刨煤机动力学分析及对刨链可靠性影响的研究
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摘要
我国的煤炭资源丰富,薄煤层开采还没有完全实现机械化,工人劳动强度大,资源回收率低。刨煤机是开采薄和中厚煤层的采煤机械,并且逐渐向大功率、高刨速、自动化方向发展。随之而来的是刨煤机运行中的动力学问题更加突出,以及由此带来对刨链可靠性的影响,迫切需要深入研究与探讨,为分析刨煤机运行问题和提高刨链可靠性提供理论基础,对加快我国刨煤机的研发与应用具有重要意义。为此本文围绕刨煤机动力学问题及动载荷作用下刨链可靠性的相关问题,通过理论分析、数值仿真和实验研究相结合的方法,进行了系统深入的研究,主要研究内容包括:
1.根据刨煤机实际运行工况,考虑煤壁作用力、刨链预紧力、链轮多边形效应等因素影响,建立了刨煤机非线性动力学模型。建立单自由度动力学模型作为初步研究和简单分析之用,进一步建立了较全面的多自由度动力学模型,并且考虑了双端驱动和单端驱动的区别,为详细研究和具体分析刨煤机各种动力学问题提供理论基础。
2.对刨煤机非线性动力学方程进行求解和仿真分析。在特定条件下,简化单自由度刨煤机动力学方程,运用多尺度和等效线性化方法分别对确定性和随机的煤壁作用力条件下的单自由度非线性动力学方程求得近似解析解。考虑各种影响因素,在确定性和随机的煤壁作用力两种情况下分别对单自由度和多自由度刨煤机动力学方程采用数值方法进行求解和仿真。
仿真结果表明煤壁作用力、刨链预紧力对刨煤机刨头速度和刨链张力有较大影响,链轮多边形效应影响较小,并且随机的煤壁作用力弱化了链轮多边形效应的影响作用。双端驱动时,链条承受的张力均值较小,降低了刨链负荷。通过比较单自由度模型和多自由度模型的仿真结果,得到单自由度模型作为简单分析具有一定的参考价值,但多自由度动力学模型更加准确,更符合实际工况。
3.分析影响刨链可靠性的因素,其中疲劳破坏是重要因素之一。随机的煤壁作用力、刨链预紧力、链轮多边形效应等作用使刨链承受较高的动应力。采用雨流法、线性Miner疲劳累积损伤模型,对刨链疲劳寿命进行预测。通过仿真和计算,得到不同随机煤壁作用力、不同刨链预紧力和不同链轮齿数作用下的刨链疲劳寿命。分析结果表明,随机煤壁作用力和刨链预紧力对刨链疲劳寿命影响较大,链轮多边形效应影响较小,这将为提高刨煤机运行的可靠性和刨链维护提供理论依据,并提出了提高刨链可靠性的具体措施。
4.通过自行研制的刨煤机实验台进行刨链张力测试,得到在不同刨削深度情况下刨链的张力变化情况,并与随机的煤壁作用力条件下多自由度动力学模型的仿真结果进行比较,仿真曲线基本符合实验测试曲线的变化规律。分析刨链张力实验数据,得到不同刨深情况下的刨链疲劳累积损伤规律,与通过动力学模型仿真得到的刨链疲劳累积损伤规律一致,为刨链可靠性分析提供了依据。
Coal resource is abundant in China. But thin coal seam mining has not been realized mechanization, workload of workers is large and rate of resources recovery is low. Coal plow is the coal mining machinery for thin and medium seams. Coal plow is developed by the way of high power, high plow body velocity, high strength and automatization. With the development of the coal plow dynamic problem is more obvious during the working of the coal plow and its influences on the reliability of plow chain need research and discussion imminently and deeply. It provides theoretical foundation for coal plow running and improvement of the reliability of plow chain, and it is important to accelerate the development of coal plow in China. Therefore, in this paper, dynamic problem of coal plow and reliability of plow chain under dynamic load are studied deeply and systemically with theoretical analysis, numerical simulation and experimental methods. Research works include:
1. According to actual working conditions of the coal plow, and considering the factors of forces of coal, pretension force of plow chain and sprocket polygon effect, nonlinear dynamic model of the coal plow is presented. Single-degree-of-freedom (single-DOF) dynamic model is presented for primary study and simple analysis of the coal plow. Then, multi-degree-of-freedom (multi-DOF) dynamic model considering various factors is presented for detailed research and analysis of various dynamic problems of the coal plow, and difference between single drive and double drive is considered.
