矿用液压支架液压系统优化设计与验证.pdf

授予单位代码授予单位代码学号或申请号学号或申请号密密级级中原工学院硕硕士士学学位位论论文文矿用液压支架液压系统优化设计与验证矿用液压支架液压系统优化设计与验证刘刘芳芳指导教师指导教师安向东安向东教授教授申请学位级别申请学位级别硕硕士士专业名称专业名称机械工程机械工程提交日期提交日期 2017年年3 月月论文答辩日期论文答辩日期 2017年年5月月培养单位培养单位中原工学院中原工学院学位授予单位学位授予单位中原工学院中原工学院万方数据中原工学院学位论文原创性声明本人郑重声明所呈交的学位论文，是我个人在导师指导下进行的研本人郑重声明所呈交的学位论文，是我个人在导师指导下进行的研究工究工作及取得的研究成果。论文中除了特别加以标注和致谢的地方外，不作及取得的研究成果。论文中除了特别加以标注和致谢的地方外，不包含任何其他个人或集体已经公开发表或撰写过的研究成果。其他同志对包含任何其他个人或集体已经公开发表或撰写过的研究成果。其他同志对本研究的启发和所做的贡献均已在论文中作了明确的声明并表示了谢意。本研究的启发和所做的贡献均已在论文中作了明确的声明并表示了谢意。本人学位论文与资料若有不实，愿意承担一切相关的法律责任。本人学位论文与资料若有不实，愿意承担一切相关的法律责任。学位论文作者签名学位论文作者签名年年月月日日中原工学院学位论文知识产权声明本人完全了解中原工学院有关保护知识产权的规定，即研究生在校本人完全了解中原工学院有关保护知识产权的规定，即研究生在校攻读学位期间论文工作的知识产权单位属于中原工学院。学校有权保留并攻读学位期间论文工作的知识产权单位属于中原工学院。学校有权保留并向国家有关部门或机构送交论文的复印件和电子版。本人允许论向国家有关部门或机构送交论文的复印件和电子版。本人允许论文被查阅文被查阅和借阅。学校可以将本学位论文的全部或部分内容编入有关数据库进行检和借阅。学校可以将本学位论文的全部或部分内容编入有关数据库进行检索，可以采用影印、缩印或扫描等复制手段保存和汇编本学位论文。索，可以采用影印、缩印或扫描等复制手段保存和汇编本学位论文。保密论文待解密后适用本声明。保密论文待解密后适用本声明。学位论文作者签名学位论文作者签名指导教师签名指导教师签名年年月月日日年年月月日日万方数据中原工学院硕士学位论文摘要 I 矿用液压支架液压系统优化设计与验证矿用液压支架液压系统优化设计与验证专业机械工程硕士生刘芳指导教师安向东教授摘摘要要本课题来源于平顶山平煤机煤矿机械装备有限公司，针对国际上先进的 ZY16800/32/70D型号7米大采液压支架的结构和液压系统优化而进行的研究，课题于2016 年立项河南省科技攻关项目。课题对液压支架的结构及液压系统的升级与改进进行了优化设计与仿真验证。课题提出了研究方法。本文对液压支架进行了选型分析计算及主要结构件和执行件的设计，包括液压支架参数的确定、架型的确定、主体结构件的设计与校核、立柱及推移千斤顶的设计、大流量系统的设计等，并且对液压系统管路通径进行了精确的设计计算，理论上验证了液压系统设计的合理性。通过改进增加了液压管路通径，提升了液压支架移架速度。对系统建立了液压支架三维模型，应用有限元分析软件 ABAQUS 对液压支架进行分析，解决了液压支架上容易出现应力集中的部位缺陷，为今后液压支架的设计建立了设计基础。通过应用仿真软件 AMESIM 建立了液压支架液压系统的仿真模型，对立柱升降及移架过程进行了仿真，改进了现有液压系统的不足，推算出理想工况下单架支架一个动作循环需要的时间，进一步验证了液压系统设计的合理性。本文得出的研究成果以及所采用的研究方法为液压支架液压系统的相关研究提供了一定的理论和方法借鉴。关键词液压支架；液压系统；有限元分析；管路布置；仿真万方数据中原工学院硕士学位论文 Abstract II The Optimized design and verification ofHydraulic support hydraulic system Specialty Mechanical Engineering Name LiuFang Supervisor An xiang dong professor Abstract This topic comes from ping ding shan ping mei ji Coal Mine Machinery Equipment Co., Ltd , research on the structure and hydraulic system optimization of the advanced ZY16800 / 32 / 70D model 7 meters large hydraulic support of the international community and conducted, subject project Henan province science and technology public relations project in 2016. The structure of the hydraulic support and the upgrading and improvement of the hydraulic system are optimized and verified. Subject proposed research s, This article Analysis calculated and design the Selection of hydraulic support and the major structural components and element. Including the determination of hydraulic support parameters, Determination of the type of hydraulic support, The design and verification of the main structural parts, the design of the leg and Advancing ram , large flow system design and so on. And precise design and calculation the hydraulic system pipeline diameter, The oretically verifies the rationality of hydraulic system design. By increased the hydraulic diameter pipe, hydraulic support frame shift speed is improved. The establishment of a system of hydraulic support three-dimensional model, the hydraulic support is analyzed by finite element analysis software ABAQUS, This solves the hydraulic support defect prone parts of the stress concentration, for the future design of hydraulic support to establish a design basis. The simulation model of the hydraulic support hydraulic system was established by using the simulation software AMESIM. The simulation of the lifting and shifting process of the leg was carried out, and the shortcomings of the existing hydraulic system were improved. The time required for a single operation of the single frame was calculated, which further validates the rationality of hydraulic system design. The research results and the research s used in this paper provide some theoretical and ological references for the research of the hydraulic system of hydraulic support. 万方数据中原工学院硕士学位论文 Abstract III Key words Hydraulic support; Hydraulic system; Finite element analysis; Pipe arrangement; simulation. 万方数据中原工学院硕士学位论文目录 I 目录 1 绪论绪论 ....................................................................................................................................................... 1 1.1 课题背景及意义 .......................................................................................................................... 1 1.2 国内外液压支架研究现状 ......................................................................................................... 2 1.2.1 国外液压支架研究现状 ..................................................................................................... 2 1.2.2 国内液压支架研究现状 ..................................................................................................... 2 1.2.3 国内外液压支架存在的差距............................................................................................. 3 1.3 液压系统仿真技术存在的问题及发展趋势 ........................................................................... 