液压支架初撑力手动增压装置设计分析.pdf

论文题目论文题目 液压支架初撑力手动增压装置设计分析液压支架初撑力手动增压装置设计分析 作者姓名作者姓名郭郭震震入学时间入学时间2015 年年 9 月月 专业名称专业名称机机械械制制造造及及其其自自动动化化研究方向研究方向数数字字化化设设计计与与制制造造 指导教师指导教师曹曹 连连 民民职职称称副副 教教 授授 论文提交日期论文提交日期2018 年年 4 月月 论文答辩日期论文答辩日期2018 年年 5 月月 26 日日 授予学位日期授予学位日期2018 年年 6 月月 DESIGNAND ANALYSIS OFTHE MANUAL PRESSURIZATION DEVICE FOR THE INITIAL SUPPORTING FORCE OFTHE HYDRAULIC SUPPORT ADissertation ted in fulfillment of the requirements of the degree of MASTER OF PHILOSOPHY from Shandong University of Science and Technology by Guo Zhen SupervisorAssociate Professor Cao Lianmin College of Mechanical and Electronic Engineering May 2018 山东科技大学硕士学位论文摘要 I 摘摘要要 液压支架初撑力是井下采煤工作面支护设备的关键参数，其大小对采煤工 作面的正常支护及安全高效生产具有很大影响。但近年来，随着大采高综采技 术的不断进步以及矿井开采深度的不断增加，导致支架初撑力严重不足且分布 不均等问题的出现，对液压支架的支撑能力和支护性能提出了更高的要求。因 此论文对液压支架初撑力手动增压装置进行设计分析研究，提高支架初撑力， 防止顶板冒落，增加顶板稳定性。 论文首先在现有液压支架研究的基础上，对支架立柱回路系统及其承载过 程进行分析，通过多种增压方式的对比分析确定利用手动增压装置进行增压， 并基于增压控制回路设计分析确定了液压传动与机械设计相结合的设计方案。 其次，根据设计方案对液压支架初撑力手动增压装置进行结构参数设计，完成 增压缸缸体、活塞、主阀体及连接件的结构设计，并运用 Solidworks 建模软件 完成手动增压装置的三维建模；在此基础上，根据手动增压装置的增压控制阀 的结构特点建立二维流场模型进行 FLUENT 流场特性分析，完成不同阀芯开口 度下的压力、速度及矢量云图分析，分析不同开口度下的流场变化并提出优化 意见，验证增压控制阀结构设计的合理性。同时基于 AMESim 液压仿真平台对 手动增压阀、手动增压装置控制回路及支架立柱升架系统回路进行仿真分析， 模拟手动增压装置的工作性能和控制回路的动态特性。最后通过对比分析仿真 曲线及手动增压装置试制和井下现场安装试验，证明手动增压装置的设计符合 预期的增压要求，其结构设计合理、增压效果明显。 论文在传统结构设计理论的基础上，通过运用虚拟仿真与流场特性分析对 液压支架初撑力手动增压装置进行设计分析和试验证明，手动增压装置能够满 足大采高综采工作面的支护及安全生产要求，适应性好，通用性强，增压稳定 可靠。研究成果对综采工作面下的液压支架升柱系统的稳定性和矿井采煤工作 面的安全生产具有一定的参考价值，并为支架初撑力增压装置的设计与应用提 供一定的理论支撑， 为后续液压支架初撑力的研究提供了理论基础和宝贵经验， 也为煤矿综采设备的开发提供新思路，具有广阔的应用前景和推广应用价值。 关键词关键词液压支架，初撑力，手动增压装置，结构设计，仿真分析 山东科技大学硕士学位论文摘要 II ABSTRACT The initial supporting force of the hydraulic support is the key parameter of the support equipment for the coal mining face, and its size has a great influence on the normal support and safe,high-efficiency production of the coal face.with the continuous progress of fully mechanized mining technology in thick coal seam and the increasing of mine mining depth, the serious shortage of support force and uneven distribution of the support are caused, the increasing mining depth has put forward higher requirements for the support and supporting perance of hydraulic support.Therefore, the dissertation designs and analyzes the manual booster device for hydraulic support initial support, improves the initial support force of the support, prevents the roof from falling, and increases the stability of the top plate. Firstly, the paper analyzes the support column loop system and its bearing process based on the research of the existing hydraulic support, and confirms the use of manual pressurizing device for pressurization through comparative analysis of various pressurized s.Based on the design of pressure-increasing control loops, a design scheme combining hydraulic transmission and mechanical design was determined.Secondly, according to the design scheme, the structural parameters of the manual pressurization device for the initial support force of the hydraulic support are designed.The structural design of the cylinder body, the piston, the main valve body and the connecting piece of the booster cylinder is completed, and the three-dimensional modeling of the manual pressurizing device is completed using the Solidworks modeling software. Based on this, according to the structural features of the pressure booster control valve of the manual supercharger, a two-dimensional flow field model was developed to analyze the FLUENT flow field characteristics, and completed of pressure, velocity and vector cloud diagram analysis under different valve opening degree, analyzed of flow field changes at different opening degrees and suggestions for optimization, verified the rationality of the structure of the pressure control valve design.At the same time, simulated and analyzed the manual supercharging valve, the manual supercharger control loop and the support 山东科技大学硕士学位论文摘要 III column lifting frame system loop based on the AMESim hydraulic simulation plat, simulating the working perance and the dynamic characteristics of the control loop of the manual supercharger.Finally, by comparing and analyzing the simulation curves, the manual pressurization device trial and the down-hole site installation test, it is proved that the design of the manual pressurization device meets the expected pressurization requirement, and its structural design is reasonable and the pressurization effect is obvious. Based on the traditional structural design theory, the design analysis and test of the manual booster device for the hydraulic support initial support force by use of virtual simulation and analysis of flow field characteristics proves that this booster devicecanmeetthesupportandsafeproductionrequirementsforthe fully-mechanized mining face with large mining height.And this supercharging devicehasgoodadaptability,highversatility,andstableandreliable pressurization.The research results have certain reference value for the stability of the hydraulic