2. Nonlinear dynamic equation of coal plow is solved and simulated. Under the particular conditions, single-DOF dynamic equation can be simplified. Methods of multiple scales and equivalent linearization are used to obtain approximate analytical solution of the single-DOF nonlinear dynamic equations under determinate and stochastic forces of coal separately. Considering various factors, numerical method is used to solve and simulate single-DOF and multi-DOF dynamic equations under determinate and stochastic forces of coal separately.
Simulation results show that influences of forces of coal and pretension force of plow chain are obvious on plow body velocity and chain tension, influence of sprocket polygon effect is less. And stochastic forces of coal reduce the influence of sprocket polygon effect. When double drive is used, mean value of tension in the plow chain is less than single drive, and then load of chain is reduced. Comparing single-DOF dynamic model with multi-DOF dynamic model, it shows that single-DOF dynamic model can be as reference for simple analysis of coal plow, but multi-DOF dynamic model accords with actual working conditions more.
3. Factors which have effect on reliability of plow chain are analyzed, and fatigue failure is one of the important factors. Stochastic forces of coal, pretension force of plow chain and sprocket polygon effect make plow chain under high dynamic stress. Rain flow counting method and linear Miner fatigue cumulative damage model are used to predict fatigue life of plow chain. Through simulation, fatigue life of plow chain can be got under different stochastic forces of coal, different pretension forces of plow chain and different number of sprocket teeth. The simulation results show that stochastic forces of coal and pretension force of plow chain have obvious effects on fatigue life of plow chain, but influence of sprocket polygon effect is less. It provides theoretical references for coal plow running and chain maintenance. Measures to improve reliability of plow chain are presented.
4. A self-developed coal plow test-bed is used to test tension in the plow chain. Changes of chain tension are obtained under different cutting depths. Compared with simulation results of multi-DOF dynamic model under stochastic forces of coal, simulation curves are in accord with testing curves basically. Analyzing testing data of chain tension, fatigue cumulative damage change of the plow chain is got under different cutting depths, and it accords with fatigue cumulative damage change of plow chain by simulating dynamic model. It provides references for reliability analysis of plow chain.
1.根据刨煤机实际运行工况,考虑煤壁作用力、刨链预紧力、链轮多边形效应等因素影响,建立了刨煤机非线性动力学模型。建立单自由度动力学模型作为初步研究和简单分析之用,进一步建立了较全面的多自由度动力学模型,并且考虑了双端驱动和单端驱动的区别,为详细研究和具体分析刨煤机各种动力学问题提供理论基础。
2.对刨煤机非线性动力学方程进行求解和仿真分析。在特定条件下,简化单自由度刨煤机动力学方程,运用多尺度和等效线性化方法分别对确定性和随机的煤壁作用力条件下的单自由度非线性动力学方程求得近似解析解。考虑各种影响因素,在确定性和随机的煤壁作用力两种情况下分别对单自由度和多自由度刨煤机动力学方程采用数值方法进行求解和仿真。
仿真结果表明煤壁作用力、刨链预紧力对刨煤机刨头速度和刨链张力有较大影响,链轮多边形效应影响较小,并且随机的煤壁作用力弱化了链轮多边形效应的影响作用。双端驱动时,链条承受的张力均值较小,降低了刨链负荷。通过比较单自由度模型和多自由度模型的仿真结果,得到单自由度模型作为简单分析具有一定的参考价值,但多自由度动力学模型更加准确,更符合实际工况。
3.分析影响刨链可靠性的因素,其中疲劳破坏是重要因素之一。随机的煤壁作用力、刨链预紧力、链轮多边形效应等作用使刨链承受较高的动应力。采用雨流法、线性Miner疲劳累积损伤模型,对刨链疲劳寿命进行预测。通过仿真和计算,得到不同随机煤壁作用力、不同刨链预紧力和不同链轮齿数作用下的刨链疲劳寿命。分析结果表明,随机煤壁作用力和刨链预紧力对刨链疲劳寿命影响较大,链轮多边形效应影响较小,这将为提高刨煤机运行的可靠性和刨链维护提供理论依据,并提出了提高刨链可靠性的具体措施。
4.通过自行研制的刨煤机实验台进行刨链张力测试,得到在不同刨削深度情况下刨链的张力变化情况,并与随机的煤壁作用力条件下多自由度动力学模型的仿真结果进行比较,仿真曲线基本符合实验测试曲线的变化规律。分析刨链张力实验数据,得到不同刨深情况下的刨链疲劳累积损伤规律,与通过动力学模型仿真得到的刨链疲劳累积损伤规律一致,为刨链可靠性分析提供了依据。
