坑道钻机传动系统及其整机模块化设计研究
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摘要
随着煤炭开采业的日益发展,对煤炭开采时进行瓦斯抽采和地质钻探的坑道钻机提出了更高的要求,即用高效、快捷、有效的方法对钻机进行合理的改进,以提高其效率,增加可靠性。
坑道钻机是煤矿井下钻进的核心设备。钻机工作环境复杂多变,工作时钻进岩层对钻机的反馈作用力随岩层硬度而发生变化。过去,钻机的传动系统采用定量泵——定量马达和变速器组成的液压变速形式,钻机在工作时的输出速度依变速器的两个恒定档位,由于外部的反作用力的变化常常引起对钻机钻头的刚性冲击,尤其是遭遇硬岩时常常会产生剧烈震颤,严重时甚至发生打钻现象,使钻机的工作寿命降低。同时,由于液压油温加剧上升,需停机为其提供冷却时间,因而又影响了钻探的生产效率。
为解决以上问题,目前的钻机设计改用变量传动方式。即采用变量泵——变量马达和减速器组成的容积式液压变速形式,通过改变流量来改变内部输出,因此能够在一定范围内对不同硬度的岩层进行自适应式调节;同时由于液压变速自身又具有减震的性能,使钻进过程产生的刚性冲击转变为柔性冲击,从而提高了钻机的可靠性。
本文以系统设计思想为基础,以模块化设计为目标,首先对钻机整机,尤其是传动系统进行了详细的分析,通过对定型产品的传动系统进行理论分析,建立了容积式液压变速系统的理论计算模型,提出柔性设计的理论依据;其次利用其相关参数建立了其核心部件——减速器的模糊优化设计数学模型,并应用MATLAB进行了优化计算,为传动系统结构优化提供了理论支持。最后,将模块化设计思想引入钻机设计中,对坑道钻机整机进行模块化总体设计,基于VB建立了钻机产品模块化设计框架系统,完成一级模块和二级模块的划分,为钻机的系列产品设计提供基础和技术支持。
With the increasing development of coal mining industry, higher requirements are raised by tunnel drilling machine for gas extraction and geological drilling during coal mining, meaning that reasonable improvements are made to the machine by using efficient, fast and effective way to improve its efficiency and increase reliability.
Tunnel drilling machine is the core equipment for underground drilling. Since the working environment of drilling machine is complicated and changeable, rock hardness changes the reaction exerted by the rock layer on the machine while it works. In the past, the transmission system of the drilling machine include constant displacement pump - constant displacement motor and transmission. There are two constant gears according to the output speed of the working drilling machine. Because the changes of the exterior reacting force of usually cause the rigid impact of drill, especially when encountering hard rock, violent tremors are often caused, damaged bit even occurs in severe cases, which reduce the working life of drill. Meanwhile, due to the temperature of the hydraulic oil rise sharply, it is necessary for the machine to close down and provide time for the oil to cool down, which therefore affects the drilling production efficiency.
To solve the above problem, the present design of the drilling machine adopt the variable driving mode. Meaning that the transmission system of the drilling machine include variable displacement pump - variable displacement motor and transmission, by changing the flow to change the internal output, so that adaptively type adjustment to different hardness layers can be made within a certain range. Simultaneously because changing the speed oneself by hydraulic pressure can also have the performance of shock absorption, which transforms rigid impact into flexible shocks, thereby improving the reliability of the drilling machine.
Based on the system design thought, this article takes the modular design as the goal. Firstly, carry on a detailed analysis to the drilling machine especially the transmission system. Through theoretical analysis of the finalized product transmission system, the theoretical calculation model of the positive displacement hydraulic transmission system is established, and provide theory basis for the flexible design. Secondly, by using its relevant parameters, establish its core components -fuzzy optimization mathematical model of reducer, and apply MATLAB to optimize, which provides a theoretical support for transmission system structure optimization. Finally, introducing the modular design thought to the drilling machine design, modular overall design for the tunnel drilling machine is made. Driller product modular design framework system is established based on VB, level modules and secondary module are divided, which provide the basis and technical support for series products design of the drilling machine.
