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附 錄
附錄A 譯文
綜采支架液壓控制技術發(fā)展與展望
隨著“高產高效”采煤工藝技術的推廣使用，支架的作用除傳統(tǒng)意義的“支、護、移”之外，支架“速度”這個性能對綜采工作面效率的影響日趨顯著，主要表現(xiàn)在兩方面：放頂煤支架能夠輔助采煤；移架速度影響工作面推進速度，影響采煤效率。其他因素，如可靠性、系統(tǒng)的可維護性以及相關技術等直接關系到系統(tǒng)的開機率。因此“高產高效”采煤工藝推廣初期對液壓系統(tǒng)和元件的流量特性提出了很高要求，配套支架的動作必須滿足整個采煤系統(tǒng)總體需要，后期則對系統(tǒng)和元件的綜合性能提出了要求。我國綜采支架液壓系統(tǒng)和元件隨著采煤技術的發(fā)展，與上世紀80～90年代相比有了長足的進步，基本能夠滿足需要，但同國外同類先進設備相比，差距明顯。本文從技術角度詳細分析這種差距及其存在原因，力求探索發(fā)展我國相關產品的技術途徑和研究方向，加快技術發(fā)展和產品更新的步伐。
1 國內外支架液壓系統(tǒng)及元件的差別
1.1控制方式的不同
國內：手動控制。人工手液壓支架各個千斤頂?shù)膭幼鳌?
國外：電液控制。用電腦、傳感器控制電磁閥的動作，從而控制支架動作。
控制方式的不同，表明我國綜采技術裝備與國際先進水平相比有整體差距?？刂品绞降牟煌?，其根本原因是我國基礎制造業(yè)水平與先進國家相比有差距，在電控系統(tǒng)部分這種差距更加明顯。目前國內使用的電液控制系統(tǒng)主要依靠進口，相關國產設備處于試驗或研發(fā)階段。
1.2閥類元件性能的比較
液壓系統(tǒng)閥類元件主要分成：操縱閥、單向閥、安全閥及輔助元件。通過國內外同類產品的比較，可以看出國內外閥類產品性能差距是明顯的：國內產品的使用壽命在6000次左右，國際先進水平同類產品達到30000次，是國內的5倍；國內選用的材料沿用傳統(tǒng)的普通鋼材，采用鍍鋅、鍍鎳等方法進行防銹防腐處理，效果遠遠低于不銹材料（不銹鋼、銅合金、陶瓷等），就此兩項指標，反映了國產設備的可靠性較國際先進水平存在差距。閥的流量特性，是配套首選指標，國產單向閥和操縱閥的最大流量達到了國際先進水平；在一定時期內，手動操作將是我國液壓支架控制的主要方式，而不是電液控制系統(tǒng)；配套設備技術水平不能滿足需要，如國產泵站的壓力普遍較低、相關管路輔件質量不穩(wěn)定，效率低。在此基礎上要提高整個配套液壓系統(tǒng)性能，提高操縱閥和單向閥的流量是必然，也是相對容易的。
相對來說，提高安全閥（專用于液壓支架）的流量是一個世界性的難題，且安全閥的性能對“高產高效”的影響不明顯，其實際功效也很難用具體指標證明，所以我國相關產品的發(fā)展速度明顯低于其他閥類產品，與國際先進水平差距更大。
1.3系統(tǒng)及元件的使用維護性能
綜采技術發(fā)展的一個趨勢是工作面長度在不斷增加。工作面的加長，支架液壓系統(tǒng)長度隨之增加，系統(tǒng)復雜，元件數(shù)量也成比例增加。加上地下采煤條件惡劣，元件出現(xiàn)故障是很正常的，維護、維修是采煤作業(yè)日常工作之一。目前我國支架閥類產品的設計思路還處于國外80年代水平，往往忽視了產品的維護維修性能，而國外同類產品則帶有更多的人性化特點，考慮安裝、操作使用的便利。
目前國際上較先進的設計觀念是采用插裝式結構。其特點是液壓元件事先單獨組裝、調試好，在使用過程中的維修只是更換出現(xiàn)故障的元件，而不需要動作整個閥組。其優(yōu)點很明顯：效率高，降低系統(tǒng)受污染的幾率，從而降低故障率。
1.4系統(tǒng)介質、對污染的控制
國內一般采用200目左右的普通過濾器對系統(tǒng)介質進行過濾。支架液壓系統(tǒng)介質是乳化液，由水和乳化劑按一定比例混合制成的。國內生產的乳化劑以工業(yè)用油為主要原料，與水的比例一般達到5%以上。這種乳化液本身會產生一定的沉淀物而污染系統(tǒng)。目前國際上好的乳化劑幾乎不含礦物油成分，符合環(huán)保要求，與水的比例僅為1%～2%。
1.5系統(tǒng)設計方式
液壓系統(tǒng)的主要設計工作是閥的選擇、支架內管路布置、工作面管路布置、泵站參數(shù)確定。設計方法主要有兩種：經驗設計和定量化設計。
經驗設計：參照現(xiàn)有液壓支架液壓系統(tǒng)，經驗確定系統(tǒng)主要參數(shù)。
定量化設計：建立系統(tǒng)模型，定量計算確定系統(tǒng)主要參數(shù)，尤其是支架移架時間，保證小于采煤機經過支架所花費的時間，實現(xiàn)系統(tǒng)的協(xié)調動作。
目前國內外普遍采用的方法是經驗設計，定量化設計前幾年初次提出，但沒有得到推廣使用，主要原因是需要大量的基礎工作，包括基礎數(shù)據(jù)測試、建立系統(tǒng)分析模型和軟件編制等；缺乏對系統(tǒng)負載分布規(guī)律的基礎研究，系統(tǒng)計算缺少這部分數(shù)據(jù)。研究表明，合理的系統(tǒng)參數(shù)和布置方式，不僅能降低系統(tǒng)配置成本，同時能為總體設計提供更多的選擇余地。因此，國內在支架液壓系統(tǒng)設計方面，迫切希望推行定量化設計方法。
2發(fā)展我國綜采液壓技術的途徑