4 1.4 主要研究内容及研究方法 ......................................................................................................... 4 1.4.1 主要研究内容 ...................................................................................................................... 4 1.4.2 研究方法 ............................................................................................................................... 4 2 综采工作面液压系统综采工作面液压系统 ......................................................................................................................... 6 2.1 液压支架结构简介 ...................................................................................................................... 6 2.2 综采工作面液压系统的组成 ..................................................................................................... 6 2.2.1乳化液泵站 ............................................................................................................................ 7 2.2.2供液回路 ................................................................................................................................ 7 2.2.3中间支架液压系统 ............................................................................................................... 7 2.3 液压支架的工作原理 .................................................................................................................. 8 2.3.1支架升柱初撑 ....................................................................................................................... 8 2.3.2支架承载 ................................................................................................................................ 9 2.3.3支架降柱 ................................................................................................................................ 9 2.3.4移架和推溜 ............................................................................................................................ 9 2.4本章小结 ...................................................................................................................................... 10 3 液压支架结构和执行元件设计液压支架结构和执行元件设计...................................................................................................... 11 3.1 液压支架结构设计 .................................................................................................................... 11 3.1.1 液压支架选型 .................................................................................................................... 11 3.1.2 主要结构件设计 ................................................................................................................ 12 3.2 液压支架主要执行元件设计 ................................................................................................... 15 3.2.1 立柱的设计 ........................................................................................................................ 15 3.2.2 推移千斤顶的设计 ............................................................................................................ 16 3.3 本章小结 ..................................................................................................................................... 17 4 主要结构件和执行元件的强度校核与有限元分主要结构件和执行元件的强度校核与有限元分析析 ................................................................... 18 万方数据中原工学院硕士学位论文目录 II 4.1 主要结构件强度校核 ................................................................................................................ 18 4.1.1 支架力学模型 .................................................................................................................... 18 4.1.2 结构件用材料力学参数 ................................................................................................... 19 4.1.3 顶梁强度校核 .................................................................................................................... 20 4.1.4 掩护梁强度校核 ................................................................................................................ 23 4.1.5 底座强度校核 .................................................................................................................... 24 4.2 液压支架结构件有限元分析验证 .......................................................................................... 26 4.2.1 支架三维模型的建立及力学模型简化 ......................................................................... 26 4.2.2 网格的划分 ........................................................................................................................ 26 4.2.3 液压支架结构件有限元分析结果 .................................................................................. 27 4.3 立柱有限元分析 ........................................................................................................................ 31 4.4 本章小结 ..................................................................................................................................... 32 5 液压系统的优化设计液压系统的优化设计 ....................................................................................................................... 