大倾角工作面综放液压支架控制系统研究.pdf

分类号分类号TD745TD745TD745TD745密密级级公公 开开 U D CU D CU D CU D C 单位代码单位代码10424104241042410424 学学 位位 论论 文文 大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究 曹曹 连连 民民 申请学位级别申请学位级别博士博士学位学位专业专业名名称称机械机械电子工程电子工程 指导教师姓名指导教师姓名曾曾 庆庆 良良职职称称教教授授 指导教师姓名指导教师姓名程程 居居 山山职职称称教教授授 山山 东东 科科 技技 大大 学学 二〇二〇一二一二年五月年五月 论文题目论文题目论文题目论文题目 大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究大倾角工作面综放液压支架控制系统研究 作者姓名作者姓名作者姓名作者姓名 曹曹 连连 民民入学时间入学时间入学时间入学时间 2002002002007 7 7 7 年年 9 9 9 9 月月 专业名称专业名称专业名称专业名称机械机械电子工程电子工程研究方向研究方向研究方向研究方向 机电液一体化机电液一体化技术技术 指导教师指导教师指导教师指导教师 曾曾 庆庆 良良职职职职称称称称 教教授授 指导教师指导教师指导教师指导教师 程程 居居 山山职职职职称称称称 教教授授 论文提交日期论文提交日期论文提交日期论文提交日期2020202012121212 年年 4 4 4 4 月月 论文答辩日期论文答辩日期论文答辩日期论文答辩日期2020202012121212 年年 5 5 5 5 月月 授予学位日期授予学位日期授予学位日期授予学位日期 STUDYSTUDYSTUDYSTUDYONONONON CONTROLCONTROLCONTROLCONTROLSYSTEMSYSTEMSYSTEMSYSTEM OFOFOFOFMECHANIZEDMECHANIZEDMECHANIZEDMECHANIZED COALCOALCOALCOALCAVINGCAVINGCAVINGCAVING HYDRAULICHYDRAULICHYDRAULICHYDRAULIC SUPPORTSUPPORTSUPPORTSUPPORTFORFORFORFOR BIGBIGBIGBIG DIPDIPDIPDIP COALCOALCOALCOALFACEFACEFACEFACE A A A ADissertationDissertationDissertationDissertation tedtedtedted inininin fulfillmentfulfillmentfulfillmentfulfillment ofofofof thethethethe requirementsrequirementsrequirementsrequirements ofofofof thethethethe degreedegreedegreedegree ofofofof DOCTORDOCTORDOCTORDOCTOR OFOFOFOFPHILOSOPHYPHILOSOPHYPHILOSOPHYPHILOSOPHY fromfromfromfrom ShandongShandongShandongShandong UniversityUniversityUniversityUniversity ofofofof ScienceScienceScienceScience andandandand TechnologyTechnologyTechnologyTechnology b b b by y y y CAOCAOCAOCAO LianminLianminLianminLianmin SupervisorSupervisorSupervisorSupervisor ProfessorProfessorProfessorProfessor ZENGZENGZENGZENG QingliangQingliangQingliangQingliang SupervisorSupervisorSupervisorSupervisor ProfessorProfessorProfessorProfessor CHENGCHENGCHENGCHENG JushanJushanJushanJushan CollegeCollegeCollegeCollege ofofofof MechanicalMechanicalMechanicalMechanical andandandand E E E Electroniclectroniclectroniclectronic EngineeringEngineeringEngineeringEngineering MayMayMayMay2020202011111111 声声明明 本人呈交给山东科技大学的这篇博士学位论文，除了所列参考文献和世所本人呈交给山东科技大学的这篇博士学位论文，除了所列参考文献和世所 公认的文献外，全部是本人在导师指导下的研究成果。该论文资料尚没有呈交公认的文献外，全部是本人在导师指导下的研究成果。该论文资料尚没有呈交 于其它任何学术机关作鉴定。于其它任何学术机关作鉴定。 博士生签名博士生签名 日日期期 AFFIRMATIONAFFIRMATIONAFFIRMATIONAFFIRMATION I I I I declaredeclaredeclaredeclare thatthatthatthat thisthisthisthis dissertation,dissertation,dissertation,dissertation, tedtedtedted inininin fulfillmentfulfillmentfulfillmentfulfillment ofofofof thethethethe requirementsrequirementsrequirementsrequirements forforforfor thethethethe awardawardawardaward ofofofof DoctorDoctorDoctorDoctor ofofofof PhilosophyPhilosophyPhilosophyPhilosophy inininin ShandongShandongShandongShandong UniversityUniversityUniversityUniversity ofofofof ScienceScienceScienceScience andandandand Technology,Technology,Technology,Technology, is is is is whollywhollywhollywholly mymymymy ownownownown workworkworkwork unlessunlessunlessunless referencedreferencedreferencedreferenced ofofofof acknowledge.acknowledge.acknowledge.acknowledge. TheTheTheThe documentdocumentdocumentdocument hashashashas notnotnotnot beenbeenbeenbeen tedtedtedted forforforfor qualificationqualificationqualificationqualification atatatat anyanyanyany otherotherotherother academicacademicacademicacademic institute.institute.institute.institute. SignatureSignatureSignatureSignature DateDateDateDate 山东科技大学博士学位论文摘要 摘摘摘摘 要要要要 近年来，我国综放工作面的装备水平在高产高效矿井建设过程中得到了大力提高， 综放工作面配套设备正不断向大功率、高强度、高可靠性方向发展，但与国外先进水平 相比，国产工作面配套设备仍存在可靠性差、故障率高和使用寿命短等问题，特别是综 放工作面放顶煤液压支架的陷底、下滑、倾倒和扎顶等问题，对液压支架的控制系统提 出了更高的要求，成为阻碍复杂条件下综放开采发展的关键因素。