鑒于國內外的技術、產品、市場等現(xiàn)狀，發(fā)展適合中國國情的綜采支架液壓系統(tǒng)和元件，需要解決的問題很多。分析表明，應從加強液壓元件基礎和關鍵技術研究入手，強調解決影響元件性能的技術瓶頸，同時借鑒國外先進技術和經驗，標本兼顧，可以加快新產品和技術研發(fā)速度。
2.1新材料應用研究
影響液壓元件壽命的材料主要是密封材料，包括“橡膠密封件”、閥口密封材料等，尤其是“橡膠密封件”。如“O ”形密封圈，國產材料硬度低，導致摩擦系數(shù)大，耐磨性差，壽命低，而千斤頂執(zhí)行元件的性能更完全取決于所采用的密封件，因此采用我國目前常用的密封件不可能完成對液壓系統(tǒng)和元件的全面更新改造，需要改進基礎材料性能。在國內，使用什么樣的材料，還沒有形成統(tǒng)一的認識，因此需要從材料的性能、加工工藝性等方面進行研究，尋找合適的更新材料，條件成熟時可制定較規(guī)范的選材標準。
2.2提高加工工藝水平
我國液壓元件工藝水平低反映了生產廠家的技術、裝備、生產管理等水平普遍較落后，除個別廠家外，所有閥的生產均由手工操作的機床完成，零部件加工質量不穩(wěn)定。目前我國閥生產廠家對材料調質處理、零件機加工表面粗糙度等質量控制不夠，尤其是對表面粗糙度對產品質量的影響認識不足，基本不檢測這個指標，因此閥零件產品與國外同類產品相比質量至少低一個等級，需要強化這個環(huán)節(jié)的質量控制。
如要短期內提高國產閥類產品的性能，應集中力量對閥類元件，尤其國際先進產品的工藝特點進行研究，首先解決影響性能的關鍵因素，注重在工藝、質量檢驗和管理幾個環(huán)節(jié)下工夫，提高技術水平，同時根據(jù)需要更新改造必要的設備。
2.3系統(tǒng)技術研究
研究范圍包括：系統(tǒng)污染控制技術、系統(tǒng)配套技術、系統(tǒng)使用特性等。為彌補硬件產品的不足，系統(tǒng)配套技術，尤其是系統(tǒng)定量化設計方法研究在我國開展較早，并取得一定成果。但由于我國綜采支架使用地質環(huán)境、配套設備等很復雜，支架型號很多，研究不同架型、不同配套關系在不同地質條件下，液壓系統(tǒng)如何配套、或液壓系統(tǒng)是否能滿足配套要求仍是有待解決的課題。初步試用表明，合理的參數(shù)配置，不僅有助于設計出高質量的系統(tǒng)，而且能降低系統(tǒng)配套成本。
系統(tǒng)污染控制技術研究包括：污染對系統(tǒng)和元件壽命、可靠性的影響；污染控制技術和設備手段；新型乳化劑的研發(fā)等。我國在這方面的研究較少，需要加強，如乳化液污染控制設備，國外已經普及“反流沖洗過濾站”用來保證工作面乳化液的清潔度，而國產設備沒有這方面的配套要求。系統(tǒng)使用特性，主要指系統(tǒng)在使用過程體現(xiàn)出的人性化特征。從使用操作者的角度出發(fā)，充分考慮系統(tǒng)布置的合理性、操作的安全便利性、維護維修效率等，設計合理的具有人性化特征的系統(tǒng)和元件，并從行業(yè)角度考慮，制定統(tǒng)一的評價規(guī)范。
2.4改善外部環(huán)境產品和技術發(fā)展的動力在于市場需求
由于經濟、技術等多方面原因，我國在該領域對先進技術、設備的認識不深刻，市場需求不旺，因此新產品的研發(fā)缺乏市場動力。
國內閥類生產企業(yè)無新產品研發(fā)能力，同時知識產權觀念淡漠，好的產品和技術往往無法有效保護，企業(yè)對新技術的投入很謹慎，積極性不大。目前有關方面正在研究制定新的液壓支架閥類元件試驗標準。新標準一定是在原有基礎上的提高，向國際標準靠攏，對技術和產品的檢驗將更加合理科學，同時將對檢驗手段提出更高的要求。對此，行業(yè)質檢中心需要根據(jù)新標準完善和改進試驗裝備，不僅是為了提高和完善傳統(tǒng)的檢驗把關的作用和能力，同時也能起到協(xié)助生產企業(yè)開發(fā)新產品、提高技術水平的作用。眾所周知，無論是技術研究，還是產品開發(fā)，國內生產企業(yè)在一定時期不可能具備這種能力，需要借助于外部的支持。外部環(huán)境直接影響該行業(yè)的技術和產品能否快速健康發(fā)展，因此需要全行業(yè)的共同努力，尤其是行業(yè)主管、監(jiān)督和研究機構等部門，加強先進技術和產品的宣傳、投入、推廣和保護工作，培植和改善環(huán)境。有旺盛的市場需求、完善的法律法規(guī)和很好的新產品研發(fā)基礎，企業(yè)自然有積極性，其他的技術問題，在當今信息化時代，解決起來就相對容易的多了。
3結束語
國內支架液壓系統(tǒng)和元件無論是理論技術還是應用產品，較國際先進水平均有很大差距，需要解決的問題很多，短期內很難實現(xiàn)。因此需要全面深刻分析這些差距存在的原因，結合實際，從多方面入手，標本兼顧，研究適合中國國情的技術和產品發(fā)展道路。本文只是羅列和初步分析了這方面存在的問題和初步設想，更深入細致的工作需要專題研究，以便從整個行業(yè)高度制訂長期的、全面的科技發(fā)展計劃。
附錄B 外文文獻
The development and the forecast of the support hydraulic control technology in the universal mining