坑道钻机是煤矿井下钻进的核心设备。钻机工作环境复杂多变,工作时钻进岩层对钻机的反馈作用力随岩层硬度而发生变化。过去,钻机的传动系统采用定量泵——定量马达和变速器组成的液压变速形式,钻机在工作时的输出速度依变速器的两个恒定档位,由于外部的反作用力的变化常常引起对钻机钻头的刚性冲击,尤其是遭遇硬岩时常常会产生剧烈震颤,严重时甚至发生打钻现象,使钻机的工作寿命降低。同时,由于液压油温加剧上升,需停机为其提供冷却时间,因而又影响了钻探的生产效率。
为解决以上问题,目前的钻机设计改用变量传动方式。即采用变量泵——变量马达和减速器组成的容积式液压变速形式,通过改变流量来改变内部输出,因此能够在一定范围内对不同硬度的岩层进行自适应式调节;同时由于液压变速自身又具有减震的性能,使钻进过程产生的刚性冲击转变为柔性冲击,从而提高了钻机的可靠性。
本文以系统设计思想为基础,以模块化设计为目标,首先对钻机整机,尤其是传动系统进行了详细的分析,通过对定型产品的传动系统进行理论分析,建立了容积式液压变速系统的理论计算模型,提出柔性设计的理论依据;其次利用其相关参数建立了其核心部件——减速器的模糊优化设计数学模型,并应用MATLAB进行了优化计算,为传动系统结构优化提供了理论支持。最后,将模块化设计思想引入钻机设计中,对坑道钻机整机进行模块化总体设计,基于VB建立了钻机产品模块化设计框架系统,完成一级模块和二级模块的划分,为钻机的系列产品设计提供基础和技术支持。
With the increasing development of coal mining industry, higher requirements are raised by tunnel drilling machine for gas extraction and geological drilling during coal mining, meaning that reasonable improvements are made to the machine by using efficient, fast and effective way to improve its efficiency and increase reliability.
Tunnel drilling machine is the core equipment for underground drilling. Since the working environment of drilling machine is complicated and changeable, rock hardness changes the reaction exerted by the rock layer on the machine while it works. In the past, the transmission system of the drilling machine include constant displacement pump - constant displacement motor and transmission. There are two constant gears according to the output speed of the working drilling machine. Because the changes of the exterior reacting force of usually cause the rigid impact of drill, especially when encountering hard rock, violent tremors are often caused, damaged bit even occurs in severe cases, which reduce the working life of drill. Meanwhile, due to the temperature of the hydraulic oil rise sharply, it is necessary for the machine to close down and provide time for the oil to cool down, which therefore affects the drilling production efficiency.
To solve the above problem, the present design of the drilling machine adopt the variable driving mode. Meaning that the transmission system of the drilling machine include variable displacement pump - variable displacement motor and transmission, by changing the flow to change the internal output, so that adaptively type adjustment to different hardness layers can be made within a certain range. Simultaneously because changing the speed oneself by hydraulic pressure can also have the performance of shock absorption, which transforms rigid impact into flexible shocks, thereby improving the reliability of the drilling machine.
Based on the system design thought, this article takes the modular design as the goal. Firstly, carry on a detailed analysis to the drilling machine especially the transmission system. Through theoretical analysis of the finalized product transmission system, the theoretical calculation model of the positive displacement hydraulic transmission system is established, and provide theory basis for the flexible design. Secondly, by using its relevant parameters, establish its core components -fuzzy optimization mathematical model of reducer, and apply MATLAB to optimize, which provides a theoretical support for transmission system structure optimization. Finally, introducing the modular design thought to the drilling machine design, modular overall design for the tunnel drilling machine is made. Driller product modular design framework system is established based on VB, level modules and secondary module are divided, which provide the basis and technical support for series products design of the drilling machine.
引文
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[2] Hawkes,C D.Assessing the mechanical stability of horizontal boreholes in coal Canadian Georechnical Journal[J].2007,Vol44,No.7:797
[3]韩广德主编.中国煤炭工业钻探工程[M].北京:煤炭工业出版社,2000:829-836
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[5]鄢泰宁.岩土钻掘工程学[M].武汉:中国地质大学出版社,2001:25-28.
[6]梁人祝.钻探设备[M].北京:地质出版社,1986:125-129.