论文针对大倾角煤层 的复杂开采条件，以国家“十一五”科技支撑计划课题“煤矿复杂条件的综放工作面关 键设备研究” 2006BAB11B05和“液压支架及电液控制系统关键技术研究开发” 2006BAF01B11为依托，研究与之相适应的大倾角工作面综放液压支架控制系统，解 决控制系统中的关键问题，实现综放工作面的高产高效，推动我国煤矿综放工作面装备 水平的提高。 论文首先结合大倾角煤层的赋存条件，研究了大倾角工作面煤岩运动规律和大倾角 工作面综放液压支架支护性能， 提出了适用于大倾角工作面ZF5600/16.5/26综放液压支架 的控制策略；其次研究了适应于综放液压支架电控系统的控制方式，建立液压支架位置 伺服控制系统模型，推导出控制阀控液压缸的开环传递函数，并对推溜控制回路进行动 态仿真分析，验证了电控系统的稳定性；第三应用AMESim仿真软件对综放液压支架中 电磁先导阀、电液换向主阀、液控单向阀和安全阀等关键液压元件进行仿真分析，创新 性设计了一种提高液压支架初撑力的自动增压式初撑力保证器，解决了液压支架控制系 统中的关键技术问题；最后利用AMESim和EASY5仿真软件对综放液压支架控制系统回 路进行数学建模和分析，得出液压元件及油缸在工作过程中的位移、压力和流量等变化 规律， 验证了液压元件的动态稳定性； 同时将ADAMS软件中机械系统仿真分析在EASY5 环境中建立机液一体化虚拟样机简单模型，实现了液压支架机械系统与液压系统的互动 联合仿真，检验综放液压支架控制系统的动态稳定性。 通过采煤工作面试验证明， 大倾角工作面综放ZF5600/16.5/26支架控制系统能够满足 复杂条件下综放工作面支护设备采煤生产要求，系统故障率低，稳定可靠。研究成果对 大倾角松软煤层等复杂条件下移架速度慢及控制系统不稳定等难题的研究具有重要的参 考价值，对于丰富我国复杂条件下综放工作面安全高效开采发挥积极推动作用。系统的 成功应用必将促进煤炭生产高产高效集约化发展和煤炭生产技术的进步，为我国的能源 工业做出巨大的贡献。 关键词关键词液压支架，综放工作面，放顶煤，电液控制系统，建模仿真 山东科技大学博士学位论文摘要 AbstractAbstractAbstractAbstract In recent years, the equipment level of Chinas coal caving face has been highly raised in the process of high yield and high efficient mine construction. The matching equipment of coal caving face is unceasingly developing toward large power, high strength and high reliability. However, compared with the advanced level abroad, domestic mining equipment remains in poor reliability, high failure rate and short lifetime, etc. Especially in coal caving face, the trapped bottom, slip, dumping and pierced top problems of top coal caving hydraulic support have put forward higher requests of control system of hydraulic support. It is also the key factor that impedes the development of caving mining under complex conditions. According to the big obliquity, soft coal seam mining and supine complicated mining condition, this thesis based on the national 11th five-year science and technology support plan project Research on Key Equipment of Coal Caving Face under Complex Conditions 2006BAB11B05 and Research and Development on KeyTechnology of Hydraulic Support and Electro-hydraulic Control System 2006BAF001B11, this thesis aims to develop a corresponding top coal caving hydraulic support control system of big dip coal caving face, in order to solve the key problem in control system, realize high yield and high efficiency in coal caving face, and promote the enhancement of Chinas coal caving face level. Firstly, this thesis combines with the occurrence conditions of big obliquity coal seam, develops the motion law of big obliquity coal caving face coal rock and support perance of coal caving hydraulic support in big obliquity coal caving face, puts forward control strategy of ZF5600/16.5/26 hydraulic support which is applicable under the big obliquity coal caving face; Secondly, this thesis studies control mode of electronic control system applicable to coal caving hydraulic support, builds position