While “the high production is highly effective” the mining coal processing technology promoted use, support's function except the traditional significance “, protects, moves” beside, the support “the speed” this performance picks the working surface efficiency to the synthesis the influence to be day by day remarkable, mainly displays in two aspects: Puts goes against the coal support to be able to assist mines coal; Moves to a speed to affect the working surface advancement speed, affects the mining coal efficiency. Other factors, like reliable, system's maintainability as well as correlation technique and so on direct relation system's operation percentage. Therefore “the high production was highly effective” the mining coal craft promotion initial period proposed to the hydraulic system and part's discharge characteristic requested very high, the necessary support's movement must meet the entire mining coal system overall needs, later period set the request to the system and part's overall performance. Our country synthesis picks the support hydraulic system and the part along with the mining coal technology development, compared with last century 80~ the 90s had the considerable progress, basic could meet the needs, but compared with the overseas similar sophisticated equipment, the disparity was obvious. This article from technical angle multianalysis this kind of disparity and the existence reason, makes every effort to explore develops our country related product technical way and the research direction, speeds up step which the technological development and the product renew.
1 Domestic outer support hydraulic system and part's difference
1.1 Control mode different home: Hand control. Artificial hand hydraulic support each hoisting jack's movement. overseas: Battery solution control. With the computer, the sensor control solenoid valve's movement, thus control support movement. the control mode's difference, indicated that our country synthesis picks the technical equip and the international advanced level compares has the overall disparity. Control mode's difference, its basic reason is our country foundation manufacturing industry level and the advanced countries compares has the disparity, is more obvious in electrically controlled system part this kind of disparity. At present the domestic use's battery solution control system main dependence import, the related home equipment is in the experiment or the research and development stage.
