大采高液压支架稳定性技术研究.pdf

分类号分类号T TH122H122密密级级公公 开开 U D C 单位代码单位代码1042410424 学学 位位 论论 文文 大大采采高高液液压压支支架架稳稳定定性性技技术术研研究究 黄德杰黄德杰 申申请请学学位位级级别别博士学位博士学位专专业业名名称称机机械械设设计计及及理理论论 指指导导教教师师姓姓名名钟佩思钟佩思职职称称教教授授 山山 东东 科科 技技 大大 学学 二〇一二〇一七七年十年十二二月月 万方数据 论文题目论文题目 大大采采高高液液压压支支架架稳稳定定性性技技术术研研究究 作者姓名作者姓名黄黄德德杰杰入学时间入学时间2011 年年 9 月月 专业名称专业名称机机械械设设计计及及理理论论研究方向研究方向机机电电液液一一体体化化技技术术 指导教师指导教师钟钟佩佩思思职职称称教教授授 论文提交日期论文提交日期2017 年年 10 月月 论文答辩日期论文答辩日期2017 年年 12 月月 授予学位日期授予学位日期 万方数据 RESEARCH ON HYDRAULIC SUPPORT STABILITY OF LARGE MINING HEIGHT ADissertation ted in fulfillment of the requirements of the degree of DOCTOR OF PHILOSOPHY from Shandong University of Science and Technology by Huang Dejie Supervisor Professor Zhong Peisi College of Mechanical and Electronic Engineering December 2017 万方数据 学位论文原创性声明学位论文原创性声明 本人呈交给山东科技大学的这篇博士学位论文本人呈交给山东科技大学的这篇博士学位论文，，除所列参考文献和世所公认的文献除所列参考文献和世所公认的文献 外外，， 全部是本人攻读学位期间在导师指导下的研究成果全部是本人攻读学位期间在导师指导下的研究成果。。 除文中已经标明引用的内容外除文中已经标明引用的内容外，， 本论文不包含任何其他个人或集体已经发表或撰写过的研究成果本论文不包含任何其他个人或集体已经发表或撰写过的研究成果。。对本文的研究做出贡对本文的研究做出贡 献的个人和集体献的个人和集体，，均已在文中以明确方式标明均已在文中以明确方式标明。。本人完全意识到本声明的法律结果由本本人完全意识到本声明的法律结果由本 人承担。人承担。 若有不实之处，本人愿意承担相关法律责任。若有不实之处，本人愿意承担相关法律责任。 博士生签名博士生签名 日日期期 万方数据 学位论文使用授权声明学位论文使用授权声明 本人完全了解山东科技大学有关保留本人完全了解山东科技大学有关保留、、使用学位论文的规定使用学位论文的规定，，同意本人所撰写的学同意本人所撰写的学 位论文的使用授权按照学校的管理规定处理。位论文的使用授权按照学校的管理规定处理。 作为申请学位的条件之一作为申请学位的条件之一，，学校有权保留学位论文并向国家有关部门或其指定机构学校有权保留学位论文并向国家有关部门或其指定机构 送交论文的电子版和纸质版；有权将学位论文的全部或部分内容编入有关数据库发表送交论文的电子版和纸质版；有权将学位论文的全部或部分内容编入有关数据库发表，， 并可以以电子并可以以电子、、网络及其他数字媒体形式公开出版网络及其他数字媒体形式公开出版；；允许学校档案馆和图书馆保留学位允许学校档案馆和图书馆保留学位 论文的纸质版和电子版，可以使用影印、缩印或扫描等复制手段保存和汇编学位论文论文的纸质版和电子版，可以使用影印、缩印或扫描等复制手段保存和汇编学位论文；； 为教学和科研目的为教学和科研目的，，学校档案馆和图书馆可以将公开的学位论文作为资料在档案馆学校档案馆和图书馆可以将公开的学位论文作为资料在档案馆、、图图 书馆等场所或在校园网上供校内师生阅读、浏览。书馆等场所或在校园网上供校内师生阅读、浏览。 （保密的学位论文在解密后适用本授权）（保密的学位论文在解密后适用本授权） 博士生签名博士生签名导师签名导师签名 日日期期日日期期 万方数据 学位论文审查认定书学位论文审查认定书 研究生研究生在规定的学习年限内在规定的学习年限内，，按照培养方案及个人培养计划按照培养方案及个人培养计划，，完成了完成了 课程学习，成绩合格，修满规定学分；在我的指导下完成本学位论文，论文中的观点课程学习，成绩合格，修满规定学分；在我的指导下完成本学位论文，论文中的观点、、 数据数据、、表述和结构为我所认同表述和结构为我所认同，，论文撰写格式符合学校的相关规定论文撰写格式符合学校的相关规定，，同意将本论文作为同意将本论文作为 申请学位论文。申请学位论文。 导师签名导师签名 日日期期 万方数据 山东科技大学博士学位论文摘要 I 摘摘要要 随着综合机械化开采技术的完善和推广，一次性采全高成为目前厚煤层开 采的主要方式。大采高液压支架在厚煤层采全高技术中尤为关键，其稳定性决 定了煤炭开采的安全性与效率。实际生产中证明，大采高工作面极易产生端面 冒顶，煤壁片帮，液压支架失稳等安全问题。大采高液压支架的重量、重心、 受力状态的变化，使大采高液压支架对底板倾角的敏感度增加，其移架方式、 支架零部件的加工和装配精度也必须满足更高的要求。此外，大采高液压支架 的液压系统输出压力、流量、功率等关键性能参数及控制方式必须与厚煤层工 况相匹配，否则，整机将处于失稳工作状态，严重制约煤矿安全高效生产。 本文针对大采高工作面煤岩结构与液压支架结构特点，提出了提高大采高 液压支架稳定性的围岩-机械结构-液压控制系统的整套方案。采用关键层理论， 研究大采高工作面的覆岩结构与关键层断裂位态的变化特征、煤壁片帮、底板 倾角对大采高支架的要求，提出了大采高液压支架工作阻力、煤壁片帮位置及 所需支护强度的计算方法，分析底板倾角与支架稳定性间的关系并总结出防控 方法。 本文以提高大采高液压支架整机结构稳定性为目标，设计并分析支架在承 载状态时的受力模型，推导出了大采高两柱支撑掩护式液压支架力平衡区的计 算方法。分析了决定支架姿态稳定的关键因素，提出通过改善四连杆机构与顶 底座孔轴配合精度、加装结构限位块以保护平衡千斤顶；基于遗传算法，优化 了液压支架的顶梁前端面的运动轨迹，缩小了端面距变化区间，提升了大采高 液压支架自身结构的稳定性。 基于液压系统理论，对 ZY15000/29/63 大采高液压支架展开分析研究，根 据推导的公式建立出支架液压系统的重要元件和主要回路的数学模型。针对平 衡回路及结构在大采高工作面来压频繁、剧烈的环境下受到的冲击大且频繁， 容易失效的问题，设计了新的平衡回路，实现平衡回路与立柱回路联动，使平 衡机构更加稳定并提高支架适应能力。针对大采高液压支架在升架过程中由于 立柱缸径大、流量大、动力大等特点以及对顶板的冲击性较大的问题，设计了 万方数据 山东科技大学博士学位论文摘要 II 立柱位置伺服控制回路，实现顶梁接近顶板时立柱的速度控制，使顶梁与顶板 接触平稳，避免大采高液压支架对顶板冲击破坏。总结出计算立柱带压移架所 需残余支撑力的方法，设计带压移架控制回路，该回路结构组成及操作都独立 于立柱液压系统，对正常升架、降架没有不利影响，有助于液压支架在工作面 推进时自身和顶板稳定性维护。 对 ZY15000/29/63 大采高液压支架进行实验分析，在红阳三矿大采高工作 面对本文提出的大采高支架的稳定理论进行了实地检验； 采用 AMESim 软件对 改进后的平衡回路、 立柱位置伺服控制系统和带压移架控制系统进行仿真验证； 基于经典控制理论，采用 Matlab 绘制出了立柱在降-移-升工作循环中回路系统 的 Bode 图，对大采高液压支架电控系统稳定性进行了分析。 实验（仿真）结果表明本文所提出的大采高液压支架稳定性方案可行， 有助于改善大采高工作面支架与围岩关系，为厚煤层煤矿的安全高效开采提供 理论指导，具有广泛的适用性。 