电液控制液压支架大通径电磁先导阀关键技术研究.pdf

硕士学位论文 电液控制液压支架大通径电磁先导阀关键 技术研究 Research on Key Technology of Large Liameter Solenoid Pilot Operated Valve for Electro-hydraulic Control Hydraulic Support 作 者范祯科 导 师王忠宾 教授 中国矿业大学 二○一六年四月 万方数据 中图分类号 TH137 学校代码 10290 UDC 621 密 级 公开 中国矿业大学 硕士学位论文 电液控制液压支架大通径电磁先导阀关键 技术研究 Research on Key Technology of Large Liameter Solenoid Pilot Operated Valve for Electro-hydraulic Control Hydraulic Support 作 者 范祯科 导 师 王忠宾 教授 申请学位 工学硕士 培养单位 机电工程学院 学科专业 机械制造及其自动化 研究方向 煤矿机电装备自动化 答辩委员会主席 韩正铜 教授 评 阅 人 二○一六年四月 万方数据 学位论文使用授权声明 学位论文使用授权声明 本人完全了解中国矿业大学有关保留、使用学位论文的规定，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 作为申请学位的条件之一， 学位论文著作权拥有者须授权所在学校拥有学位 论文的部分使用权，即①学校档案馆和图书馆有权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；②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、图书 馆等场所或在校园网上供校内师生阅读、浏览。另外，根据有关法规，同意中国 国家图书馆保存研究生学位论文。 保密的学位论文在解密后适用本授权书。 作者签名 导师签名 年 月 日 年 月 日 万方数据 论文审阅认定书 论文审阅认定书 研究生范祯科在规定的学习年限内，按照研究生培养方案的要 求，完成了研究生课程的学习，成绩合格；在我的指导下完成本学位 论文,经审阅，论文中的观点、数据、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， 同意将本论文作为学位申请论文送专 家评审。 导师签字 年 月 日 万方数据 致谢 致谢 时光荏苒，转眼间三年的硕士研究生学习生活即将画上一个圆满的句号。蓦 然回首，感慨万千。非常有幸能够进入中国矿业大学这所百年学府，聆听老师们 的教诲，结识新的朋友。此时此刻，我的心中充满无限感激。 首先感谢我的导师王忠宾教授，本论文是在王忠宾教授的悉心指导下完成 的。三年来，导师敏锐的思维、严谨的治学态度、渊博的学识、诚挚谦虚的品格 和宽厚善良的处世方式，永远值得我学习和效仿。导师在我的学业上尤其是在论 文的撰写过程中，倾注了大量的心血，给予了我许多教诲和指导，将使我终生受 益。三年来，导师还在生活方面给予了我诸多慈父般的关怀和爱护，使我在感激 之余常常感到心有不安。我将更加努力，不辜负恩师的期望。 感谢课题组杨寅威、谭超、刘新华、姚新港、闫海峰和司垒等老师在课题研 究和科研实践中给予的热忱鼓励和悉心指导。在论文撰写过程中，徐州金枫液压 技术开发有限公司的厉军总经理提供了很多无私帮助， 丰富的现场经验帮助我攻 坚克难。在此，谨向各位前辈致以衷心的感谢。 感谢我的朋友张敏、薄晓光、魏耿赞、李亚飞和谢伟等硕士研究生在我论文 修改期间提出合理的修改意见，同样感谢他们在我三年读研期间的陪伴。 感谢课题组潘健、许静、齐楠、王艳萍、刘泽、汪佳彪、徐西华、徐荣鑫和 高鹏等硕士研究生在论文撰写期间提供的大力支持和无私帮助， 在此致以最真挚 的谢意。 感谢关爱我的父母和未婚妻曹焱丽女士， 在我求学期间给予我始终如一的鼓 励、关怀和支持，一直以来都是我前进的动力。 最后，向百忙之中评审本论文的各位专家老师表示衷心的感谢。 万方数据 I 摘 要 摘 要 电磁先导阀是液压支架电液控制系统的核心装置，由于煤矿的特殊环境，必 须满足 GB3836.4 本质安全要求，其驱动电磁铁最大工作电流被限制在 200mA 以内，可提供的电磁推力有限。目前，电磁先导阀阀芯开度基本在 0.1mm 左右， 乳化液中的煤尘、污染颗粒等容易堵塞阀芯，使液压支架电液控制系统失效，影 响煤矿的安全生产。本文基于现有电磁先导阀结构，适当增大阀芯开度，从根本 上提高其自身的抗堵塞能力；通过对阀芯关键部件及其流场进行优化，改善电磁 先导阀的响应特性和启闭特性，并搭建实验台测试优化后电磁先导阀的性能。论 文的主要研究内容如下 （1）分析了电磁先导阀结构组成以及电液控制液压支架阀组的工作原理； 通过对阀芯零件受力进行分析，构建电磁先导阀流量方程，建立了电磁先导阀工 作过程的数学模型。 （2） 通过分析故障电磁先导阀发生堵塞的原因， 将阀芯开度增大到 0.3mm， 并基于支持向量机算法对电磁先导阀复位弹簧进行优化；利用 Simulink 对结构 优化后的电磁先导阀动态特性进行了仿真分析， 得出了电磁先导阀打开和复位过 程中阀芯位移、流量和液动力等特性的变化规律。 （3）利用 Fluent 模拟电磁先导阀流场不同入口流速、不同出口压力和不同 阀芯开度条件下的流场特性得出流量越小，阀芯内流体流动越稳定，压力损失 越小，阀的寿命越长；阀芯开度增大至 0.3mm，不仅能提高电磁先导阀抗堵塞能 力，还可以改善阀芯流场性能。 （4）设计了电磁先导阀实验台，利用实验台对优化后的电磁先导阀启闭性 能、响应时间和流量-压差特性进行了测试。结果表明该电磁先导阀具有良好 的抗堵塞能力，其启闭性能、响应时间和流量-压差特性都能够满足设计要求。 该论文有图 75 幅，表 5 个，参考文献 83 篇。 关键词关键词液压支架；电磁先导阀；优化设计；仿真分析；性能测试 万方数据 II Abstract Solenoid pilot operated valve is a core device of the hydraulic support electro-hydraulic control system. Due to the special environment of coal mine, the current hydraulic support electro-hydraulic control system needs to meet essential safety requirements of GB3836.4, and the maximum working current of the electromagnet is limited to 200mA, which limits the electromagnetic thrust. At present, the valve core opening is around 0.1mm, which can be easily blocked by the coal dust and particulate contamination in emulsion. This phenomenon may lead to the electro-hydraulic control system failure and affects the safety production of coal mine. In this paper, the opening of valve core is appropriately enlarged to improve the anti-blockage capability of solenoid pilot operated valve fundamentally, on the basis of existing structure. The core components and flow field are optimized to enhance the response characteristics and opening-closing characteristics of solenoid pilot operated valve. The experiment bench is established to verify the perance of solenoid pilot operated valve. The main research contents of this paper are as follows 1 The structure composition of solenoid pilot operated valve and principle of electro-hydraulic control hydraulic support valve group was analyzed. Through the force analysis of the valve parts, the flow equation and the mathematical model of solenoid pilot operated valve were established. 2 According to the analysis of the reasons for blocking solenoid pilot operated valve, the valve core opening increased to 0.3mm and the reset spring is optimized based on a support vector machine. The dynamic characteristic of the optimized valve was simulated by the use of Simulink, and the change rules of valve core displacement, flow and hydrodynamic characteristics were explored in the open and reset process. 3 The flow field characteristics of solenoid pilot operated valve with different inlet flow rates, outlet pressure and valve core openings were simulated by the use of Fluent. The simulation results indicated that the flux is smaller, the fluid flow is more stable, the pressure is less loss, and the life of the valve is longer. When the opening of valve core is enlarged to 0.3mm, the anti-blockage capability of valve can be improved and the flow field perance of valve core can be perfected. 