裝配圖低位放頂煤液壓支架的設(shè)計(1)

裝配圖低位放頂煤液壓支架的設(shè)計(1),裝配,低位,放頂煤,液壓,支架,設(shè)計 液壓支架分級分布式微機(jī)電磁閥液壓控制系統(tǒng) 摘要以集散型控制理論為基礎(chǔ)，論述了綜采工作面液壓支架分級分布式微機(jī)電液控制系統(tǒng)的原理，給出了液壓支架的3種控制模型，設(shè)計了以MCS-51單片機(jī)為核心的液壓支架控制器，進(jìn)行了控制器的硬件設(shè)計和軟件調(diào)試。關(guān)鍵詞集散型控制系統(tǒng)；液壓支架；單片機(jī)中圖分類號TP273；TD355.4A Distributed Computer Control System of Mining Hydraulic SupportMa ChunyanLi GengxinYang Jiankang(College of Information Engineering of TUT)(Jin Cheng Mining Bureau)AbstractThis paper presents the principles of distributed computer control system of mining hydraulic support for the coalface with complex cutting equipment on the basis of the distributed computer control theory.Three control modes of the hydraulic support are supplied in the paper.It also deals with the design of the hydraulic support controller with the pricipal part of a MCS-51 single chip computer.In addition,the hardware circuits design and software program adjustment of the controller are also mentioned in the paper.Key wordsdistributed computer control system;hydraulic support;single chip microcomputer 采煤工作面綜合機(jī)械化設(shè)備CCME(Coalface Complex Mechanical Equipements),主要由采煤機(jī)、液壓支架和刮板運(yùn)輸機(jī)(俗稱煤溜子)等設(shè)備組成。液壓支架是綜合機(jī)械化采煤工作面的主要設(shè)備之一，它分散布置在整個采煤工作面上。一個工作面一般裝備100架左右或更多的液壓支架。為了有效地提高綜采工作面的生產(chǎn)效率和管理水平，本文以集散型控制系統(tǒng)DCCS(Distributed Computer Control Systems)理論為基礎(chǔ)，設(shè)計了液壓支架分級分布式微機(jī)電液控制系統(tǒng)。中文摘要 課題根據(jù)當(dāng)前綜合機(jī)械化采煤工作面所采用支護(hù)方式暴露出來的問題，提出采用自移式超前支護(hù)液壓支架對綜放面端頭進(jìn)行超前支護(hù)；考慮到現(xiàn)今液壓支架生產(chǎn)企業(yè)在產(chǎn)品開發(fā)過程中存在的種種弊端，提出將虛擬樣機(jī)技術(shù)應(yīng)用到液壓支架的設(shè)計開發(fā)中。在支架投入生產(chǎn)之前在計算機(jī)上仿真和修改數(shù)字樣機(jī)，縮短了研發(fā)周期，提高了產(chǎn)品質(zhì)量，減少了由于制造物理樣機(jī)而增加的成本。本課題也為其他機(jī)械產(chǎn)品的開發(fā)提供了一個成功的范例。課題介紹了虛擬樣機(jī)技術(shù)、國內(nèi)外液壓支架的發(fā)展?fàn)顩r以及利用虛擬樣機(jī)技術(shù)進(jìn)行自移式超前支架開發(fā)的意義；介紹了自移式超前支架的結(jié)構(gòu)特點(diǎn)、承載原理以及應(yīng)用MALTAB語言編寫M文件的方式自動計算出自移式超前支架的主要技術(shù)參數(shù)；介紹了自移式超前支架液壓控制系統(tǒng)的特點(diǎn)和常用的液壓基本回路，設(shè)計出自移式超前支架的液壓控制系統(tǒng)，提出基于虛擬樣機(jī)技術(shù)的液壓控制系統(tǒng)的實(shí)現(xiàn)方法。在UG-NX環(huán)境下完成了自移式超前支架零部件的三維造型設(shè)計并采用自底向上的裝配方式，完成了支架的虛擬裝配，查找設(shè)計不合理的因素，計算出自移式超前支架的質(zhì)量、體積、轉(zhuǎn)動慣量等物理特性，并且完成了從3D實(shí)體模型圖到2D工程圖的生成。將零部件的3D模型按照Parasolid標(biāo)準(zhǔn)輸出“.x_t”文件，為ANSYS進(jìn)行有限元分析做準(zhǔn)備。介紹了有限元法的基本原理及其求解步驟，在研究CAE技術(shù)和CAD技術(shù)之間的數(shù)據(jù)傳輸?shù)幕A(chǔ)上，提出利用ANSYS和UG-NX的數(shù)據(jù)接口，將UG-NX環(huán)境下輸出的“.x_t”文件導(dǎo)入ANSYS環(huán)境下，進(jìn)行網(wǎng)格劃分、約束加載求解、后處理，完成自移式超前支架主要承載部件（如頂梁等）的應(yīng)變、應(yīng)力分析，根據(jù)零部件在承載狀態(tài)下變形量的大小驗(yàn)證零部件的設(shè)計是否合理。 外文摘要 The thesis raises designing the automatic advanced hydraulic bracket to support the terminal of the working fields according to the problems exposed to the supporting method nowadays being used in mechanized coal cutting. Considering the hydraulic bracket company has many maladies during the development of the products, The thesis raises adopting Virtual Prototyping to design the product. By simulation and modifying digital prototyping on computer before product, we can reduce the costs and shorten the design interval and improve the quality of the products. The theme also provides a successful paradigm for the design of other machinery products. The thesis introduces Virtual Prototyping technology, development of the hydraulic supports and the significance of designing automatic advanced bracket based on Virtual Prototyping technology. The thesis introduces the structure features of the bracket, the principle for enduring the load and instructs