[7]胡少韵.我国煤矿坑道钻探技术发展及存在的问题[J].煤田地质与勘探,1998(26):增刊59-62
[8]刁叔钧,胡少韵.全液压坑道钻机故障预测与诊断的现代化技术探讨[J].煤田地质与勘探,1999,27(4):68
[9]田宏亮.全液压动力头式钻机液压系统动态分析及控制方法的研究[D].西安:煤炭总院西安研究院,2008
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[12]殷新胜,姚宁平,陈跟马等ZDY6000L型履带式全液压坑道钻机液压系统设计[J].陕西:煤炭科学研究总院西安研究院,2007.12
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[23]余虹波.多轴摆动减速器的设计与优化[D].武汉理工大学,2008
[24]韩彬.基于Pro/Engineer齿轮传动模糊优化设计及系统开发[D].北京交通大学,2006
[25]濮良贵,纪明刚.机械设计第八版[M].北京:高等教育出版社,2006:206-208
[26] Zadeh L A.Fuzzy sets. Information and Cotrol,1965,8:338-353
[27]游斌弟.复杂机械结构模糊优化方法及工程应用[M].科学出版社,2007:31-38
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[32] Wang G Y, Qiao Z. Linear programming with fuzzy random variable coefficients. Fuzzy Sets andSystems,1993,57(3):295-311
[33] Qiao Z, Wang G Y. On solutions and distribution problems of the linear programming with fuzzy random varble coefficients. Fuzzy Sets and System, 1993,58(2):155-170
[34]梁新华.平面连杆机构的模糊综合与模糊优化[D].昆明理工大学,2002
[35]陈卫东,蔡萌琳,于诗源.工程优化方法[M].哈尔滨工程大学出版社,2006:276-282
[36]李万祥.工程优化设计与MATLAB实现[M].北京:清华大学出版社,2010:251-258
[37]巫少龙.机械模糊可靠性优化设计研究[D].浙江工业大学,2004
[38]童时中.模块化原理设计方法及应用[M].中国标准出版社,2000.5
[39] Urich,k.and K,Tung.Fundamentals of product Modularity,Issues in Design/Manufacturing Integration. pp.73-79,A,ASME,1991
[40]祁卓娅.机械产品模块化设计方法研究[D].北京:机械科学研究院,,2006
[41]郑甲红,郭文举,李健等.基于CBR的机械系列产品模块化设计[M].机械设计与制造,2009
[42]蔡盛保.桥式起重机的模块化设计[D].大连理工大学硕士学位论文,2004:20-25
[43]郑建启,李翔.设计方法学[M].清华大学出版社,2006
[44]戴端,黄智宇.产品设计方法学[M].中国轻工业出版社,2005
[45]高健,孙湘明.系统艺术概论[M].中国文史出版社,2002.3
[46]祁卓娅.机械产品模块化设计方法研究[D].北京:机械科学研究院,,2006
[47]何涛,杨竞,范云.先进制造技术[M].北京大学出版社,2006
[48]任小中,苏建新,邓效忠.基于模块化设计理论的数控成形磨齿机模块化结构[M].机械设计与制造,2007
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[2] Hawkes,C D.Assessing the mechanical stability of horizontal boreholes in coal Canadian Georechnical Journal[J].2007,Vol44,No.7:797
[3]韩广德主编.中国煤炭工业钻探工程[M].北京:煤炭工业出版社,2000:829-836
[4]杨惠民.钻探设备[M].北京:地质出版社,1988:77-84.
[5]鄢泰宁.岩土钻掘工程学[M].武汉:中国地质大学出版社,2001:25-28.
[6]梁人祝.钻探设备[M].北京:地质出版社,1986:125-129.