servo control system model of hydraulic support, deduces open-loop transfer function of control valve hydraulic cylinder, makes dynamic simulation analysis of hydraulic support moving scraper conveyor, and verifies the stability of the electrical control system. Thirdly, by means of AMESim simulation software, the thesis makes simulation analysis of key hydraulic parts in coal caving hydraulic support, such as solenoid pilot valve, electro-hydraulic control reversing valves, the pilot controlled one way valve, the safety valve and so on, innovatively designs a kind of the automatic 山东科技大学博士学位论文摘要 pressure control device to ensure setting load to raise the setting load of hydraulic support, solves the key problem in hydraulic support control system. Lastly, by means of AMESim and EASY5 simulation software, the thesis makes mathematical modeling and analysis of hydraulic control loop, obtains the variation of the displacement, pressure and flow in the working process of hydraulic parts and cylinder, and verifies the dynamic stability of hydraulic components.Meanwhile ， itbuildssimpleMechanical-hydraulicIntegration Virtual Prototyping model in EASY5 by means of mechanical system simulation analysis in ADAMS software, realizes mechanical system and hydraulic system Interactive co-simulation of hydraulic support, and test the dynamic stability of coal caving hydraulic support control system. The industrial test of the big dip coal caving face proved that the hydraulic support control system of ZF5600/16.5/26 can meet the mining production requirement of supporting equipment of coal caving face in complex conditions and the system has a low failure rate and it is very reliable and stable. The research results are very useful as reference materials for slow to shift hydraulic support and contol system instability in the complex conditions that there are large inclination and the soft coal seam and it is beneficial to reduce the comprehensive cost of coal caving face and mine production safety. It also plays an active role to enrich the s for our countrys coal caving faces in complex conditions are explored in a safety and high efficiency way. The successful application of this system will promote coal production’s high yield, high efficiency and intensive development and technology progress of coal production. It makes a great contribution for Chinas energy industry. KeyKeyKeyKey wordswordswordswords hydraulic support, coal caving face, top coal caving, electro-hydraulic control system, modeling simulation 山东科技大学博士学位论文目录 目目目目录录录录 1 1 1 1 概概概概述述述述 ..1..1..1..1 1.1 课题的提出 1 1.2 国内外研究现状 2 1.3 研究目的和内容 10 2 2 2 2 大倾角工作面综放液压支架支护性能与控制策略研究大倾角工作面综放液压支架支护性能与控制策略研究大倾角工作面综放液压支架支护性能与控制策略研究大倾角工作面综放液压支架支护性能与控制策略研究..12..12..12..12 2.1 大倾角工作面煤岩运动规律研究12 2.2 大倾角工作面综放液压支架支护性能与控制参数研究..20 2.3 大倾角工作面综放液压支架控制策略研究..32 2.4 小结 ..35 3 3 3 3 大倾角工作面综放液压支架电控系统研究大倾角工作面综放液压支架电控系统研究大倾角工作面综放液压支架电控系统研究大倾角工作面综放液压支架电控系统研究36363636 3.1 大倾角工作面综放液压支架电控系统控制方式研究..36 3.2 大倾角工作面综放液压支架电控硬件系统研究..43 3.3 大倾角工作面综放液压支架电控软件系统研究..45 3.4 大倾角工作面综放液压支架电控系统性能分析..50 3.5 大倾角工作面综放液压支架电控系统特性研究..53 3.6 小结 ..61 4 4 4 4 大倾角工作面综放液压支架液控系统研究大倾角工作面综放液压支架液控系统研究大倾角工作面综放液压支架液控系统研究大倾角工作面综放液压支架液控系统研究62626262 4.1 大倾角工作面综放液压支架液控系统分析62 4.2 大倾角工作面综放液压支架关键液压元件动态性能研究63 4.3 