关键词关键词大采高液压支架；围岩；厚煤层；稳定性；液压仿真 万方数据 山东科技大学博士学位论文Abstract I Abstract With the development of comprehensive coal mining technology, one-time mining full height technique becomes the main way in current thick coal seam mining area. As one of the most important equipment, the large mining height hydraulic support stability directly determines the safety and efficiency of coal mining. It has been proved by practices that the large height mining face is prone to occur roof fall, rib spalling, hydraulic support instability, and other security accidences. The changes of hydraulic support height, weight, gravity center and stressconditionsincreasehigh-endhydraulicsupportsensitivitiesto floor slope angle, and they also bring the new requirements for large mining height stability design and sliding advance . In the case of thick coal seam mining, it requires that large mining height must have high quality components with large output pressure, flow rate, and power, and it also requires that the large mining height perance matches with corresponding condition, otherwise, large mining height support will be unstable, thus it will restrict safe and efficient coal production. Aiming at the characteristics of coal and rock, and special structure of hydraulic support in large height mining face, this paper proposes a set of complete schemes to improve large mining height stability, which includes physical characteristics analysis for surrounding rock, mechanical design for large mining height support, and control s for large mining height support. First of all, this work studies overlying strata structure and key strata fracture position characteristics in large height mining face by adopting the key strata theory, and then studies requirements for large mining height which are brought by rib spalling and floor slope angle. Furthermore, this work works out the calculating for large mining height working resistance, required support strength and potential rib spalling position, and explores the influence factors that the floor slope angle impacts on hydraulic support, and then figures out the prevent 万方数据 山东科技大学博士学位论文Abstract II s. Based on improvement for large mining height structure stability, this work establishes the force model of the support in the loading state, puts forward algorithms for calculating double-cylinders-support large mining height supporting force balance zone, summarizes the large mining height stability influence factors, and then proposes balance jack protection s by improving the fitting accuracy between the four-link hole and shaft, and installing structural limit block. Taking advantages of genetic algorithm, the trajectory of the top beam of the hydraulic support is optimized in this work, and the end distance is reduced, so as to ensure and improve large mining height stability. Aiming atZY15000/29/63 largemining heighthydraulic support, the mathematical model of the key components and the main large mining height circuits are analyzed and derived by advantages of hydraulic system theory. Targeting at high failure probability of balance loop and structure under the conditions of pressure varying sharply and bad operating environment, a novel balance circuit is designed in this work to realize jointly interaction between balance and prop circuits, therefore to improve balance mechanism’s stability and support’s adaptability. Aiming at large impact on the roof and new characteristics of big prop cylinder’s size, large flow and momentum during support littering