[7]胡少韵.我国煤矿坑道钻探技术发展及存在的问题[J].煤田地质与勘探,1998(26):增刊59-62
[8]刁叔钧,胡少韵.全液压坑道钻机故障预测与诊断的现代化技术探讨[J].煤田地质与勘探,1999,27(4):68
[9]田宏亮.全液压动力头式钻机液压系统动态分析及控制方法的研究[D].西安:煤炭总院西安研究院,2008
[10]韩广德.中国煤炭工业钻探工程学[M].北京:煤炭工业出版社,2001:25-40
[11]邬迪.全液压坑道钻机配油套密封性能试验研究[D].西安:煤炭总院西安研究院,2008
[12]殷新胜,姚宁平,陈跟马等ZDY6000L型履带式全液压坑道钻机液压系统设计[J].陕西:煤炭科学研究总院西安研究院,2007.12
[13]田宏亮.全液压动力头式钻机液压系统动态分析及控制方法的研究[D].煤炭科学研究总院.2008
[14]穆英姿.模块化设计方法在固井水泥车中的应用研究[D].吉林大学.2005
[15]王贺剑,李栋,刘庆修.提高坑道钻机液压系统可靠性方法浅析[M].煤炭工程,2009.4:10-35
[16]王炜方.液压无级变速器的设计与研究[D].南京理工大学.2004
[17]庞方.岩层定向钻进非开挖铺管技术研究[D].成都理工大学.2004,4-10
[18]王人杰,蒋荣庆,韩军智.液动冲击回转钻探[M].北京,地质出版社,1988.7:15-46
[19]庞方.岩层定向钻进非开挖铺管技术研究[D].成都:成都理工大学.2004
[20]马林,李天珍,李磊.采场岩层的力学分析[J].江苏徐州:徐州工程学院学报, 2008.12
[21]干茂华,王忠利,闫.晓莹浅议我国工程机械定轴式变速器的应用与发展[J].工程机械.2008.9
[22]丁问司,彭浩舸,黄麓升.柔性冲击、柔性冲击器及柔性冲击系统[J].中国机械工程.2002.7
[23]余虹波.多轴摆动减速器的设计与优化[D].武汉理工大学,2008
[24]韩彬.基于Pro/Engineer齿轮传动模糊优化设计及系统开发[D].北京交通大学,2006
[25]濮良贵,纪明刚.机械设计第八版[M].北京:高等教育出版社,2006:206-208
[26] Zadeh L A.Fuzzy sets. Information and Cotrol,1965,8:338-353
[27]游斌弟.复杂机械结构模糊优化方法及工程应用[M].科学出版社,2007:31-38
[28]黄洪钟.模糊机械科学与技术——21世纪机械科学的重要发展方向[J].机械工程学报,1996.3
[29]王光远,王文泉.具有广义模糊约束的数学规划[M].模糊数学,1986:1-8
[30]王光远.工程软件设计理论[M].北京:科学出版社,1992:23-33
[31] Wang G Y, Zhang Y. The theory of fuzzy stochastic processes. Fuzzy Sets and Systens,1992,51(2):161-178
[32] Wang G Y, Qiao Z. Linear programming with fuzzy random variable coefficients. Fuzzy Sets andSystems,1993,57(3):295-311
[33] Qiao Z, Wang G Y. On solutions and distribution problems of the linear programming with fuzzy random varble coefficients. Fuzzy Sets and System, 1993,58(2):155-170
[34]梁新华.平面连杆机构的模糊综合与模糊优化[D].昆明理工大学,2002
[35]陈卫东,蔡萌琳,于诗源.工程优化方法[M].哈尔滨工程大学出版社,2006:276-282
[36]李万祥.工程优化设计与MATLAB实现[M].北京:清华大学出版社,2010:251-258
[37]巫少龙.机械模糊可靠性优化设计研究[D].浙江工业大学,2004
[38]童时中.模块化原理设计方法及应用[M].中国标准出版社,2000.5
[39] Urich,k.and K,Tung.Fundamentals of product Modularity,Issues in Design/Manufacturing Integration. pp.73-79,A,ASME,1991
[40]祁卓娅.机械产品模块化设计方法研究[D].北京:机械科学研究院,,2006
[41]郑甲红,郭文举,李健等.基于CBR的机械系列产品模块化设计[M].机械设计与制造,2009
[42]蔡盛保.桥式起重机的模块化设计[D].大连理工大学硕士学位论文,2004:20-25
[43]郑建启,李翔.设计方法学[M].清华大学出版社,2006
[44]戴端,黄智宇.产品设计方法学[M].中国轻工业出版社,2005
[45]高健,孙湘明.系统艺术概论[M].中国文史出版社,2002.3
[46]祁卓娅.机械产品模块化设计方法研究[D].北京:机械科学研究院,,2006
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