6.2米液压支架关键技术研究与优化设计
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摘要
本文在借鉴国外液压支架先进设计制造经验的基础上,运用理论计算、数值分析和试验相结合的方法,一次性成功研发了ZY9400/28/26型大采高、大工作阻力两柱掩护式液压支架。这是世界上第一套超过6m的高可靠性大采高电液控制支架,解决了多个大采高、高可靠性液压支架的技术难题,使我国液压支架的设计与制造达到了国际先进水平。
为解决液压支架设计与制造中的难点,本文的主要研究工作和创新性从如下几个方面得以体现:
1)根据首采工作面的水文、地质条件,首次研究了6m以上液压支架的综采设备的配套问题,计算了6.2m液压支架的主要技术参数。借助CAD/CAE技术,采用自上而下的设计理念,对6.2m液压支架进行了设计和分析计算。应用SolidWorks、COSMOS软件进行了支架的三维设计,完成了虚拟样机干涉分析和动态仿真。应用近似分析方法,对液压支架双扭线进行了比较和优化,并进一步采用有限元方法对液压支架的整体强度进行了分析计算。在整体强度计算的基础上对液压支架的结构件形式、截面形式、关键部位进行仿真计算,保证了支架的稳定性和可靠性。
2)对900MPa级高强钢在当前液压支架中的选用情况和焊接难点进行了分析,应用Formaster-D型全自动快速膨胀仪采用热模拟的方法对SHT900钢的焊接CCT图进行了测定,根据焊接CCT图对高强钢(HAZ)过热区组织转变规律进行测定和研究,对SHT900钢焊接性进行了理论计算。采用斜Y型坡口焊接性试验、最高硬度试验和焊接金相试验等试验方法研究了预热温度、层间温度、热输入等参数对高强钢焊接的影响。通过理论计算和试验研究相结合的方法准确确定焊接工艺参数,并通过冲击性试验和残余应力测定试验的方法确定了高强钢的焊后热处理工艺。
3)针对现有液压支架柱窝材料强度低,加工热裂纹倾向严重,不能满足高端液压支架对材料高强度和良好塑性、韧性和可加工性的要求的现状,通过正交实验优化设计了一种新型ZG30Cr06A高强钢。通过热模拟交换法、射线衍射法等试验方法测定了新材料的机械性能参数和热物性参数,将相关参数添加到铸造CAE软件-MAGMAsoft中,实现了铸造工艺的优化设计。最后对柱窝的热处理方法和焊接性进行了研究。研究结果表明新材料具有优良的机械性能、良好的可铸性和可焊性,能够满足6.2m液压支架设计和使用要求。
4)6.2m液压支架采用先进的PM-4电液控制系统进行集成控制。通过新型插装式液控单向阀的开发解决了现有液控单向阀流通能力有限,卸载冲击大的问题。建立了液压系统的功率键合图,根据功率键合图建立了液压系统状态方程。应用Matlab/Simulink软件对先导阀进行了动态仿真,优化了先导阀的结构。通过对电液控制系统的研究和选型设计保证了移架速度8s/架设计要求。
Based on the experiences of advanced design and manufacture of hydraulic support, great mining height, large resistance 6.2m support with two-prop shield is investigated and designed successfully using the combination of theoretical calculations, numerical simulation and experimenal measurement. In order to reach international advanced level, the researching project has solved a series of key techlonogies during the design and manufacture of high-end hydraulic support.
For solving these difficulties of hydraulic support design and manufacture, the achievement and originality of the thesis are mainly presented in the following:
1) The questions of over 6m synthesizing mining equipment were firstly studied. According to the hydrogeology condition and matching equipment, main technical parameters ware confirmed. With CAD/CAE and adopting overall designing idea, 6.2m hydraulic support is designed and analyzed. Dynamic simulation of virtual prototyping and interference analysis has been achieved based on Solid-Works and COSMOS 3D design. Hyperbola of support has been optimized. Though using finite element analysis, the whole strength of this support has been examined. Then the simulation of structure part, section type and key parts of support has been analyzed in terms of the strength examination. High stability and reliability of the mechanism are got efficiently.
2) The welding CCT diagram of SHT900 steel was investigated by thermal simulated technique, which is Formast-D automatic expansion instrument. The phase transformation of overheated zone is studied based on the HAZ CCT, and the weld-ability of SHT900 has been calculated. The relations between preheat temperature, inter-ass temperature and weld-ability are researched depending on slit type cracking test, maximum hardness test and metallographic analysis. Process parameters is obtained by dint of testing and calculated, and the post-weld heat treatment process has been ascertained by impact test and residual welding stress test.
3) Aim at in existence of low strength and severe trend of hottear of materials of Hydraulic support socket post, which can not adapt to the design of high strength、good toughness and workability of high hydraulic support. A new kind of high strength steel ZG30Cr06A has been designed by the orthogonal experimentation. The new material's thermo-physical and other parameters have been measured by heat exchange-simulation and ray attenuation methods, Addition these data to the cast CAE software MAGMA, and application simulation method for the socket post optimization process. Finally, researched on the heat treating process and weld-ability of the new material, results demonstrate that ZG30Cr06A has good mechanical performance, upstanding Weld-ability and casting properties, this material can meet the design and use requirement of high hydraulic support.
4) The advanced electro-hydraulic controlling system was designed and introduced to the 6.2m hydraulic support. A new kinds of plug-in electro-hydraulic directional control valve has been developed. Therefore the drawback of poor one-way valve flow and large unloading impact problems are solved. Power bond graph of hydraulic systems is established, which can derive equation of state in the dynamic course. The dynamic simulation and optimization of the pilot valve structure are performed with Matlab/Simulink. Through research and selecting design of the electro-hydraulic control system, Support-moving speed has reached 8s/rack, which guarantee the design requirements.