process, a position servo control system for support cylinders is established to control littering velocity of support cylinders, so as to realize large mining height contacting with roof, and avoid support impacting on the roof. Analytical ulation of the residual supporting force of support cylinders is deduced, and an independent control circuit for sliding advance with pressure is designed to realize and maintain the stability during large mining height sliding advance with operating pressure. Taking ZY15000/29/63 large mining height as test object, this work verifies the proposed theory and design s in large height mining face of No. 3 Hongyang Mining company. The perance of the balance circuit, position servo control system for support cylinders, and large mining height sliding advance with operating 万方数据 山东科技大学博士学位论文Abstract III pressure system is verified with the simulation tool of AMESim. By using Matlab, the Bode curves of the prop in the down-shift-rise working cycle is plotted, and the stability of the hydraulic control system of the large mining height hydraulic support is analyzed. The results show that the theory and ologies developed in this work is feasible and they have important guiding significances and application values for improving the safe and efficient mining of thick coal seam in coal mine. Key words Large Mining Height Hydraulic Support; Surrounding Rock; Thick Coal Seam; Stability; Hydraulic Simulation 万方数据 山东科技大学博士学位论文目录 I 目目录录 1绪绪 论论....................................................................................................1 1.1研究背景与意义.................................................................................................1 1.2液压支架稳定性国内外研究现状..................................................................... 2 1.3厚煤层大采高液压支架稳定性存在的问题..................................................... 6 1.4本文主要研究内容.............................................................................................9 2大采高液压支架与围岩的大采高液压支架与围岩的耦合耦合关系研究关系研究.......................................11 2.1大采高采场的覆岩结构及断裂形态变化规律............................................... 11 2.2大采高液压支架工作阻力的确定................................................................... 18 2.3大采高液压支架对煤壁稳定性的响应研究................................................... 21 2.4底板倾角对大采高液压支架稳定性的影响分析........................................... 25 2.5本章小结...........................................................................................................35 3大采高液压支架稳定性力学分析及结构优化大采高液压支架稳定性力学分析及结构优化...............................38 3.1大采高液压支架姿态稳定的适应性分析....................................................... 38 3.2大采高液压支架顶梁前端失稳分析及改进措施........................................... 48 3.3面向大采高液压支架运动稳定的结构优化................................................... 53 3.4本章小结...........................................................................................................61 4厚煤层工作面大采高液压支架控制系统研究厚煤层工作面大采高液压支架控制系统研究...............................62 4.1液压系统控制元件性能分析........................................................................... 63 4.2大采高支架液压系统平衡回路分析............................................................... 70 4.3大采高液压支架立柱回路模型建立............................................................... 75 4.4带压移架控制系统的研究............................................................................... 79 4.5大采高液压支架电控系统研究....................................................................... 