刮板输送机可靠性寿命的研究
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摘要
刮板输送机作为综采工作面重要的设备之一,它的可靠性寿命直接影响着煤矿企业的安全、经济、高效生产。作为综采工作面唯一的运输设备,其工作条件恶劣、负载复杂多变,其安全可靠运行至关重要。近年来,随着新技术、新材料、新工艺的大量应用,国产重型刮板输送机装备的技术也得到飞速的发展,为煤矿生产实现高产高效起到了极大的推动作用。但是,国产刮板输送机与国外先进设备还是存在一定的差距,主要体现在可靠性和使用寿命方面,因此迫切需要对刮板输送机可靠性寿命进行分析研究,以提高其国产刮板输送机的可靠性水平。
本课题以可靠性寿命理论和疲劳寿命理论为依据来对刮板输送机的可靠性寿命进行分析研究。首先,根据可靠性寿命理论并结合刮板输送机的实际工作条件,筛选其可靠性寿命指标。然后,对神东公司刮板输送机两年的故障统计数据进行分析,获得刮板输送机整机的可靠性水平,找出影响可靠性寿命的最薄弱环节,进而分析最薄弱环节失效的主要原因。接着,利用ANSYS/FE-SAVE软件,对48mm×152mm刮板链应力和疲劳寿命进行了分析,得出链与链接触面和刮板链直边内侧与弧段相接处存在应力集中,刮板链的疲劳寿命最小值和安全系数最小值在链与链接触面和刮板链直边内侧与弧段相接位置,刮板链疲劳寿命是外侧大于内侧。随后,对刮板输送机的故障数据进行分析,验证出该刮板输送机的寿命服从威布尔寿命分布,计算其寿命指标,找出寿命规律,判断其可靠性寿命的总体水平。利用“等劣化”理论预计其大修次数和每次大修的总过煤量。
本文通过对刮板输送机整机可靠性分析找出影响可靠性寿命的最薄弱环节；然后再对其进行疲劳可靠性寿命预测；最后对故障数据分析得出刮板输送机的寿命规律,预计其大修次数和每次大修的总过煤量,为生产管理者提供提前维修的依据,也为其他型号的刮板输送机的可靠性寿命分析提供参考方法,这样对于提高刮板输送机的可靠性寿命,合理进行生产管理具有现实意义,为管理者提供参考和借鉴。
As one of the important equipment of fully mechanized coal face, scraper conveyor's reliability life directly affects enterprise security, economic, efficient production of the coal. As the only transport equipment for fully mechanized coal mining face, for the poor working conditions, load diversity, the safety and reliable operation is very important. In recent years, along with the application of new technology, new materials and new technology, domestic scraper conveyor equipment and technology has been rapid development, and played a great role in promoting coal production to achieve high yield efficient. However, there is still a certain gap between the domestic and foreign advanced equipment of scraper conveyor, mainly reflected in the reliability and service life, so it is an urgent need to study the reliability and service life of scraper conveyor, and then improve its reliability level.
This topic is based on the theory of reliability life and fatigue life theory to analyze the reliability of life of the scraper conveyor. First, according to the theory of reliability life combined with the actual working conditions of the scraper conveyor, screening the reliability of life indicators. Then, analyze two years of failure statistics of the Shen Dong scraper conveyor, scraper its reliability level, and identify the weakest link of the reliability life, and then analyzes the main reasons of its weakest link.Then, using the ANSYS/FE-SAVE software, analyze48mm X152mm ring chain stress and fatigue life,analysis shows that the chain and chain contact surface and ring chain straight edge to the inside of the arc phase exist stress concentration, chain's fatigue life minimum and the safety factor minimum are at the position of the straight edge of the inside of the chain and chain contact surface and the ring chain and arc phase position, the ring chain fatigue life of the outside is greater than the inside. Subsequently, analyze the fault data of the scraper conveyor, proved that the life of the scraper conveyor obey the Weibull life distribution, to calculate the life expectancy indicators and identify the law of life, then judge the overall level of reliability life. Use "Degradation" theory to expect its number of overhaul and the amount of coal of the each overhaul.