大倾角工作面综放液压支架液控系统压力损失分析.84 4.4 自动增压式初撑力保证器研究91 4.5 小结 .98 5 5 5 5 大倾角工作面综放液压支架控制系统特性研究大倾角工作面综放液压支架控制系统特性研究大倾角工作面综放液压支架控制系统特性研究大倾角工作面综放液压支架控制系统特性研究100100100100 5.1 大倾角工作面综放液压支架液压系统回路动态特性研究..100 5.2 大倾角工作面综放液压支架机液联合仿真技术117 5.3 大倾角工作面综放液压支架工作过程控制分析..127 山东科技大学博士学位论文目录 5.4 小结 .131 6 6 6 6 大倾角工作面综放液压支架控制系统试验大倾角工作面综放液压支架控制系统试验大倾角工作面综放液压支架控制系统试验大倾角工作面综放液压支架控制系统试验133133133133 6.1 大倾角工作面综放液压支架控制系统试验检测..133 6.2 大倾角工作面综放液压支架控制系统工业性试验135 6.3 小结 .137 7 7 7 7 结论与展望结论与展望结论与展望结论与展望138138138138 7.1 结论及创新..138 7.2 进一步工作展望 ...139 致致致致谢谢谢谢141141141141 参考文献参考文献参考文献参考文献142142142142 攻读博士期间主要成果攻读博士期间主要成果攻读博士期间主要成果攻读博士期间主要成果149149149149 山东科技大学博士学位论文目录 ContentsContentsContentsContents 1 1 1 1 S S S Summaryummaryummaryummary 1 1 1 1 1.1 Proposition of the project 1 1.2 Current situation of the project studied in China and foreign......2 1.3 Purpose and content of the project studied .10 2 2 2 2 StudyStudyStudyStudy onononon s s s supportupportupportupport peranceperanceperanceperance andandandand controlcontrolcontrolcontrol strategystrategystrategystrategy ofofofof bigbigbigbig dipdipdipdip cavingcavingcavingcaving facefacefaceface supportsupportsupportsupport12121212 2.1 Study on coal and rock movement regular pattern of big dip face 12 2.2 Study on support perance and control parameters of big dip caving face hydraulic support.......20 2.3 Study on control strategy of big dip caving face hydraulic support..32 2.4 Conclusion ..35 3 3 3 3 StudyStudyStudyStudy onononon e e e electroniclectroniclectroniclectronic c c c controlontrolontrolontrol systemsystemsystemsystem ofofofof bigbigbigbig dipdipdipdip cavingcavingcavingcaving facefacefaceface hydraulichydraulichydraulichydraulic supportsupportsupportsupport.36.36.36.36 3.1 Study on control mode of electronic control system for big dip caving face hydraulic support36 3.2 Study on electronic hardware control system of big dip caving face hydraulic support..43 3.3 Study on electronic software control system of big dip caving face hydraulic support...45 3.4 Electronic control system perance analysis of big dip caving face hydraulic support..50 3.5 Study on electronic control system characteristic of big dip caving face hydraulic support53 3.6 Conclusion.61 4 4 4 4 StudyStudyStudyStudy onononon hydraulichydraulichydraulichydraulic c c c controlontrolontrolontrol systemsystemsystemsystem ofofofof bigbigbigbig dipdipdipdip cavingcavingcavingcaving facefacefaceface hydraulichydraulichydraulichydraulic supportsupportsupportsupport..62..62..62..62 4.1 Analysis of hydraulic control system for big dip caving face hydraulic support..62 4.2 Study on key hydraulic components dynsmic characteristic for big dip caving face support63 4.3 Analysis of hydraulic control system pressure loss for big dip caving face hydraulic support..84 4.4 Study on automatic pressure control device to ensure setting load.91 4.5 Conclusion98 5 5 5 5StudyStudyStudyStudyononononcontrolcontrolcontrolcontrolsystemsystemsystemsystemcharacteristiccharacteristiccharacteristiccharacteristicofofofofbigbigbigbigdipdipdipdipcavingcavingcavingcavingfacefacefacefacehydraulichydraulichydraulichydraulic supportsupportsupportsupport100100100100 5.1 Study on hydraulic system control loop dynamic characteristic of big dip caving face support