support lifting system under the fully mechanized coal mining face and the safe production of the coal mining face, and provide a certain theoretical support for the design and application of the initial support force booster device for the support. It provides a theoretical basis and valuable experience for the follow-up study of the hydraulic supports initial supporting force. It also provides new ideas for the development of the coal mine comprehensive mining equipment and has broad application prospects and popularization and application value. Keywords hydraulic support，initial support force，manual pressurization， structural design，simulation analysis 山东科技大学硕士学位论文目录 I 目目录录 1绪论绪论.......................................................................................................... 1 1.1课题研究背景..........................................................................................................1 1.2国内外研究现状及发展趋势..................................................................................1 1.3课题研究目的与意义..............................................................................................5 1.4主要研究内容..........................................................................................................6 2液压支架初撑力手动增压装置总体方案设计研究液压支架初撑力手动增压装置总体方案设计研究.............................3 2.1液压支架立柱回路系统分析..................................................................................8 2.2液压支架初撑力增压方式分析及手动增压方式确定........................................10 2.3液压支架初撑力手动增压装置具体设计方案....................................................15 2.4手动增压装置预期增压效果................................................................................18 2.5本章小结................................................................................................................19 3液压支架初撑力手动增压装置结构设计研究液压支架初撑力手动增压装置结构设计研究...................................20 3.1手动增压装置液压系统设计................................................................................20 3.2手动增压装置总体结构设计................................................................................21 3.3手动增压装置增压缸设计研究............................................................................24 3.4手动增压装置主阀体设计研究............................................................................34 3.5手动增压装置连接结构设计研究........................................................................39 3.6本章小结................................................................................................................43 4基于基于 ANSYS FLUENT 的的增压控制阀流场特性分析增压控制阀流场特性分析.......................44 4.1物理模型的建立及简化........................................................................................44 4.2数值模拟计算........................................................................................................45 4.3网格划分................................................................................................................48 4.4初始条件及边界条件设定....................................................................................49 4.5增压控制阀的仿真结果及分析............................................................................49 4.6本章小结................................................................................................................53 5基于基于 AMESim 的手动增压装置动态特性仿真分析的手动增压装置动态特性仿真分析.........................54 5.1手动增压阀的仿真分析........................................................................................54 5.2手动增压装置控制回路仿真分析........................................................................55 山东科技大学硕士学位论文目录 II 5.3支架升柱液压系统仿真分析................................................................................58 5.4手动增压装置现场试验........................................................................................61 5.5本章小结................................................................................................................64 6结论与展望结论与展望............................................................................................65 6.1结论........................................................................................................................65 6.2展望........................................................................................................................66 参考文献参考文献...................................................................................................... 67 致致谢谢.......................................................................................................... 71 攻读学位期间取得的学术成果和获奖情况攻读学位期间取得的学术成果和获奖情况............................................. 72 山东科技大学硕士学位论文目录 III Contents 1Introduction................................................................................................................1 1.1Research background.....................................................................................................................1 1.2Current situation and trend of research at home and abroad.........................................................2 1.3The goal and purpose of research.................................................................................................. 