本文關(guān)鍵詞：基于數(shù)據(jù)記錄儀的掘進(jìn)機(jī)載荷譜測定與分析方法研究　出處：《中國礦業(yè)大學(xué)(北京)》2017年博士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： 掘進(jìn)機(jī) 數(shù)據(jù)記錄儀 載荷測定 載荷譜 雨流計(jì)數(shù)法

【摘要】：隨著采煤機(jī)械化程度的不斷提高,對(duì)工作面的推進(jìn)速度提出更高的要求。掘進(jìn)機(jī)械是實(shí)現(xiàn)快速掘進(jìn),保證礦井實(shí)現(xiàn)高產(chǎn)高效的重要裝備。而載荷譜是掘進(jìn)機(jī)結(jié)構(gòu)設(shè)計(jì)與改進(jìn)的重要依據(jù)。在煤巷掘進(jìn)過程中快速、準(zhǔn)確、有效的測取實(shí)際工況下的掘進(jìn)機(jī)載荷,是保證煤礦安全高效生產(chǎn)的一項(xiàng)重要任務(wù)。但受井下環(huán)境的惡劣性和復(fù)雜性的制約,使得基于井下實(shí)際工況的載荷譜測取技術(shù)難度大,國內(nèi)外相關(guān)研究報(bào)道較少。研究結(jié)果表明,經(jīng)實(shí)際測取的載荷經(jīng)過編制后形成的載荷譜可以用于疲勞試驗(yàn)或結(jié)構(gòu)設(shè)計(jì)。其主要分為兩類,連續(xù)譜和離散譜。離散譜由各級(jí)載荷及其頻次按某種方法排序而成,連續(xù)譜由載荷歷程直接表示。若用于疲勞實(shí)驗(yàn),連續(xù)譜能更加真實(shí)地再現(xiàn)載荷歷程,然而實(shí)驗(yàn)要求高、代價(jià)昂貴;而離散譜由于將載荷分為不同等級(jí),可有效降低成本。而載荷譜的表示方式一般分為兩種:在幅值域頻域中加以描述。在機(jī)械試驗(yàn)中,用得最多的是載荷幅值分布特性,一般是先將載荷信號(hào)離散化,使其變成載荷數(shù)據(jù)序列,然后從中找出載荷變化的幅值大小并進(jìn)行計(jì)數(shù)處理。因此,井下實(shí)測載荷信號(hào)的測定與分析技術(shù)一直以來都是眾多學(xué)者關(guān)注的課題和研究方向。目前,各個(gè)領(lǐng)域普遍采用的載荷譜編制理論有三種:循環(huán)計(jì)數(shù)法、載荷-時(shí)間歷程再造、疲勞損傷理論。但是由于煤巷特定的工作環(huán)境以及煤礦對(duì)載荷測試系統(tǒng)和儀器裝備的特殊要求,給載荷的測取和編制帶來了技術(shù)瓶頸大,干擾因素多,數(shù)據(jù)采集和資料解釋難度大等諸多難題。這也使得現(xiàn)有載荷譜編制方法存在著一定的缺陷。分析總結(jié)眾多載荷譜測取與編制的原理之后,提出了基于大容量數(shù)據(jù)記錄儀的掘進(jìn)機(jī)載荷譜的測定與分析方法。該方法以石家莊煤礦機(jī)械廠生產(chǎn)的EBZ160型掘進(jìn)機(jī)為實(shí)驗(yàn)樣機(jī),加裝整套傳感檢測系統(tǒng),以煤礦井下采集的數(shù)據(jù)為基礎(chǔ),分析并研究了掘進(jìn)機(jī)關(guān)鍵部件的載荷。本論文圍繞數(shù)據(jù)記錄儀存儲(chǔ)的掘進(jìn)機(jī)運(yùn)行和狀態(tài)信息展開研究,詳細(xì)分析了掘進(jìn)機(jī)工作過程中的受載荷情況,根據(jù)截割頭的受力建立了受載模型,結(jié)合數(shù)據(jù)得出其三向力和阻力矩的大小,分析了單周期下的載荷—時(shí)間歷程;根據(jù)壓力變送器所測取的油路壓力,通過分析控制油路和油缸結(jié)構(gòu),研究了單周期下回轉(zhuǎn)油缸和升降油缸的載荷—時(shí)間歷程,統(tǒng)計(jì)了時(shí)域和幅值域特征值,通過雨流計(jì)數(shù)編制了載荷譜并擴(kuò)展成為工作載荷譜,提出了實(shí)測載荷信號(hào)測定與編制分析方法。