过计算获得了各设计方案的质量特性数据,以信噪比为工具得到了符合设计要求的马达结构参数的组合,且在较宽松的工艺条件下即可使马达具有较强的鲁棒性。在鲁棒优化设计的基础上,完成了非圆行星齿轮液压马达以及新型液压锚杆钻机的产品设计,委托加工厂家试制了样机。
细长的锚杆钻具在旋转切削破岩钻孔过程中有着复杂的工况,受到复杂的外力,具有复杂的变形和运动学、动力学状态。论文利用有限元仿真软件ANSYS软件对锚杆钻具整体的静力学和动力学特性进行了更加精确、可靠地分析与研究。主要研究内容包括锚杆钻具有限元模型建立、边界条件确定、约束及载荷加载、钻具受力与变形特点分析以及钻具可能同时受到扭转振动、纵向振动和横向振动等激励的模态分析,为科学设计锚杆钻具及钻机、合理确定钻进参数和指导实际生产等提供了重要的参考。
论文在合理假设的基础上,建立了液压锚杆钻机静动态特性的数学模型,研究了其静动态特性,得到了其在额定负载条件下启动的速度特性方程、在正常工作条件下的负载特性方程以及马达输出转速对阶跃流量输入和阶跃负载输入的动态响应方程。通过试验确定了钻机特性数学模型中的参量值,得到了反映钻机静动态特性的试验曲线,并采用仿真软件MATLAB对其进行了仿真。仿真曲线与试验曲线具有较好的一致性,表明所建立的描述该锚杆钻机特性的物理模型、数学模型以及仿真模型的合理性,验证了理论分析研究的正确性。通过井下实钻试验,表明了该液压锚杆钻机设计合理,具有结构紧凑、重量轻、钻孔速度快、操作方便、可靠性高等特点,完全能满足煤矿现场的使用要求。
Roofbolter is one of the key equipments for the construction of bolt support, which influences support quality and support speed. The monomer roofbolter by rotary cutting breaking rock, has become the main trend of the production and development of drilling machines for bolt support Heavy machine body and low reliability is one of the main common factors restricting them further spreading use. It is urgently necessary to develop a kind of roofbolter with high performance. According to the existing problem, hydraulic roofbolter is designed and researched in this dissertation.
Firstly, the breaking rock mechanism of roofbolter is studied. This dissertation systematically analyses the breaking rock characteristics, the physical and mechanical property of rock while rotary cutting, and some factors influencing drilling rate and effectiveness of rotary cutting breaking rock.
This paper puts forward applying non-circular planetary gear hydraulic motor to roofbolter, and analyzes the structures and performances of different types of non-circular planetary gear motors. On the basis of studying on the non-circular planetary gear mechanism and movement, the design formula and constraint condition of pitch curve is theoretically derived. There are many objective functions and design variables to optimally design a non-circular planetary gear motor, the design variables are discrete, some parameters are interdependent and the influence relation among them can not be seen clearly, so the robust optimization design method based on orthogonal test is adopted to design a non-circular planetary gear motor. The mathematical model of robust optimization design for a non-circular planetary gear motor is established. Quality characteristic datum of various design schemes are obtained by computing. By means of signal-to-noise ratio, combination of motor structure parameters to meet design requirements is gained. All these ensure the motor to have a strong robustness under a more loose process condition. Based on robust optimization design for the motor, product design of the non-circular planetary gear motor and the new hydraulic roofbolter is carried out, trial production is performed by a manufacturer.
While rotary cutting rock, the slender drilling tool for roofbolter bears rather complicated working conditions and outside force. It has complicated deformation, kinematics and dynamics status. This paper analyzes and researches the statics and dynamics characteristics of drilling tool using finite element analysis simulation software ANSYS more accurately and reliably, which mainly includes foundation of finite element model for drilling tool, determination of boundary conditions, setting of restrictions and load, analysis of force-bearing and deformation characteristics, modal analysis including torsional vibration, longitudinal vibration and transverse vibration. The research results can provide important reference for scientifically designing drilling tool and roofbolter, reasonably determining drilling parameters and directing practical production.
The mathematical model of static and dynamic characteristic of the hydraulic roofbolter is established on the basis of reasonable hypothesis. After studying, the velocity characteristic equation of rated load starting, the load characteristic equation of normal work and the dynamic characteristic equations which are the response of speed output to input of step flow and the response of speed output to input of step load are obtained. By experiment, parameter values in the mathematical model and test curves related to the characteristic of hydraulic roofbolter are gained. The simulation is carried out with MATLAB and the simulation curves are in good consistency with test curves. The results show that physical model, mathematical model and simulation model of roofbolter’s characteristic are reasonable. It verifies the accuracy of theoretical analysis research. Underground practical drilling test has indicated that the roofbolter possesses the features of reasonable design, compact structure, light weight, fast drilling rate, easy operation and high reliability, which can completely meet the demands of application.
引文
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