4 The experiment bench of solenoid pilot operated valve was built, and the opening-closing perance, response time and flow-pressure difference 万方数据 III characteristic of the optimized valve were tested. The results showed that the solenoid pilot operated valve possesses better anti-clogging ability, and its opening-closing perance, response time and flow-pressure difference characteristic can meet the design requirements. There are 75 figures, 5 tables and 83 references in this thesis Keywords hydraulic support; solenoid pilot operated valve; optimal design; simulation analysis; perance test 万方数据 IV 目目 录录 摘摘 要要................................................................................................................................ I 目目 录录............................................................................................................................. IV 图清单图清单.......................................................................................................................... VIII 表清单表清单.......................................................................................................................... XIII 变量注释表变量注释表 ................................................................................................................. XIV 1 绪论绪论 .............................................................................................................................. 1 1.1 课题来源及背景 ....................................................................................................... 1 1.2 课题研究现状及存在问题 ....................................................................................... 2 1.3 课题研究内容与方法 ............................................................................................... 5 1.4 课题研究意义 ........................................................................................................... 6 1.5 论文结构 ................................................................................................................... 6 2 电磁先导阀数学模型的建立电磁先导阀数学模型的建立 ...................................................................................... 7 2.1 电磁先导阀简介 ....................................................................................................... 9 2.2 电磁先导阀数学模型的建立 .................................................................................... 10 2.3 本章小结 ................................................................................................................. 15 3 电磁先导阀结构优化及其动态性能仿真电磁先导阀结构优化及其动态性能仿真 ............................................................... 17 3.1 电磁先导阀故障分析 ............................................................................................. 17 3.2 电磁先导阀结构优化 ............................................................................................. 18 3.3 电磁先导阀动态性能仿真 ..................................................................................... 31 3.4 本章小结 ................................................................................................................. 40 4 电磁先导阀流场数值模拟电磁先导阀流场数值模拟 ........................................................................................ 41 4.1 计算流体力学基础 ................................................................................................. 41 4.2 电磁先导阀流场数值模拟 ..................................................................................... 43 4.3 电磁先导阀流场仿真结果分析 ............................................................................. 46 4.4 不同边界条件下电磁先导阀流场仿真结果分析 ................................................. 50 4.5 不同阀芯开度的电磁先导阀流场仿真结果分析 ................................................. 52 4.6 本章小结 ................................................................................................................. 56 5 电磁先导阀实验研究电磁先导阀实验研究 ................................................................................................ 57 万方数据 V 5.1 电磁先导阀实验内容 ............................................................................................. 57 5.2 电磁先导阀实验台设计 ......................................................................................... 57 5.3 电磁先导阀性能测试 ............................................................................................. 64 5.4 本章小结 ................................................................................................................. 67 6 总结与展望总结与展望 ................................................................................................................ 68 6.1 总结 ......................................................................................................................... 68 6.2 展望 ......................................................................................................................... 69 参考文献参考文献 ........................................................................................................................ 