Coal resource is abundant in China. But thin coal seam mining has not been realized mechanization, workload of workers is large and rate of resources recovery is low. Coal plow is the coal mining machinery for thin and medium seams. Coal plow is developed by the way of high power, high plow body velocity, high strength and automatization. With the development of the coal plow dynamic problem is more obvious during the working of the coal plow and its influences on the reliability of plow chain need research and discussion imminently and deeply. It provides theoretical foundation for coal plow running and improvement of the reliability of plow chain, and it is important to accelerate the development of coal plow in China. Therefore, in this paper, dynamic problem of coal plow and reliability of plow chain under dynamic load are studied deeply and systemically with theoretical analysis, numerical simulation and experimental methods. Research works include:
1. According to actual working conditions of the coal plow, and considering the factors of forces of coal, pretension force of plow chain and sprocket polygon effect, nonlinear dynamic model of the coal plow is presented. Single-degree-of-freedom (single-DOF) dynamic model is presented for primary study and simple analysis of the coal plow. Then, multi-degree-of-freedom (multi-DOF) dynamic model considering various factors is presented for detailed research and analysis of various dynamic problems of the coal plow, and difference between single drive and double drive is considered.
2. Nonlinear dynamic equation of coal plow is solved and simulated. Under the particular conditions, single-DOF dynamic equation can be simplified. Methods of multiple scales and equivalent linearization are used to obtain approximate analytical solution of the single-DOF nonlinear dynamic equations under determinate and stochastic forces of coal separately. Considering various factors, numerical method is used to solve and simulate single-DOF and multi-DOF dynamic equations under determinate and stochastic forces of coal separately.
Simulation results show that influences of forces of coal and pretension force of plow chain are obvious on plow body velocity and chain tension, influence of sprocket polygon effect is less. And stochastic forces of coal reduce the influence of sprocket polygon effect. When double drive is used, mean value of tension in the plow chain is less than single drive, and then load of chain is reduced. Comparing single-DOF dynamic model with multi-DOF dynamic model, it shows that single-DOF dynamic model can be as reference for simple analysis of coal plow, but multi-DOF dynamic model accords with actual working conditions more.
3. Factors which have effect on reliability of plow chain are analyzed, and fatigue failure is one of the important factors. Stochastic forces of coal, pretension force of plow chain and sprocket polygon effect make plow chain under high dynamic stress. Rain flow counting method and linear Miner fatigue cumulative damage model are used to predict fatigue life of plow chain. Through simulation, fatigue life of plow chain can be got under different stochastic forces of coal, different pretension forces of plow chain and different number of sprocket teeth. The simulation results show that stochastic forces of coal and pretension force of plow chain have obvious effects on fatigue life of plow chain, but influence of sprocket polygon effect is less. It provides theoretical references for coal plow running and chain maintenance. Measures to improve reliability of plow chain are presented.
4. A self-developed coal plow test-bed is used to test tension in the plow chain. Changes of chain tension are obtained under different cutting depths. Compared with simulation results of multi-DOF dynamic model under stochastic forces of coal, simulation curves are in accord with testing curves basically. Analyzing testing data of chain tension, fatigue cumulative damage change of the plow chain is got under different cutting depths, and it accords with fatigue cumulative damage change of plow chain by simulating dynamic model. It provides references for reliability analysis of plow chain.
引文
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