a method of counting key technology parameters using MATLAB to edit M files. The features and the fundamental circuit of the hydraulic controlling system are also instructed, and the hydraulic controlling system of the automatic advanced bracket is designed, putting forward the method of emulating based on the Virtual Prototyping technology. The thesis achieves three dimension design for the parts of the bracket, and completes virtual assemble using Bottom-Up assembly, checking irrational factors in the design, counting the quality, volume and the retary inertia of the assembly solid and creating engineering drawing from 3D model to 2D view in UG-NX. “.x_t” files of the 3D models are exported by Parasolid standard and make ready for the analysis using ANSYS software. The thesis instructs the principle for the FEA and solving steps, put forward the method of guiding the “.x_t” file into ANSYS conditions based on the investigation of the interface between the CAE technology and CAD technology, making analysis of stress and strain for the main loading parts (ef. upper beam, etc) of the automatic advanced bracket by meshing, loading-solving and postprocessing, and verifying the result of the design of the parts in loading conditions according to the strain. 高強(qiáng)度結(jié)構(gòu)鋼的焊接試驗(yàn)及液壓支架有限元分析/THE WELDING EXPERIMENTS OF HIGH STRENGTH STRUCTURAL STEEL AND THE FINITE ELEMENT STRENHTH ANLYSIS OF FLUID POWER BEARER中文摘要 本文對抗拉強(qiáng)度為800 高強(qiáng)鋼WH80的焊接性能進(jìn)行了研究，實(shí)驗(yàn)數(shù)據(jù)表明高強(qiáng)鋼WH80可以用于支架設(shè)計。初步總結(jié)了一套焊接工藝，包括預(yù)熱溫度的確定、低強(qiáng)度匹配的可行性、焊接速度的選取以及線能量的確定等，這些研究方法與手段可以直接用于生產(chǎn)實(shí)踐。對支架整架結(jié)構(gòu)件裝配體進(jìn)行了應(yīng)力分析，建立了具體的分析模型，對于外載荷的處理、邊界條件的確定提出了具體的處理方法，建立了完整的支架簡化結(jié)構(gòu)模型。通過研究，可以得出如下結(jié)論： (1) 高強(qiáng)鋼WH80屬于低焊接冷裂紋敏感性鋼，可用作支架設(shè)計板材。 (2) WH80鋼可以選用比母材強(qiáng)度低的焊接材料J707RH進(jìn)行焊接，以使接頭強(qiáng)度與母材強(qiáng)度等強(qiáng)。 (3) 預(yù)熱溫度的確定除考慮材料化學(xué)成份外，還應(yīng)考慮到晶向組織的變化。對于WH8O高強(qiáng)鋼為防止脆化，預(yù)熱溫度應(yīng)選定在120 左右。 (4) 支架在頂梁偏載工況下受力狀況最為惡劣，表現(xiàn)為支架頂梁、斜梁、前后連桿和底座等處都有較大的應(yīng)力分布。 (5) 最高Von Mises應(yīng)力分布表現(xiàn)為區(qū)域性、局部性的存在，在實(shí)際設(shè)計中應(yīng)考慮在該區(qū)域施以高強(qiáng)度板材，而無需整架采用高強(qiáng)度板材，以節(jié)省支架成本。 外文摘要 This topic research content was 800 high tensile steel WH80 welding performance conducts the research to the tensile strength, the empirical datum had indicated high tensile steel WH80 was allowed to use in the support design. This topic research initially summarized set of weldings crafts, including the preheating temperature determination, the low intensity match feasibility, the welding speed selection as well as the line energy indeed grades, these research techniques and the method may directly use in the production practice. Has carried on the stress analysis to the support entire frame structural element assembly body, has established the concrete analysis model, regarding outside load processing, the boundary condition determination proposed the concrete processing method, established the integrity support to simplify the structural model. Through the research, we may draw following conclusion: (1) High tensile steel WH80 belongs to the low welding cold crack sensitive steel and may serve as the support design plate. (2) The WH80 steel may select compared to parent metal intensity low welding material J707RH carries on the welding, causes the attachment intensity and the parent metal intensity and so on is strong. (3) Preheating temperature determination besides