70 作者简历作者简历 ........................................................................................................................ 75 学位论文原创性声明学位论文原创性声明 .................................................................................................... 76 学位论文数据集学位论文数据集 ............................................................................................................ 77 万方数据 VI Contents Abstract ........................................................................................................................... II Contents ......................................................................................................................... VI List of Figures ............................................................................................................. VIII List of Tables .............................................................................................................. XIII List of Variables ......................................................................................................... XIV 1 Introduction ................................................................................................................ 1 1.1 Origin and Background .............................................................................................. 1 1.2 Research Status and Problems ................................................................................... 2 1.3 Research Contents and s ................................................................................ 5 1.4 Research Significance ................................................................................................ 6 1.5 Structure of Thesis ..................................................................................................... 6 2 Mathematical Model of Solenoid Pilot Operated Valve ......................................... 7 2.1 Introduction of Solenoid Pilot Operated Valve ......................................................... 7 2.2 Mathematical Model of Solenoid Pilot Operated Valve ............................................ 10 2.5 Summary .................................................................................................................. 15 3 Solenoid Pilot Operated Valve Structure Optimization and Its Dynamic Characteristics Simulation ...................................................................................... 17 3.1 Solenoid Pilot Operated Valve Failure Analysis ..................................................... 17 3.2 Solenoid Pilot Operated Valve Structure Optimization ........................................... 18 3.3 Dynamic Perance Simulation of Solenoid Pilot Operated Valve..................... 31 3.4 Summary .................................................................................................................. 40 4 Numerical Simulation on Flow Field of Solenoid Pilot Operated Valve .............. 41 4.1 Basis of Computational Fluid Dynamics ................................................................. 41 4.2 Numerical Simulation on Flow Field of Solenoid Pilot Operated Valve.................. 43 4.3 Anslysis of Flow Field Simulation Results of Solenoid Pilot Operated Valve ....... 46 4.4 Anslysis of Flow Field Simulation Results of Solenoid Pilot Operated Valve under Different Boundary Conditions ..................................................................... 50 4.5 Anslysis of Flow Field Simulation Results of Solenoid Pilot Operated Valve under Different Opening .......................................................................................... 52 万方数据 VII 4.6 Summary .................................................................................................................. 56 5 Experimental Research of Solenoid Pilot Operated Valve ................................... 57 5.1 Experiment Content of Solenoid Pilot Operated Valve ........................................... 57 5.2 Design of Solenoid Pilot Operated Valve Test Bench ............................................. 57 5.3 Perance Test of Solenoid Pilot Operated Valve ............................................... 64 5.4 Summary .................................................................................................................. 67 6 Summary and Forecast ............................................................................................ 68 6.1 Summary .................................................................................................................. 68 6.2 Forecast .................................................................................................................... 69 References ...................................................................................................................... 70 Author’s Resume .............................................