为解决液压支架设计与制造中的难点,本文的主要研究工作和创新性从如下几个方面得以体现:
1)根据首采工作面的水文、地质条件,首次研究了6m以上液压支架的综采设备的配套问题,计算了6.2m液压支架的主要技术参数。借助CAD/CAE技术,采用自上而下的设计理念,对6.2m液压支架进行了设计和分析计算。应用SolidWorks、COSMOS软件进行了支架的三维设计,完成了虚拟样机干涉分析和动态仿真。应用近似分析方法,对液压支架双扭线进行了比较和优化,并进一步采用有限元方法对液压支架的整体强度进行了分析计算。在整体强度计算的基础上对液压支架的结构件形式、截面形式、关键部位进行仿真计算,保证了支架的稳定性和可靠性。
2)对900MPa级高强钢在当前液压支架中的选用情况和焊接难点进行了分析,应用Formaster-D型全自动快速膨胀仪采用热模拟的方法对SHT900钢的焊接CCT图进行了测定,根据焊接CCT图对高强钢(HAZ)过热区组织转变规律进行测定和研究,对SHT900钢焊接性进行了理论计算。采用斜Y型坡口焊接性试验、最高硬度试验和焊接金相试验等试验方法研究了预热温度、层间温度、热输入等参数对高强钢焊接的影响。通过理论计算和试验研究相结合的方法准确确定焊接工艺参数,并通过冲击性试验和残余应力测定试验的方法确定了高强钢的焊后热处理工艺。
3)针对现有液压支架柱窝材料强度低,加工热裂纹倾向严重,不能满足高端液压支架对材料高强度和良好塑性、韧性和可加工性的要求的现状,通过正交实验优化设计了一种新型ZG30Cr06A高强钢。通过热模拟交换法、射线衍射法等试验方法测定了新材料的机械性能参数和热物性参数,将相关参数添加到铸造CAE软件-MAGMAsoft中,实现了铸造工艺的优化设计。最后对柱窝的热处理方法和焊接性进行了研究。研究结果表明新材料具有优良的机械性能、良好的可铸性和可焊性,能够满足6.2m液压支架设计和使用要求。
4)6.2m液压支架采用先进的PM-4电液控制系统进行集成控制。通过新型插装式液控单向阀的开发解决了现有液控单向阀流通能力有限,卸载冲击大的问题。建立了液压系统的功率键合图,根据功率键合图建立了液压系统状态方程。应用Matlab/Simulink软件对先导阀进行了动态仿真,优化了先导阀的结构。通过对电液控制系统的研究和选型设计保证了移架速度8s/架设计要求。
Based on the experiences of advanced design and manufacture of hydraulic support, great mining height, large resistance 6.2m support with two-prop shield is investigated and designed successfully using the combination of theoretical calculations, numerical simulation and experimenal measurement. In order to reach international advanced level, the researching project has solved a series of key techlonogies during the design and manufacture of high-end hydraulic support.
For solving these difficulties of hydraulic support design and manufacture, the achievement and originality of the thesis are mainly presented in the following:
1) The questions of over 6m synthesizing mining equipment were firstly studied. According to the hydrogeology condition and matching equipment, main technical parameters ware confirmed. With CAD/CAE and adopting overall designing idea, 6.2m hydraulic support is designed and analyzed. Dynamic simulation of virtual prototyping and interference analysis has been achieved based on Solid-Works and COSMOS 3D design. Hyperbola of support has been optimized. Though using finite element analysis, the whole strength of this support has been examined. Then the simulation of structure part, section type and key parts of support has been analyzed in terms of the strength examination. High stability and reliability of the mechanism are got efficiently.
2) The welding CCT diagram of SHT900 steel was investigated by thermal simulated technique, which is Formast-D automatic expansion instrument. The phase transformation of overheated zone is studied based on the HAZ CCT, and the weld-ability of SHT900 has been calculated. The relations between preheat temperature, inter-ass temperature and weld-ability are researched depending on slit type cracking test, maximum hardness test and metallographic analysis. Process parameters is obtained by dint of testing and calculated, and the post-weld heat treatment process has been ascertained by impact test and residual welding stress test.
3) Aim at in existence of low strength and severe trend of hottear of materials of Hydraulic support socket post, which can not adapt to the design of high strength、good toughness and workability of high hydraulic support. A new kind of high strength steel ZG30Cr06A has been designed by the orthogonal experimentation. The new material's thermo-physical and other parameters have been measured by heat exchange-simulation and ray attenuation methods, Addition these data to the cast CAE software MAGMA, and application simulation method for the socket post optimization process. Finally, researched on the heat treating process and weld-ability of the new material, results demonstrate that ZG30Cr06A has good mechanical performance, upstanding Weld-ability and casting properties, this material can meet the design and use requirement of high hydraulic support.
4) The advanced electro-hydraulic controlling system was designed and introduced to the 6.2m hydraulic support. A new kinds of plug-in electro-hydraulic directional control valve has been developed. Therefore the drawback of poor one-way valve flow and large unloading impact problems are solved. Power bond graph of hydraulic systems is established, which can derive equation of state in the dynamic course. The dynamic simulation and optimization of the pilot valve structure are performed with Matlab/Simulink. Through research and selecting design of the electro-hydraulic control system, Support-moving speed has reached 8s/rack, which guarantee the design requirements.
引文
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