采煤机截割滚筒（Φ1.6m）截齿的合理布置研究
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摘要
采煤机是综采工作面装最重要的工作设备之一,在煤炭采掘中起着重要作用。采煤机滚筒最为重要的工作执行机构,承担着截煤、落煤、装煤的关键任务,消耗采煤机的大部分功率。由于滚筒结构的不合理,并在截割过程中其受到高周期性的应力、负荷、磨损,所以在实际工况中,某型号采煤机经常发生一部分截齿的损坏,大大影响着采煤机工作性能和生产效率,这说明采煤机滚筒各截齿受力不均匀、差异较大。为此,要对该型号采煤机滚筒截齿进行合理布局。
本课题通过在Pro/Engineering wildfire4.0中建立采煤机的滚筒三维模型和煤体三维的模型,利用显示动力学软件ANSYS/LS-DYNA进行滚筒截割煤体的数值模拟,得到各截齿和滚筒截割煤体过程中的受力情况,并对各截齿受力和滚筒受力进行统计分析,发现采煤机各截齿受力不均、滚筒波动性较大。采煤机滚筒零件繁多,结构复杂；煤体的结构性质多变；其工作时的受力情况也相当复杂,因此影响截割性能的参数众多。本文截齿排列方式作为优化参数,以各截齿受力差异最小、滚筒波动系数最小为目标函数,通过局部调节截线距离和安装角度,达到减小各截齿受力差异,降低滚筒波动的目的。
The coal mining machine is one of the most important equipment of Fully-mechanized mining, which alsoplay an important role in coal mining. Shearer drum is the most important working mechanism; which undertakes the key task such as the cutting, coal dropping, and coal consumping.Most of the power in the coal mining machine is consumed by the drum. It not only is under high cyclic stress, load, wear and tear in the cutting process, but also has unreasonable structure. As a result, in real working condition, some part of tooth always damage on a certain type of coal mining machine, which greatly affects performance and production efficiency of the coal mining machinem It shows that the stress of the cutting teeth on this shearer drum is not uniform, and the difference is quite great. Therefore, the structure of this model shearer drum should be impoved.
In this research, the author set up the three-dimemsional model of the shearer drum and coal body in Pro/Engineering wildfire4.0.And then, numerically simulate the drum cutting coal body in the display dynamics software ANSYS/LS-DYNA. Get the stress situation of every teeth and the drum when cutting coal process, and statistically analysis the stress. Shearer drum has lots of parts, whose structure is complex, and coal body structure is varied. What's worse, when working, the force of the drum is quite complex.So, there are many parameters which effect of cutting performance. Only take the pick arrangement method as optimization parameters, with each cutting tooth force difference minimum, drum fluctuation coefficient minimum as the objective function, the locally regulat section distance and angle to reduce the cutting tooth stress difference and drum fluctuation.
本课题通过在Pro/Engineering wildfire4.0中建立采煤机的滚筒三维模型和煤体三维的模型,利用显示动力学软件ANSYS/LS-DYNA进行滚筒截割煤体的数值模拟,得到各截齿和滚筒截割煤体过程中的受力情况,并对各截齿受力和滚筒受力进行统计分析,发现采煤机各截齿受力不均、滚筒波动性较大。采煤机滚筒零件繁多,结构复杂；煤体的结构性质多变；其工作时的受力情况也相当复杂,因此影响截割性能的参数众多。本文截齿排列方式作为优化参数,以各截齿受力差异最小、滚筒波动系数最小为目标函数,通过局部调节截线距离和安装角度,达到减小各截齿受力差异,降低滚筒波动的目的。
The coal mining machine is one of the most important equipment of Fully-mechanized mining, which alsoplay an important role in coal mining. Shearer drum is the most important working mechanism; which undertakes the key task such as the cutting, coal dropping, and coal consumping.Most of the power in the coal mining machine is consumed by the drum. It not only is under high cyclic stress, load, wear and tear in the cutting process, but also has unreasonable structure. As a result, in real working condition, some part of tooth always damage on a certain type of coal mining machine, which greatly affects performance and production efficiency of the coal mining machinem It shows that the stress of the cutting teeth on this shearer drum is not uniform, and the difference is quite great. Therefore, the structure of this model shearer drum should be impoved.