5 1.4Main research contents.................................................................................................................. 6 2Study on the overall scheme design of the manual pressurization device for the initial support force of the hydraulic support.........................................................8 2.1Analysis of hydraulic support column loop system.......................................................................8 2.2Analysis of the of the initial support force of the hydraulic support and the determination of the manual pressurization .............................................................................10 2.3The specific design scheme of the manual pressurization device for the initial support force of the hydraulic support........................................................................................................................15 2.4Expected booster effect of a manual supercharging device........................................................ 18 2.5Summary......................................................................................................................................19 3Study on the structure design of the manual pressurization device for the initial support force of the hydraulic support.............................................................20 3.1Hydraulic system design of manual pressurization device..........................................................20 3.2Overall structure design of manual pressurization device...........................................................21 3.3Study on the design of turbocharging cylinder for manual pressurization device......................24 3.4Design and study of the main valve body of manual pressurization device...............................34 3.5Research on connection structure design of manual pressurization device................................39 3.6Summary......................................................................................................................................43 4Analysis of flow field characteristics of pressurized control valve based on ANSYS FLUENT...........................................................................................................44 4.1The establishment and simplification of physical model............................................................44 4.2Numerical simulation calculation................................................................................................45 4.3Grid partition................................................................................................................................48 4.4Initial condition and boundary condition setting.........................................................................49 山东科技大学硕士学位论文目录 IV 4.5Simulation results and analysis of pressurized control valve......................................................49 4.6Summary......................................................................................................................................53 5Simulationandanalysisofdynamiccharacteristicsofamanual pressurization device based onAMESim.................................................................... 54 5.1Simulation analysis of manual pressurization valve................................................................... 54 5.2Simulation analysis of control loop of manual pressurization device.........................................55 5.3Simulation analysis of lifting column hydraulic system............................................................. 58 5.4Field test of manual pressurization device...................................................................................61 5.5Summary......................................................................................................................................64 6Conclusion and Prospects.......................................................................................65 6.1conclusion.................................................................................................................65 6.2Prospects.................................................................................................................66 References.......................................................................................................................67 Acknowledgements........................................................................................................71 Academic achievements and awards during the Degree of Study............................ 72 山东科技大学硕士学位论文绪论 1 1绪论绪论 1.1课题研究背景课题研究背景 液压支架作为煤矿井下机械化开采的关键支护设备， 是保证矿井安全开采、 高效生产的前提，因此其支护性能关系到支架自身稳定性、顶板支护状态以及 整个工作面的安全生产，同时又关系着工作面的生产效率和生产量[1-2]。支架初 撑力作为采煤工作面液压支架最关键的技术指标之一，其作用是使支架立柱按 照增阻规律进行增阻，使液压支架处于合理、安全的工作状态，从而发挥其最 大的支护性能，加强液压支架支撑系统刚度，提高支架对顶板的支撑能力，实 现对顶板的有效管理[3-7]。在煤矿开采过程中，若液压支架初撑力达不到设计要 求，经常出现直接顶的初期离层与破坏问题，导致支架不能利用直接顶的传递 对老顶取得平衡而失去对工作面的