采煤机短链传动的变速截割部可靠性研究.pdf

工程硕士专业学位论文 采煤机短链传动的变速截割部可靠性研究 Research on Reliability of Variable-Speed Cutting Section with Short Chain Transmission of Shearer 作 者邱教娟 导 师葛世荣 教授 中国矿业大学 二〇一九年五月 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 中图分类号 TD421 学校代码 10290 UDC 621 密 级 公开 中国矿业大学 工程硕士专业学位论文 采煤机短链传动的变速截割部可靠性研究 Research on Reliability of Variable-Speed Cutting Section with Short Chain Transmission of Shearer 作 者 邱教娟 导 师 葛世荣 申请学位 工程硕士专业学位 培养单位 机电工程学院 学科专业 机械工程 研究方向 矿山机械 答辩委员会主席 李艾民 评 阅 人 二〇一九年五月 万方数据 致谢致谢 两年硕士研究生学习生活转眼即逝，在这两年中，无论是生活还是学习都让我受益匪 浅， 在此， 特向所有在学习与生活上关心、 帮助与支持我的人们致以最真挚的谢意与祝福。 特别感谢我的导师葛世荣教授和王世博教授，本研究和学位论文是在他们的悉心指导 下完成的。感谢两位导师在论文选题时为我点拨和解惑，感谢两位导师在我研究过程中给 我支持和指导，感谢两位导师对我论文的提炼和修改。他们敏锐的洞察力和渊博的学识， 让我在研究的路上少走弯路；他们严谨的治学态度和精益求精的工作作风，让我在研究中 不敢有一丝懈怠。感谢刘万里老师在学习上对我的帮助，感谢我的校外导师郝尚清高级工 程师在专业实践中为我提供实践学习的场地、资源等，使我有机会进行系统的专业实践， 这一切让我获益匪浅。 特别感谢实验室博士师兄李雪峰、杨恩、王世佳、曹波等在学术方面对我的指导；感 谢硕士师兄张博渊、张务果和田野等给我传授经验、指点迷津；感谢 18 级师弟师妹们为我 充实的科研生活平添一缕青春和欢快；感谢 17 级朝夕相处的小伙伴孔维、张辉、向阳、舒 子龙、刘旭、鲁程、孟庆丰、王子超，你们的帮助和关怀，让我受益良多，袍泽之谊，我 将终生难忘；感谢我的研究生舍友孔维，你的包容和理解，让我在宿舍里也能感受家的温 暖；最后感谢赵旭同学、王凯旋同学、邱文强师兄在科研上对我的帮助。 感谢中国矿业大学为我提供良好的生活与学习环境，为我提供了一个广阔的学习平台， 让我能够不断的汲取新知识，充实自己。 感谢我的父母、兄长和姐姐，感谢父母在这二十多年为我提供衣食无忧的生活以及无 微不至的关心，让我能够在求学的路上坚定不移地走下去。感谢我的兄长，在我求学路上 为我挑灯指路。感谢我的姐姐对我生活的关心。在二十余年的求学生活中，感谢他们在我 背后的支持，使我成功地度过一次又一次的逆境，让我的精神变得更加强大，他们为我的 成长倾注了太多的心血，我每次的进步与成功都包含着他们无私的关爱，感谢我的家人为 我所做的一切。 谨以此文献给所有关心和帮助过我的人，祝福我的师长、朋友、家人身体健康及生活 愉快。 最后非常感谢在百忙之中抽出时间评阅论文和参加答辩的各位专家和评委们。 万方数据 I 摘摘 要要 地质条件、煤岩属性多变，使得采煤机截割部负载具有重载强冲击特点，极 易导致截割部驱动系统发生故障。本文以 MG250/601-WD 电牵引采煤机截割部 为基础，设计一种采煤机截割部新型的短链传动系统，旨在改善截割部的性能， 提高系统的可靠性。主要研究工作和结论如下 （1）根据某矿区故障数据，得出采煤机截割部故障的类型。通过分析传统 采煤机截割部的传动系统， 针对其中故障多发的三相异步电动机和齿轮传动进行 深入研究，最终设计了新型的采煤机短链传动系统。设计了 NGW 减速器和齿形 链传动，并进行强度校核，接着对永磁同步电机和变频器进行选型。短链传动从 源头降低转速，减少齿轮的啮合频率，提高齿轮的使用寿命。在 SOLIDWORKS 中建立齿形链传动系统几何模型，截取其中 5 节齿形链，利用有限元分析软件 WORKBENCH 进行处理并仿真，得到应力云图，验证齿形链材料选择和结构设 计满足强度要求，并找到设计中薄弱环节，为加工制造提供理论依据。 （2）通过对两种系统建立故障树，找到导致故障发生的所有故障模式，通 过最小割集对两种系统进行定性分析，结果表明短链传动系统最小割集的数目 比现有传动系统减少 12 个，减速器底事件由 22 个减少到 16 个，短链传动系统 可靠性更高。用可靠性预测的方法，分别求出两种系统截割电机和减速箱传动系 统的基本失效率。结果表明采煤机截割部电机失效率远低于传动系统失效率， 短链传动系统的截割电机和减速箱失效率低于现有系统。从可靠性的角度分析， 用短链传动系统代替现有的齿轮传动系统应用到采煤机上是切实可行的， 而且达 到了预期的效果，在相同条件下可靠度增加了 23.48，具有较好的应用前景。 （3）对短链传动系统应用三维实体建模软件 SOLIDWORKS 建立正确的几 何模型， 然后联合 ADAMS 建立采煤机截割部的刚体模型， 对导入模型进行前处 理、添加约束、接触和负载。联合 MATLAB 和 ADAMS 建立 3 种工况下的随机 负载曲线，并仿真短链传动系统在不同负载情况下链节的运动轨迹、从动链轮角 速度变化和齿形链系统瞬时传动比。分析表明随着负载的增加，运动轨迹无明 显变化，基本按照设计轨迹运行；输出角速度的波动量和瞬时传动比误差随之增 加， 但是在合理范围之内； 短链传动系统在三种工况下， 都具有良好的动态特性， 短链传动系统可以与 3m/min、4m/min、5m/min 的牵引速度配合工作，提高采煤 机的工作效率。 该论文有图 60 幅，表 11 个，参考文献 98 篇。 关键关键词词采煤机截割部；短链传动；齿轮传动；可靠性 万方数据 II Abstract The geological conditions and the properties of coal and rock are changeable, which makes the load of the cutting part of the shearer have the characteristics of heavy load and strong impact. This can easily lead to failure of the cutting drive system. Based on the cutting section of MG250/601-WD electric haulage shearer, this paper designs according to the cutting section of a new type of gear-chain transmission shearer proposed by Professor Ge Shirong, aiming at improving the perance of the cutting section and improving the system. Reliability. Mainly carry out the following research work 1 According to the fault data of a mining area, the type of fault of the cutting part of the shearer is obtained. The shearer short-chain transmission system is designed for multi-fault three-phase asynchronous motor and gear transmission. The permanent magnet synchronous motor and frequency converter are designed and designed, and the NGW reducer