consideration material chemical composition, but also should consider the crystal to organizations change. For prevents the embrittlement regarding the WH8O high tensile steel, the preheating temperature should designate about 120. (4) The support carries under the operating mode in the top-beam the stress condition to be worst, displays for the support top-beam, Sloping beams, around the connecting rod and the foundation and so on place all has the bigger stress distribution. (5) Highest Von the Mises stress distribution performance for the regional characteristic, the partial existence, in the actual design should consider serves with the high strength plate in this region, but need not the entire frame to use the high strength plate, saves the support cost. 現(xiàn)代煤礦高效工作面的關(guān)鍵設(shè)備液壓支架 ,是煤礦實(shí)現(xiàn)采煤、運(yùn)輸和支護(hù)等所有工序全部機(jī)械化的重要環(huán)節(jié)。結(jié)合多年的液壓支架制造經(jīng)驗(yàn) ,分析了液壓支架標(biāo)準(zhǔn)化現(xiàn)狀及弊端 ,進(jìn)而對液壓支架標(biāo)準(zhǔn)化的實(shí)施途徑提出了建議 ,以期對推動液壓支架標(biāo)準(zhǔn)化的進(jìn)程有所裨益 【英文摘要】 The hydraulic support is the key equipment in todays high production faces underground,it is important tache to realize the mechanisation of all process including mining,transport and shoring etc.Combining years experience of the hydraulic support production,author analysed hydraulic support standardization present situation and abuse,and then made suggestion about the implement channel of hydraulic support standardization,in order to for promote the process of hydraulic support standardization benifit.在詳細(xì)分析液壓支架初撐力與直接頂相互作用機(jī)理的基礎(chǔ)上,對支架合理初撐力的確定進(jìn)行了分析研究,并提出了合理支架初撐力的確定方法。 【英文摘要】 On the basis of analysis of the reciprocity mechanism of original pressure and direct roof, the author analyzes the setting methods of appropriate original pressure of powered support is put forward finally.綜合分析了國產(chǎn)液壓支架與國外先進(jìn)國家支架間在技術(shù)性能、控制系統(tǒng)、元件制造以及工作介質(zhì)等諸方面的差異,設(shè)計了以插裝閥為控制元件的液壓系統(tǒng),研究了以水為工作介質(zhì)的支架液壓元件制造技術(shù)。 【英文摘要】 The paper gives a synthetic analysis to the difference between homemade hydraulic timbering and imported one from advanced country on technical properties, control system, parts manufacture and working medium etc., designs the hydraulic system which is used plug-in valve as controlling part and researches the manufacturing technique of hydraulic part in timbering which is working by the medium of water課題根據(jù)當(dāng)前綜合機(jī)械化采煤工作面所采用支護(hù)方式暴露出來的問題，提出采用自移式超前支護(hù)液壓支架對綜放面端頭進(jìn)行超前支護(hù)；考慮到現(xiàn)今液壓支架生產(chǎn)企業(yè)在產(chǎn)品開發(fā)過程中存在的種種弊端，提出將虛擬樣機(jī)技術(shù)應(yīng)用到液壓支架的設(shè)計開發(fā)中。在支架投入生產(chǎn)之前在計算機(jī)上仿真和修改數(shù)字樣機(jī)，縮短了研發(fā)周期，提高了產(chǎn)品質(zhì)量，減少了由于制造物理樣機(jī)而增加的成本。本課題也為其他機(jī)械產(chǎn)品的開發(fā)提供了一個成功的范例。課題介紹了虛擬樣機(jī)技術(shù)、國內(nèi)外液壓支架的發(fā)展?fàn)顩r以及利用虛擬樣機(jī)技術(shù)進(jìn)行自移式超前支架開發(fā)的意義；介紹了自移式超前支架的結(jié)構(gòu)特點(diǎn)、承載原理以及應(yīng)用MATLAB 語言編寫M 文件的方式自動計算出自移式超前支架的主要技術(shù)參數(shù)；介紹了自移式超前支架液壓控制系統(tǒng)的特點(diǎn)和常用的液壓基本回路，設(shè)計出自移式超前支架的液壓控制系統(tǒng)，提出基于虛擬樣機(jī)技術(shù)的液壓控制系統(tǒng)的實(shí)現(xiàn)方法。在UG-NX 環(huán)境下完成了自移式超前支架零部件的三維造型設(shè)計并采用自底向上的裝配方式，完成了支架的虛擬裝配，查找設(shè)計不合理的因素，計算出自移式超前支架的質(zhì)量、體積、轉(zhuǎn)動慣量等物理特性，并且完成了從3D 實(shí)體模型圖到2D 工程圖的生成。將零部件的3D 模型按照Parasolid 標(biāo)準(zhǔn)輸出“.x_t”文件，為ANSYS 進(jìn)行有限元分析做準(zhǔn)備。介紹了有限元法的基本原理及其求解步驟，在研究CAE技術(shù)和CAD技術(shù)之間的數(shù)據(jù)傳輸?shù)幕A(chǔ)上，提出利用ANSYS 和UG-NX 的數(shù)據(jù)接口UG-NX 環(huán)境下輸出的“.x_t”文件導(dǎo)入ANSYS 環(huán)境下，進(jìn)行網(wǎng)格劃分、約束加載求解、后處理，完成自移式超前支架主要承載部件（如頂梁等）的應(yīng)變、應(yīng)力分析，根據(jù)零部件在承載狀態(tài)下變形量的大小驗(yàn)證零部件的設(shè)計是否合理。