84 4.6本章小结...........................................................................................................89 5厚煤层工作面大采高液压支架稳定性试验分析厚煤层工作面大采高液压支架稳定性试验分析...........................90 5.1厚煤层工作面围岩与片帮稳定性试验........................................................... 90 万方数据 山东科技大学博士学位论文目录 II 5.2大采高液压支架控制回路的仿真................................................................... 94 5.3本章小结...........................................................................................................99 6结论与展望结论与展望......................................................................................100 6.1主要结论.........................................................................................................100 6.2创新点.............................................................................................................101 6.3工作展望.........................................................................................................102 参考文献参考文献................................................................................................103 附附录录....................................................................................................109 攻读博士期间主要成果攻读博士期间主要成果........................................................................113 致致谢谢.................................................................................................... 115 万方数据 山东科技大学博士学位论文Contents I Contents 1Introduction1 1.1Background and Motivation 1 1.2Literature Studies on Hydraulic Support2 1.3Key Issues of Stability of Large Mining Height Hydraulic Support Used in Thick-Coal-Seam-Mining 6 1.4Main Research Contents9 2Coupling Mechanism between Large Mining Height Hydraulic Support and Surrounding Rocks11 2.1Overlying Strata Characteristics and Fracture Morphology of Large Mining Height Stope11 2.2Working Resistance Calculation for Large Mining HeightHydrauluc Support18 2.3Large Mining HeightHydrauluc Support impacting on Coal wall Stability21 2.4Impact Analysis for Floor Slope on Stability of Large Mining Height Hydraulic Support25 2.5Summary 35 3Mechanical Analysis and Structural Optimization for Large Mining Height Hydraulic Support Stability38 3.1Adaptability Analysis for Hydraulic Support Stability of Large Mining Height38 3.2Instability Analysis and Improvement for Front Part of Hydraulic Support of Large Mining Height48 3.3Motion-Stabilization Oriented Hydraulic Support Structure Optimization of Large Mining Height53 3.4Summary 61 4Control System Design for Large Mining HeightHydraulic Support in Thick Coal Seam Face62 万方数据 山东科技大学博士学位论文Contents II 4.1Perance Analysis for Hydraulic Components 63 4.2Perance Analysis for Balance Circuit of Hydraulic Support70 4.3Modeling and Simulation for Hydraulic Prop Circuit of Large Mining Height75 4.4Novel Control for Sliding Advance of Support79 4.5Electronic Control System Design for Large Mining Height Hydraulic Support84 4.6Summary89 5Test and Stability Analysis for Large Mining Height Hydraulic Support in Thick Coal Seam90 5.1Stability Test for Large Mining HeightHydraulic Support90 5.2Simulation-based Verification for Large Mining HeightHydraulic Support Control Circuit94 5.3Summary99 6Conclusion and Future Work100 6.1Conclusions100 6.2Highlights101 6.3Future Work102 References103 Appendix109 Outcome andAchievements 113 Acknowledgement115 万方数据 山东科技大学博士学位论文绪 论 1 1绪绪 论论 随着煤矿开采技术的完善与发展，厚煤层矿井一次采全高技术受到广泛青 睐， 大采高技术与厚煤层的开采条件相适应， 且该技术具有高效而稳定的特点， 完全适用于厚煤层工况。目前，普遍使用一次采全高综采设备进行煤矿大采高 开采，其中，支护设备采用大采高液压支架。由于厚煤层工况的复杂性增大， 液压支架的支护难度比普遍液压支架更高，而其稳定性