This paper identify the weakest link of the reliability life scraper conveyor machine through reliability life analysis; and then predict its life prediction of fatigue reliability; Finally, analyze the failure data to come to the law of the life of the scraper conveyor, expect the number of overhaul and the amount of coal each overhaul, provide the basis for early repair, and also provide a reference method for the reliability of life of the other types of scraper conveyor, It's advantageous to improve the reliability life of scraper conveyor, and has practical significance for reasonable production management,and provide reference for managers.
本课题以可靠性寿命理论和疲劳寿命理论为依据来对刮板输送机的可靠性寿命进行分析研究。首先,根据可靠性寿命理论并结合刮板输送机的实际工作条件,筛选其可靠性寿命指标。然后,对神东公司刮板输送机两年的故障统计数据进行分析,获得刮板输送机整机的可靠性水平,找出影响可靠性寿命的最薄弱环节,进而分析最薄弱环节失效的主要原因。接着,利用ANSYS/FE-SAVE软件,对48mm×152mm刮板链应力和疲劳寿命进行了分析,得出链与链接触面和刮板链直边内侧与弧段相接处存在应力集中,刮板链的疲劳寿命最小值和安全系数最小值在链与链接触面和刮板链直边内侧与弧段相接位置,刮板链疲劳寿命是外侧大于内侧。随后,对刮板输送机的故障数据进行分析,验证出该刮板输送机的寿命服从威布尔寿命分布,计算其寿命指标,找出寿命规律,判断其可靠性寿命的总体水平。利用“等劣化”理论预计其大修次数和每次大修的总过煤量。
本文通过对刮板输送机整机可靠性分析找出影响可靠性寿命的最薄弱环节；然后再对其进行疲劳可靠性寿命预测；最后对故障数据分析得出刮板输送机的寿命规律,预计其大修次数和每次大修的总过煤量,为生产管理者提供提前维修的依据,也为其他型号的刮板输送机的可靠性寿命分析提供参考方法,这样对于提高刮板输送机的可靠性寿命,合理进行生产管理具有现实意义,为管理者提供参考和借鉴。
As one of the important equipment of fully mechanized coal face, scraper conveyor's reliability life directly affects enterprise security, economic, efficient production of the coal. As the only transport equipment for fully mechanized coal mining face, for the poor working conditions, load diversity, the safety and reliable operation is very important. In recent years, along with the application of new technology, new materials and new technology, domestic scraper conveyor equipment and technology has been rapid development, and played a great role in promoting coal production to achieve high yield efficient. However, there is still a certain gap between the domestic and foreign advanced equipment of scraper conveyor, mainly reflected in the reliability and service life, so it is an urgent need to study the reliability and service life of scraper conveyor, and then improve its reliability level.
This topic is based on the theory of reliability life and fatigue life theory to analyze the reliability of life of the scraper conveyor. First, according to the theory of reliability life combined with the actual working conditions of the scraper conveyor, screening the reliability of life indicators. Then, analyze two years of failure statistics of the Shen Dong scraper conveyor, scraper its reliability level, and identify the weakest link of the reliability life, and then analyzes the main reasons of its weakest link.Then, using the ANSYS/FE-SAVE software, analyze48mm X152mm ring chain stress and fatigue life,analysis shows that the chain and chain contact surface and ring chain straight edge to the inside of the arc phase exist stress concentration, chain's fatigue life minimum and the safety factor minimum are at the position of the straight edge of the inside of the chain and chain contact surface and the ring chain and arc phase position, the ring chain fatigue life of the outside is greater than the inside. Subsequently, analyze the fault data of the scraper conveyor, proved that the life of the scraper conveyor obey the Weibull life distribution, to calculate the life expectancy indicators and identify the law of life, then judge the overall level of reliability life. Use "Degradation" theory to expect its number of overhaul and the amount of coal of the each overhaul.