In this research, the author set up the three-dimemsional model of the shearer drum and coal body in Pro/Engineering wildfire4.0.And then, numerically simulate the drum cutting coal body in the display dynamics software ANSYS/LS-DYNA. Get the stress situation of every teeth and the drum when cutting coal process, and statistically analysis the stress. Shearer drum has lots of parts, whose structure is complex, and coal body structure is varied. What's worse, when working, the force of the drum is quite complex.So, there are many parameters which effect of cutting performance. Only take the pick arrangement method as optimization parameters, with each cutting tooth force difference minimum, drum fluctuation coefficient minimum as the objective function, the locally regulat section distance and angle to reduce the cutting tooth stress difference and drum fluctuation.
引文
[1]庞世忠.采煤机滚筒的改革与盘式截割机构的探讨[J].煤炭科学技术1988,12：41-44.
[2]蔡玉生.采用滚筒式露天采煤机的开采工艺[J].露天采矿技术,2011,3：278-280.
[3]常炳林.功率电牵引采煤机：怎样缩短与国外的差距[J].中国煤炭报.2005,(03)：5-8.
[4]刘送永,杜长龙,崔新霞.采煤机滚筒截齿排列的试验研究[J].中南大学学报.2009,(05),202-205.
[5]候殿军.大倾角煤层开采方法概论[M].北京：煤炭工业出版,2009.
[6]马壮.采煤机截齿齿体耐磨性对比分析[J].煤矿机械.2008,29(2)362-364
[7]E.3.保晋,王庆康,门迎春译.采煤机破煤理论[M].北京：煤炭工业出版社,1992.
[8]向虎.虚拟样机技术在采煤机滚筒调高系统中的应用[J].煤矿机械.2004,05,7981.
[9]汪崇建,刘振.现代煤炭科学技术理论与实践[M].北京：煤炭工业出版,2007.
[10]Venkata Babu Achanti. Parametric study of dust generation with rock ridge breakage analysis usinga simulated continuous miner [D]. USA:College of Engineering and Mineral Resources at West Virginia University,1998.
[11]Rizwan A. Qayyum. Effects of bit geometry in multiple bit rock interaction [D]. USA: College of Engineering and Mineral Resources at West Virginia University,2003.
[12]刘送永,杜长龙.采煤机滚筒截割性能及截割系统动力学研究[D].徐州：中国矿业大学,2009.
[13]李晓豁.连续采煤机滚筒的运动学分析[J].辽宁工程技术大学学报.2005,24(06),900-903.
[14]焦丽.基于动力学分析的采煤机截齿可靠性[J].辽宁工程技术大学学报.2006,25,249-250.
[15]于信伟.基于遗传算法的连续采煤机滚筒参数优化设计[J].辽宁工程技术大学学报.2008,27(05),750-751.
[16]Mazurkiewicz D. Empirical and analytical models of cutting gprocess of rocks[J]. Journal of Mining Science,2000,36(5):481-486.
[17]Hekimoglu O Z, Ozdemir L. Effect of angle of wrap on cuttingperformance of drum shearers and continuous miners [J]. Mining Technology (Trans Inst Min Metall A),2004, 113:118-122.
[18]朱才朝,冯代辉,陆波.V钻柱结构与井壁岩石互作用下系统耦合非线性动力学研究[J].机械工程学报,2007,43(5)：145-149.
[19]任昌玉.采煤机端盘截齿排列及安装条件[J].黑龙江科技学院学报,2008,04：59-62.
[20]王峥荣,熊晓燕,张宏.基于LS-DYNA采煤机镐型截齿截割有限元分析[J].振动、测试与诊断,2010,(02),163-165.
[21]Bo Yu. Numerical simulation of continuous miner rock cutting process [D]. USA: College of ngineering and Mineral Resources at West Virginia University,2005.
[22]姬国强,廉自生,卢绰.基于LS-DYNA的镐型截齿截割力模拟[J].煤矿机电,2008,4：131-132.
[23]郭迎福,罗善明.采煤机滚筒的计算机辅助设计[J].辽宁工程技术大学学报,1999,18(6)：653-656.
[24]赵丽娟,王乘云.采煤机截割部建模与动力学仿真研究[J].工程技术学报,2010(2)：119-123
[25]王德春,孔小艳.MG250/591-WD型采煤机截割部的有限元分析[J].济源职业技术学院学报,2008(3)：1-3
[26]刘胜利.矿山机械[M].北京：煤炭工业出版社,2005.
[27]王启广,黄嘉兴.液压传动与采掘机械[M].北京：中国矿业大学出版社,2005.
[28]和青芳,周四新Pro/ENGINEER Wildfire 4.0曲面设计专家实例精讲[M].机械工业出版社,2009.
[29]刘英杰.磨损失效分析案例汇集[M].机械工业出版社,2009.
[30]李裕春,时党勇,赵远ANSYS 11.0/LS-DYNA基础理论与工程实践[M].水利水电出版社,2008.