本文主要研究成果和結(jié)論如下:(1)研究了掘進(jìn)機(jī)載荷測試方法并構(gòu)建了測試系統(tǒng)井下實(shí)測機(jī)型為EBZ-160二代掘進(jìn)機(jī),服役地點(diǎn)為冀中能源邢東礦的1100南部采區(qū)集中運(yùn)料巷和1100南部采區(qū)集中運(yùn)輸巷,巷道斷面為梯形。確定并搭建掘進(jìn)機(jī)載荷實(shí)測系統(tǒng),基于自主研發(fā)的“數(shù)據(jù)記錄儀”監(jiān)測掘進(jìn)機(jī)的各種狀態(tài)信息和控制信息,如電機(jī)的各相電流,液壓油的油溫油壓,截割臂的擺動(dòng)角度等,這些信息由PLC發(fā)出或由傳感器反饋至PLC的寄存器中,再通過RS232串口通信傳送到大容量固態(tài)硬盤中。通過建立掘進(jìn)機(jī)運(yùn)行信息數(shù)據(jù)庫,分析了掘進(jìn)機(jī)工作狀態(tài)情況,進(jìn)行了載荷譜的測定與分析,為懸臂式掘進(jìn)機(jī)的結(jié)構(gòu)優(yōu)化提供必要的實(shí)測數(shù)據(jù)支持。該測試系統(tǒng)采用BYD-60型礦用隔爆型壓力變送器測取油壓信號(hào);利用“數(shù)據(jù)記錄儀”采集YBUD-200/110-4/8(1140)隔爆型雙速三相異步截割電動(dòng)機(jī)電流數(shù)值I、工作電壓U,估算截割電機(jī)功率和轉(zhuǎn)矩值;選取W18LD型雙路測速傳感器測截割臂空間水平角度,選取GUC360礦用傾角傳感器測截割臂空間垂直角度;掘進(jìn)機(jī)在工作時(shí)整機(jī)振動(dòng)強(qiáng)烈,尤其是截割部和回轉(zhuǎn)臺(tái)部分,利用本安型振動(dòng)加速度傳感器記錄振動(dòng)信號(hào)。利用掘進(jìn)機(jī)電控箱記錄測取的狀態(tài)信號(hào)和控制信號(hào),用PLC記錄掘進(jìn)機(jī)工作時(shí)的控制信號(hào)和開關(guān)量等信號(hào),這類信號(hào)可以用來輔助判斷掘進(jìn)機(jī)的截割工況和掘進(jìn)機(jī)位姿等信息。(2)雨流計(jì)數(shù)法編制掘進(jìn)機(jī)油缸載荷譜掘進(jìn)機(jī)截割頭水平截割煤壁時(shí),通過一對(duì)同步升降油缸完成;截割頭垂直截割煤壁時(shí),通過一對(duì)回轉(zhuǎn)液壓缸完成。所以升降、回轉(zhuǎn)液壓缸的壓力是實(shí)時(shí)變化的,急需開展液壓缸方面的載荷研究。首先解算截割臂位姿,其次實(shí)現(xiàn)回轉(zhuǎn)、升降液壓缸壓力信號(hào)數(shù)據(jù)換算,結(jié)合油缸的結(jié)構(gòu)尺寸及連接方式得出其載荷計(jì)算公式。提出了截割周期判定和數(shù)據(jù)選擇的四條標(biāo)準(zhǔn),并通過該四條判定依據(jù)選出數(shù)據(jù)后對(duì)其進(jìn)行處理,在時(shí)域和幅值域上進(jìn)行了統(tǒng)計(jì)和簡單分析,通過雨流計(jì)數(shù)法編制了載荷譜,并擴(kuò)展為工作載荷譜,這些數(shù)據(jù)對(duì)掘進(jìn)機(jī)油缸的改進(jìn)和動(dòng)態(tài)性能及工作可靠性的提高有很大幫助。(3)雨流計(jì)數(shù)法編制掘進(jìn)機(jī)截割頭載荷譜截割頭是掘進(jìn)機(jī)的直接受載部分,截割電機(jī)是驅(qū)動(dòng)截割頭的直接動(dòng)力源。多年來許多科研工作者對(duì)截割頭進(jìn)行了結(jié)構(gòu)分析、模擬仿真和優(yōu)化設(shè)計(jì),然而都不能得到其在工作時(shí)的真實(shí)載荷數(shù)據(jù)。