This paper identify the weakest link of the reliability life scraper conveyor machine through reliability life analysis; and then predict its life prediction of fatigue reliability; Finally, analyze the failure data to come to the law of the life of the scraper conveyor, expect the number of overhaul and the amount of coal each overhaul, provide the basis for early repair, and also provide a reference method for the reliability of life of the other types of scraper conveyor, It's advantageous to improve the reliability life of scraper conveyor, and has practical significance for reasonable production management,and provide reference for managers.
引文
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[7]董从林.水润滑艉轴承的可靠性寿命评估[D].武汉：武汉理工大学2010.
[8]李志华.重载列车钩舌疲劳可靠性寿命分析[D].北京：北京交通大学2008.
[9]腾云.国产汽车使用可靠性评价研究[D].西安：长安大学,2010.
[10]刘混举,杨兆建.基于“等劣化模型”的综采设备可靠性寿命研究[J].太原理工大学学报.2009,40(5)458-460.
[11]程亚兵.汽车链疲劳寿命分布规律的研究[D].长春：吉林大学2004.
[12]王兴前.液压支架报废评价体系的研究[D].太原：太原理工大学2008.
[13]张宏斌,贾志新等.DK77系列电火花线切割机床可靠性评价模型[J].制造技术与机床,2010(4)88-91.
[14]邹辉,黄筱等.调基于两重威布尔分布的大型数控铣齿机可靠性评价[J].机械设计与制造,2010(2)198-200.
[15]刘惟信.机械可靠性设计[M].北京：清华大学出版社,1996,56-62.
[16]Thomas A.C. Reliability-Based Mechanical Design[M].Marcel Dekker,1997.
[17]张茂.刮板输送机传动系统的可靠性研究[D].阜新：辽宁工程技术大学,2006.
[18]高社生,张玲霞.可靠性理论与工程应用[M].北京：国防工业出版社,2002.08.
[19]朱文予.机械可靠性设计[M].上海：上海交通大学出版社,1992,156-171.
[20]扈书光.某特种设备可靠性研究[D].西安：长安大学,2009.
[21]万正高.国产电动汽车的可靠性评估与故障规律研究[D].武汉：武汉理工大学,2008.
[22]薛震.高速冲压系统可靠性研究[D].西安：长安大学,2008.
[23]游达章.最小二乘法在威布尔分布的可靠性疲劳[J].湖北工业大学学报,2009.
[24]宋保维,王晓娟.系统可靠性设计与分析[M].西安：西北工业大学出版社,2000.205-214.
[25]谢锡纯,李晓豁.矿山机械与设备[M].徐州：中国矿业大学出版社,1999,264-267.
[26]陈维健,齐秀丽.矿山运输与提升设备[M]北京：中国矿业大学出版社：1997.
[27]S. Saitta, B. Raphael, I.F.C. Smith. Data mining techniques for improving the reliability of system identification [J].Advanced Engineering Informatics, Volume 19, Issue 4, October 2005, Pages 289-298.
[28]宋保维,王晓娟.系统可靠性设计与分析[M].西安：西北工业大学出版社,2000.205-214.
[29]S. Saitta, B. Raphael, I.F.C. Smith. Data mining techniques for improving the reliability of system identification [J].Advanced Engineering Informatics, Volume 19, Issue 4, October 2005, Pages 289-298.
[30]Sinnamon R M,Andrews J D. New approaches to evaluating fault trees [J]. Reliability Engineering and System Safety,1997,(58):89-96.
[31]徐祺祥.机械产品的可靠性分析——介绍FMEA和FTA分析法[J].机械设计与研究,1984(01)：12-14.
[32]晏飞,郁钟铭等.刮板输送机断链原因及预防措施研究[J].煤炭工程,2008,(10).
[33]GB7829-1987.故障树分析程序[S].北京：中华人民共和国电子工业部,1988.
[34]熊峻江.疲劳断裂可靠性工程学[M].北京：国防工业出版社,第一版,2008.
[35]郭坤,孙远涛等.基于有限元法的刮板输送机刮板链接触强度分析[J].矿山机械,2011(1)26-27.
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