關(guān)鍵詞：虛擬樣機(jī)，自移式超前支架，Parasolid，ANSYSABSTRACTThe thesis raises designing the automatic advanced hydraulic bracket to support theterminal of the working fields according to the problems exposed to the supporting methodnowadays being used in mechanized coal cutting. Considering the hydraulic bracket companyhas many maladies during the development of the products, The thesis raises adopting Virtual Prototyping to design the product. By simulation and modifying digital prototyping oncomputer before product, we can reduce the costs and shorten the design interval and improvethe quality of the products. The theme also provides a successful paradigm for the design ofother machinery products.The thesis introduces Virtual Prototyping technology, development of the hydraulicsupports and the significance of designing automatic advanced bracket based on VirtualPrototyping technology. The thesis introduces the structure features of the bracket, theprinciple for enduring the load and instructs a method of counting key technology parametersusing MATLAB to edit M files. The features and the fundamental circuit of the hydrauliccontrolling system are also instructed, and the hydraulic controlling system of the automaticadvanced bracket is designed, putting forward the method of emulating based on the VirtualPrototyping technology. The thesis achieves three dimension design for the parts of thebracket, and completes virtual assemble using Bottom-Up assembly, checking irrationalfactors in the design, counting the quality, volume and the retary inertia of the assembly solidand creating engineering drawing from 3D model to 2D view in UG-NX. “.x_t” files of the3D models are exported by Parasolid standard and make ready for the analysis using ANSYSsoftware. The thesis instructs the principle for the FEA and solving steps, put forward themethod of guiding the “.x_t” file into ANSYS conditions based on the investigation of theinterface between the CAE technology and CAD technology, making analysis of stress andstrain for the main loading parts (ef. upper beam, etc) of the automatic advanced bracket bymeshing, loading-solving and postprocessing, and verifying the result of the design of theparts in loading conditions according to the strain.Keywords：Virtual Prototyping, automatic advanced bracket, Parasolid, ANSYSII現(xiàn)代煤礦高效工作面的關(guān)鍵設(shè)備液壓支架 ,是煤礦實(shí)現(xiàn)采煤、運(yùn)輸和支護(hù)等所有工序全部機(jī)械化的重要環(huán)節(jié)。支撐掩護(hù)式支架是以支撐為主 ,掩護(hù)為輔的液壓支架 ,用來控制采場頂板下沉斷裂及冒落 ,保證控頂距內(nèi)頂板完整和必要的回采空間。對支撐掩護(hù)式液壓支架的結(jié)構(gòu)特點(diǎn)及合理應(yīng)用等進(jìn)行了簡要介紹。為保證支架的合理工作狀態(tài) ,應(yīng)盡量縮短降架時間 ,快速移架 ,及時支護(hù) ,并保持足夠的支架初撐力在詳細(xì)分析液壓支架初撐力與直接頂相互作用機(jī)理的基礎(chǔ)上,對支架合理初撐力的確定進(jìn)行了分析研究,并提出了合理支架初撐力的確定方法。 【英文摘要】The hydraulic support is the key equipment in todays high production faces underground,it is importantStanding shield hydraulic support can control the subsidence,rupture and inbreak of the stope roof,and assure the integrity of the roof and necessary extraction space.The structural feature and its rational application of standing shield hydraulic are introduced in brief.According to the paper,it is necessary to reduce the time of falling support,to move support quickly,to timber the roof in time and keep enough setting pressure. On the basis of analysis of the reciprocity mechanism of original pressure and direct roof, the author analyzes the setting methods of appropriate original pressure of powered support is put forward finally.