本文首先通過“數(shù)據(jù)記錄儀”中截割電機(jī)的功率和轉(zhuǎn)矩兩個(gè)載荷相關(guān)參數(shù),從時(shí)域分析、概率密度兩方面進(jìn)行分析研究;然后建立截割頭受載力學(xué)模型,結(jié)合井下數(shù)據(jù)記錄儀實(shí)測數(shù)據(jù)推導(dǎo)其載荷歷程、通過對(duì)載荷信號(hào)的計(jì)數(shù)處理和累積頻次圖的擴(kuò)展得到載荷譜,這些為掘進(jìn)機(jī)截割電機(jī)井下實(shí)際工作情況分析和截割頭的分析改進(jìn)提供了依據(jù)。(4)研究掘進(jìn)機(jī)不同截割工況對(duì)掘進(jìn)機(jī)載荷影響掘進(jìn)機(jī)工作環(huán)境復(fù)雜,截割煤、夾矸、巖石時(shí)掘進(jìn)機(jī)的載荷變化明顯,機(jī)身振動(dòng)情況也變化劇烈;同樣在截割頭轉(zhuǎn)速和截割臂擺速變化時(shí),掘進(jìn)機(jī)截割部受到的載荷也是不相同的,所以研究不同截割工況下的載荷變化是研究掘進(jìn)機(jī)載荷的一個(gè)重要方面,主要有以下內(nèi)容:研究不同硬度煤巖、截割頭轉(zhuǎn)速變化、截割臂擺速變化時(shí)在掘進(jìn)機(jī)截割時(shí)對(duì)其載荷的影響;掘進(jìn)機(jī)工作時(shí)截割臂需要根據(jù)要求在空間變換位姿來完成截割任務(wù),不同位姿下完成同樣的截割動(dòng)作時(shí),截割電機(jī)的功率和升降、回轉(zhuǎn)液壓缸的壓力也是不同的,確定掘進(jìn)機(jī)受載最大的一種位姿的載荷參數(shù)作為掘進(jìn)機(jī)設(shè)計(jì)和改進(jìn)的依據(jù)。(5)研究掘進(jìn)機(jī)回轉(zhuǎn)臺(tái)應(yīng)力應(yīng)變及疲勞強(qiáng)度回轉(zhuǎn)臺(tái)是掘進(jìn)機(jī)的重要組成部分,它連接機(jī)架、支撐截割臂,實(shí)現(xiàn)截割頭的鉆進(jìn)掏槽、掃落煤巖、截割臂的升降、回轉(zhuǎn)等各項(xiàng)運(yùn)動(dòng),并承受來自截割頭的復(fù)雜多變的沖擊載荷。這些載荷的落腳點(diǎn)均設(shè)在回轉(zhuǎn)臺(tái)機(jī)構(gòu)上,并通過它傳遞到機(jī)架上去。因此回轉(zhuǎn)臺(tái)設(shè)計(jì)是否合理直接影響掘進(jìn)機(jī)的工作性能和可靠性,所以對(duì)回轉(zhuǎn)臺(tái)的應(yīng)力應(yīng)變、模態(tài)、疲勞強(qiáng)度進(jìn)行分析。根據(jù)截割部受力合成原理,將截割煤巖巷作業(yè)中每一狀態(tài)拆分為升降擠壓破碎、回轉(zhuǎn)擠壓破碎和截割頭轉(zhuǎn)動(dòng)截割分析再受力合成。利用ADAMS虛擬樣機(jī)技術(shù)建立截割部及回轉(zhuǎn)臺(tái)的虛擬樣機(jī)動(dòng)力學(xué)仿真模型,選取截割頭處于下段、中段和上段的左中右端各三組位置進(jìn)行受力分析研究并進(jìn)行回轉(zhuǎn)臺(tái)靜態(tài)有限元分析,獲取對(duì)應(yīng)的應(yīng)力云圖。對(duì)自由狀態(tài)下的回轉(zhuǎn)臺(tái)進(jìn)行模態(tài)分析,確定回轉(zhuǎn)臺(tái)前6階模態(tài)振型。因EBZ160掘進(jìn)機(jī)回轉(zhuǎn)臺(tái)為大型低合金鋼鑄件,其材質(zhì)為ZG35Cr Mo,建立回轉(zhuǎn)臺(tái)SN曲線,并運(yùn)用AWE對(duì)回轉(zhuǎn)臺(tái)進(jìn)行疲勞分析。
[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.

【學(xué)位授予單位】：中國礦業(yè)大學(xué)(北京)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2017
【分類號(hào)】：TD421.5

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