33 5.1优化设计的目标 ......................................................................................................................... 33 5.2关键技术 ...................................................................................................................................... 34 5.2.1 高压大流量系统配置 ....................................................................................................... 34 5.2.2 立柱双进双回，旁路回液 ............................................................................................... 34 5.2.3 一、二级护帮差动连接 ................................................................................................... 35 5.2.4 升立柱与收抬底联动 ....................................................................................................... 35 5.2.5 平衡补偿双向锁实现平衡千斤顶差动连接 ................................................................. 35 5.3 工作面进回液管路通径的设计计算 ...................................................................................... 36 5.3.1 工作面顺槽管路压力损失的计算 .................................................................................. 36 5.3.2 工作面进回液管路的计算 ............................................................................................... 39 5.3.3 工作面及顺槽总压力降计算........................................................................................... 41 5.3.4 计算结论 ............................................................................................................................. 41 5.4 架内主进回液管路的计算 ....................................................................................................... 41 5.5 确定主要胶管直径 .................................................................................................................... 42 5.6 关键元件的设计选型与分析 ................................................................................................... 43 5.6.1 电液主控阀 ........................................................................................................................ 43 5.6.2 双进双回立柱液控单向阀（带旁路回液） ................................................................. 43 5.6.3 专供液控阀 ........................................................................................................................ 44 5.6.4 立柱安全阀（3000L/min500 L/min） ......................................................................... 44 5.6.5 推移液控单向阀 ................................................................................................................ 47 5.6.6 一、二级护帮联动控制双向锁 ...................................................................................... 48 万方数据中原工学院硕士学位论文目录 III 5.6.7平衡补偿双向锁 ................................................................................................................. 49 5.7 单台支架一个动作循环时间计算 .......................................................................................... 49 5.7.1 降架时间 ............................................................................................................................. 51 5.7.2 移架时间 ............................................................................................................................. 51 5.7.3 升架时间 ............................................................................................................................. 51 5.8 本章小结 ..................................................................................................................................... 52 6 液压支架架内管路布置优化液压支架架内管路布置优化 .......................................................................................................... 53 6.1 管路布置优化的背景和目的 ................................................................................................... 53 6.1.1 架内管路布置优化的背景 ............................................................................................... 53 6.1.2 架内管路布置优化的目标 ............................................................................................... 53 6.2 液压支架架内管路布置存在的问题 ...................................................................................... 53 6.3 造成以上问题的原因分析 ....................................................................................................... 54 6.3.1 造成“胶管长度不合理”的原因分析 ......................................................................... 54 6.3.2 造成“架内胶管相互交错、挤压”的原因分析 ........................................................ 55 6.3.3 造成“管夹规格不合理”的原因分析 ......................................................................... 55 6.3.4 造成“批量系统管路布置不一致”的原因分析 ........................................................ 55 6.4 改进措施 ..................................................................................................................................... 55 6.5 改进成果 ..................................................................................................................................... 56 6.5