[31]张雄,王天舒.计算动力学[M].北京,清华大学出版社,2007.
[32]J.Wang.Simulation of Landmine Explosion Using LS-DYNA3D Software.Benchmaark Work of Simulation of Explosion in Soil and Air,2001.
[33]J.O.HALLQUIST.LS-DYNA Theoretical Manual.Livermore Software Technology Corporation, ivermore,1998.
[34]王富耻,张朝辉ANSYS 10.0有限元分析理论与工程应用[M].电子工业出版社,2006.
[35]张顶立综合机械化放顶煤开采采场矿山压力控制[M].北京：煤炭工业出版社1999.
[36]E.Mustafa Eyyuboglu,Naci Bolukbasi.. Effects of circumferential pick spacing on boom type roadheader cutting head performance[J].Tunnelling and Underground Space Technology,2005,20(5):418-425.
[37]兰晓峰,李春英.EBZ-135型悬臂式掘进机截割头结构的改进[D].太原：太原理工大学,2010.
[38]LS-DYNA KEYWORD USER'S MANUAL [M]2003.
[39]ANSYS/LS-DYNA中国技术支持中心ANSYS/LS-DYNA算法基础理论与工程实践[M].北京理工大学,1999.
[40]赵丽娟,周宇.基于ANSYS/LS_DYNA的薄煤层采煤机扭矩轴动力学接触分析[J].煤矿机械,2009,30(04),68-70.
[41]盛和太,喻海良,范训益ANSYS有限元原理与工程应用实例大全[M].北京：清华大学出版社,2006.
[42]岳欣,陶驰东.采煤机螺旋滚筒总体参数优化设计[J],煤炭学报,1999,21(5)：543--544.
[43]N.Bilgin, MA.Demircin, H.Copur, C.Balci, Tuncdemir H, Akcin N.Dominant rock propertiesaffecting the performance of conical picks and the comparison of some experimental andtheoretical results [J].Int J Rock Mech Min Sci,2006,43(2):39-56.
[44]刘送永,杜长龙,崔新霞.采煤机滚筒运动参数的分析研究[J].中南大学学报,2009,40(05)：1281-1283.
[45]陈奇,许景昆.双滚筒采煤机[M].北京：煤炭工业出版社,1992.
[46]陶嵘.采煤机螺旋滚筒截齿排列与块煤率的研究[J].煤矿机电,2004(06),256-258.
[47]纪玉杰.基于LS-DYNA的掘进机截齿有限元分析[J].矿山机械,2011,39(2)：34-36
[2]蔡玉生.采用滚筒式露天采煤机的开采工艺[J].露天采矿技术,2011,3：278-280.
[3]常炳林.功率电牵引采煤机：怎样缩短与国外的差距[J].中国煤炭报.2005,(03)：5-8.
[4]刘送永,杜长龙,崔新霞.采煤机滚筒截齿排列的试验研究[J].中南大学学报.2009,(05),202-205.
[5]候殿军.大倾角煤层开采方法概论[M].北京：煤炭工业出版,2009.
[6]马壮.采煤机截齿齿体耐磨性对比分析[J].煤矿机械.2008,29(2)362-364
[7]E.3.保晋,王庆康,门迎春译.采煤机破煤理论[M].北京：煤炭工业出版社,1992.
[8]向虎.虚拟样机技术在采煤机滚筒调高系统中的应用[J].煤矿机械.2004,05,7981.
[9]汪崇建,刘振.现代煤炭科学技术理论与实践[M].北京：煤炭工业出版,2007.
[10]Venkata Babu Achanti. Parametric study of dust generation with rock ridge breakage analysis usinga simulated continuous miner [D]. USA:College of Engineering and Mineral Resources at West Virginia University,1998.
[11]Rizwan A. Qayyum. Effects of bit geometry in multiple bit rock interaction [D]. USA: College of Engineering and Mineral Resources at West Virginia University,2003.
[12]刘送永,杜长龙.采煤机滚筒截割性能及截割系统动力学研究[D].徐州：中国矿业大学,2009.
[13]李晓豁.连续采煤机滚筒的运动学分析[J].辽宁工程技术大学学报.2005,24(06),900-903.
[14]焦丽.基于动力学分析的采煤机截齿可靠性[J].辽宁工程技术大学学报.2006,25,249-250.
[15]于信伟.基于遗传算法的连续采煤机滚筒参数优化设计[J].辽宁工程技术大学学报.2008,27(05),750-751.
[16]Mazurkiewicz D. Empirical and analytical models of cutting gprocess of rocks[J]. Journal of Mining Science,2000,36(5):481-486.