1.2 Valve class part performance comparison
The hydraulic system valve class part mainly divides into: Control valve, cone-way valve, safety valve and auxiliary element. Through the domestic and foreign similar products' comparison, may see the domestic and foreign valve class product performance disparity is obvious: Domestic product's service life about 6000 times, the international advanced level similar products achieves 30000 times, is domestic 5 times; The home selects the material continues to use traditional the ordinary steel products, uses methods and so on galvanization, nickel plating to carry on the rust prevention antiseptic treatment, the effect is lower than the non-corrosive material by far (stainless steel, copper alloy, ceramics and so on), two targets, have reflected home equipment's reliable international advanced level existence disparity in light of this. Valve's discharge characteristic, was the necessary first choice target, the domestically produced cone-way valve and control valve's maximum current capacity has achieved the international advanced level; Withing certain amount of time, the manual operation will be the fundamental mode which our country hydraulic support controls, but is not the battery solution control system; The supplementary equipment technical level cannot meet the needs, like the domestically produced pumping station's pressure is generally low, the related pipeline auxiliary quality not to be unstable, the efficiency is low. Based on this must enhance the entire necessary hydraulic system performance, enhances the control valve and cone-way valve's current capacity is inevitable, is also relatively easy.
On the other hand, enhances the safety valve (uses in hydraulic support specially) the current capacity is a worldwide basis difficult problem, and safety valve's performance is right “the high production is highly effective” the influence not to be obvious, its actual efficiency is also very difficult with the concrete target to prove, therefore our country related product's development speed is lower than other valve class product obviously, is bigger with the international advanced level disparity.
1.3 System and part's use maintenance performance
The synthesis picks the technological development a tendency is the working surface length is increasing unceasingly. The working surface lengthen, the support hydraulic system length increases along with it, the system is complex, part quantity also becomes the proportion to increase. In addition the underground mining coal condition is bad, the part presents the breakdown is very normal, maintains, the service is one of mining coal work routine work. At present our country support valve class product's design mentality is also in the overseas the 80s level, often has neglected the product maintenance service performance, but the overseas similar products have more user-friendly characteristics, consideration installment, operation use convenience.
At present internationally the advanced design idea is uses inserts installs the type structure. Its characteristic is the hydraulic element assembles alone beforehand, debugs, is only the replacement presents the breakdown in the use process's service the part, but does not need to act the entire valve group. Its merit is very obvious: The efficiency is high, reduces the system the probability which pollutes, thus cuts the failure rate.
1.4 System medium, to pollution control
The home uses 200 item of about the ordinary filter to carry on the filtration generally to the system medium. The support hydraulic system medium is the emulsion, is made by the water and the emulsifier according to the certain proportion mix. Home production's emulsifier take the industrial oil as the primary data, achieves above generally 5% with the water proportion. This kind of emulsion itself will produce certain settling to pollute the system. At present the international very good emulsifier including the mineral oil ingredient, does not meet the environmental protection requirement nearly, with the water proportion is only 1%~2%.
1.5 System design way
Hydraulic system's main project work is in valve's choice, the support the pipeline arrangement, the working surface pipeline arrangement, the pumping station parameter determination. The design method mainly has two kinds: Empirical design and quantitative design. empirical design: Refers to the existing hydraulic support hydraulic system, the experience determines the system main parameter. quantifying design: Establishes the system model, the quantitative evaluation determination system main parameter, particularly the support moves to a time, guaranteed that is smaller than the coal mining machine the time which spends after the support, realizes system's synchronized action. present domestic and foreign uses generally the method is the empirical design, quantifying designs most recent several years first to propose, but has not obtained the promoted use, the primary cause needs the massive foundation work, including essential data test, establishment system analysis model and software establishment and so on; Lacks to the system load distribution rule basic research, the system computation lacks this part of data. The research indicated that reasonable system parameters and arrangement way, not can only reduce the system disposition cost, simultaneously can provide the more choice leeway for the system design. Therefore, the home in the support hydraulic system design aspect, earnestly hopes the carrying out quantifying design method..
2 Develops our country synthesis to pick the hydraulic technique the way
In view of the fact that domestic and foreign present situations and so on technologies, product, market, the development suits the Chinese national condition the synthesis to pick the support hydraulic system and the part, needs to solve the question are many. The analysis indicated that should from strengthen the hydraulic element foundation and the key technologies research obtains, to stress the solution influence part performance the technical bottleneck, simultaneously profits from the overseas vanguard technology and the experience, the specimen proper attention to both, may speed up the new product and the technical research and development speed.
2.1 New material applied research
The influence hydraulic element life's material is mainly the packing material, including “rubber seal”, valve port packing material and so on, particularly “rubber seal”. Like “O” the shape seal packing collar, homemade materials degree of hardness is low, causes the friction coefficient to be big, the resistance to wear is bad, the life is low, but the hoisting jack functional element's performance is decided completely by the seal which uses, therefore uses our country present commonly used seal not to be impossible to complete to the hydraulic system and part's comprehensive renewal transformation, needs to improve the foundation material performance. In the home, what material uses, has not formed the unified understanding, therefore needs from aspects and so on material performance, processing technology capability to conduct the research, seeks for the appropriate renewal material, when the conditions are ripe may formulate the standard selection standard.
2.2 Raises the processing technological level
Our country hydraulic element technological level had reflected lowly levels and so on Manufacturer's technology, equipment, production management are generally backward, besides the individual factory, all valve's production completes by manual operation's engine bed, the spare part processing quality is unstable. At present our country valve Manufacturer to material quality control and so on quenching and retempering treatment, components machining surface roughness is insufficient, particularly to the surface roughness to product quality's influence understanding insufficiency, basic does not examine this target, therefore the valve components product and the overseas similar products compare the quality to lower a rank at least, needs to strengthen this link's quality control. like wants in the short-term to enhance the domestically produced valve class product the performance, should the concentrate efforts to the valve class part, the especially international advanced product's craft characteristic conducts the research, first solves the influence performance key aspect, pays great attention in the craft, the performance test and manages several links to work hard, raises the technical level, simultaneously according to needs to renew the transformation essential equipment.
2.3 System technology research
The range of study includes: System contamination control technology, systems assembly technology, system operating characteristic and so on. In order to make up the hardware product the insufficiency, the systems assembly technology, the system quantifying design method research develops particularly in our country early, and makes certain progress. But because our country synthesis picks the support use geological environment, the supplementary equipment and so on to be very complex, the support model are many, research different frame, different necessary relations under different geological condition, hydraulic system how necessary, or hydraulic system whether can satisfy the topic which the necessary request was still waits for solving. The preliminary test indicated that reasonable parameter disposition, is not only helpful in designs the high grade system, moreover can reduce the systems assembly cost. the system contamination control engineering research includes: Pollution to system and component life, reliable influence; Contamination control technology and equipment method; New emulsifier research and development and so on. Our country are few in this aspect's research, needs to strengthen, if the emulsion contamination control equipment, overseas already popularized “the regurgitation flushing filtration station” to use for to guarantee the working surface emulsion the cleanliness, but home equipment not this aspect necessary request. The system operating characteristic, mainly refers to the system the user-friendly characteristic which manifests in the use process. From uses operator's angle embarking, considered fully the system arrangement the rationality, the operation security convenience, the maintenance service efficiency and so on, the rational design has the user-friendly characteristic system and the part, and considered from the profession angle, formulates the unified appraisal standard.
2.4 Improves the external environment product and the technological development power lies in the market demand
Because the economy, the technology and so on various reason, our country in this domain to the vanguard technology, equipment's understanding is not profound, the market demand is not prosperous, therefore the new product's research and development lack the market power. domestic valve class Production enterprise not new product research and development ability, the intellectual property rights idea is simultaneously faint, the good product and the technology are often unable to protect effectively, the enterprise is very discrete to the new technology's investment, the enthusiasm is not big. At present the parties concerned are studying formulate the new hydraulic support valve class part experiment standard. The new standard certainly is in the original foundation enhancement, to the international standard stem for stem, to technical and the product examination a more reasonable science, simultaneously to will examine the method to set a higher request. Regarding this, the profession quality testing center needs according to the new standard consummation and the improvement experiment equipment, not only to enhance and consummate traditional the examination check role and ability, simultaneously can also play assists the Production enterprise to develop the new product, to raise the technical level the function. It is well known, regardless of being the engineering research, the product development, the home production enterprise is impossible in certain time to have this kind of ability, needs to draw support the exterior support. External environment immediate influence this profession technology and product whether fast healthy development, therefore needs the entire profession the joint effort, particularly departments and so on profession manager, inspector general and development facility, strengthen the vanguard technology and the product propaganda, the investment, the promotion and the protection work, the cultivation and the environmental enhancement. Has the exuberant market demand, the consummation laws and regulations and the very good new product research and development foundation, the enterprise has the enthusiasm naturally, other technical question, in the informationization time, solves now relatively easily to be many.
3 Concluding remark
Domestic support hydraulic system and part, regardless of being the theory technology or using the product, the international advanced water has the very big disparity equally, needs to solve the question are many, in the short-term is very difficult to realize. Therefore needs the comprehensive to analyze these disparity existence the reason, the union reality, from obtains variously, the specimen proper attention to both, the resear