[17]Hekimoglu O Z, Ozdemir L. Effect of angle of wrap on cuttingperformance of drum shearers and continuous miners [J]. Mining Technology (Trans Inst Min Metall A),2004, 113:118-122.
[18]朱才朝,冯代辉,陆波.V钻柱结构与井壁岩石互作用下系统耦合非线性动力学研究[J].机械工程学报,2007,43(5)：145-149.
[19]任昌玉.采煤机端盘截齿排列及安装条件[J].黑龙江科技学院学报,2008,04：59-62.
[20]王峥荣,熊晓燕,张宏.基于LS-DYNA采煤机镐型截齿截割有限元分析[J].振动、测试与诊断,2010,(02),163-165.
[21]Bo Yu. Numerical simulation of continuous miner rock cutting process [D]. USA: College of ngineering and Mineral Resources at West Virginia University,2005.
[22]姬国强,廉自生,卢绰.基于LS-DYNA的镐型截齿截割力模拟[J].煤矿机电,2008,4：131-132.
[23]郭迎福,罗善明.采煤机滚筒的计算机辅助设计[J].辽宁工程技术大学学报,1999,18(6)：653-656.
[24]赵丽娟,王乘云.采煤机截割部建模与动力学仿真研究[J].工程技术学报,2010(2)：119-123
[25]王德春,孔小艳.MG250/591-WD型采煤机截割部的有限元分析[J].济源职业技术学院学报,2008(3)：1-3
[26]刘胜利.矿山机械[M].北京：煤炭工业出版社,2005.
[27]王启广,黄嘉兴.液压传动与采掘机械[M].北京：中国矿业大学出版社,2005.
[28]和青芳,周四新Pro/ENGINEER Wildfire 4.0曲面设计专家实例精讲[M].机械工业出版社,2009.
[29]刘英杰.磨损失效分析案例汇集[M].机械工业出版社,2009.
[30]李裕春,时党勇,赵远ANSYS 11.0/LS-DYNA基础理论与工程实践[M].水利水电出版社,2008.
[31]张雄,王天舒.计算动力学[M].北京,清华大学出版社,2007.
[32]J.Wang.Simulation of Landmine Explosion Using LS-DYNA3D Software.Benchmaark Work of Simulation of Explosion in Soil and Air,2001.
[33]J.O.HALLQUIST.LS-DYNA Theoretical Manual.Livermore Software Technology Corporation, ivermore,1998.
[34]王富耻,张朝辉ANSYS 10.0有限元分析理论与工程应用[M].电子工业出版社,2006.
[35]张顶立综合机械化放顶煤开采采场矿山压力控制[M].北京：煤炭工业出版社1999.
[36]E.Mustafa Eyyuboglu,Naci Bolukbasi.. Effects of circumferential pick spacing on boom type roadheader cutting head performance[J].Tunnelling and Underground Space Technology,2005,20(5):418-425.
[37]兰晓峰,李春英.EBZ-135型悬臂式掘进机截割头结构的改进[D].太原：太原理工大学,2010.
[38]LS-DYNA KEYWORD USER'S MANUAL [M]2003.
[39]ANSYS/LS-DYNA中国技术支持中心ANSYS/LS-DYNA算法基础理论与工程实践[M].北京理工大学,1999.
[40]赵丽娟,周宇.基于ANSYS/LS_DYNA的薄煤层采煤机扭矩轴动力学接触分析[J].煤矿机械,2009,30(04),68-70.
[41]盛和太,喻海良,范训益ANSYS有限元原理与工程应用实例大全[M].北京：清华大学出版社,2006.
[42]岳欣,陶驰东.采煤机螺旋滚筒总体参数优化设计[J],煤炭学报,1999,21(5)：543--544.
[43]N.Bilgin, MA.Demircin, H.Copur, C.Balci, Tuncdemir H, Akcin N.Dominant rock propertiesaffecting the performance of conical picks and the comparison of some experimental andtheoretical results [J].Int J Rock Mech Min Sci,2006,43(2):39-56.
[44]刘送永,杜长龙,崔新霞.采煤机滚筒运动参数的分析研究[J].中南大学学报,2009,40(05)：1281-1283.
[45]陈奇,许景昆.双滚筒采煤机[M].北京：煤炭工业出版社,1992.
[46]陶嵘.采煤机螺旋滚筒截齿排列与块煤率的研究[J].煤矿机电,2004(06),256-258.
[47]纪玉杰.基于LS-DYNA的掘进机截齿有限元分析[J].矿山机械,2011,39(2)：34-36