and the slient chain drive are designed and the strength check is pered. The short-chain drive reduces the speed from the source, reduces the meshing frequency of the gears, and increases the service life of the gears. In the SOLIDWORKS, the geometric model of the non-standard slient chain drive system is established, and the five silent chains are intercepted. The soft-work WORKBENCH is used to process and simulate the stress cloud image to verify the material selection and structural design of the slient chain to meet the strength requirements. Find weaknesses and provide a basis for manufacturing. 2 By establishing a fault tree for the two systems, it is possible to clearly find out all the fault modes that caused the fault, and qualitatively analyze the two systems by solving the minimum cut set. The results show that the number of minimum cut sets of the short-chain drive system Compared with the existing transmission system, the number of deceleration parts is reduced from 22 to 16 and the short-chain transmission system is more reliable. The basic failure rate of the two system cutting motor and gearbox transmission system is obtained by the reliability prediction . The results show that the motor failure rate of the shearer cutting section is much lower than that of the transmission system. The failure rate of the cutting motor and the reduction gearbox of the short-chain transmission system is lower than that of the existing system. From the perspective of reliability, it is feasible to apply the existing transmission system with short-chain transmission system instead of pure gear transmission to the 万方数据 III shearer, and achieve the expected effect. The reliability is increased by 23.48, which has a good application. prospect. 3 Apply the 3D solid modeling software SOLIDWORKS to the two systems to establish the correct geometric model, then combine the ADAMS to establish the rigid body model of the shearer cutting section, pre-process the imported model, and add constraints, contacts and loads. Combining MATLAB and ADAMS to establish the random load curve under three working conditions, and simulating the trajectory of the chain link, the angular velocity of the driven sprocket and the instantaneous gear ratio of the slient chain system under different load conditions. The analysis shows the analysis shows that the motion trajectory does not change significantly with the increase of the load, and basically runs according to the design trajectory; the fluctuation of the output angular velocity and the instantaneous transmission ratio error increase, but within a reasonable range. The short-chain transmission system has good motion characteristics under three working conditions. The short-chain transmission system can work with the traction speed of 3m/min, 4m/min and 5m/min to improve the working efficiency. Keywords shearer cutting section; short chain drive; gear transmission; reliability 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........................................................................................................................ XII 变量注释表变量注释表 ............................................................................................................. XIII 1 绪论绪论............................................................................................................................. 1 1.1 课题研究来源、背景和意义 .................................................................................. 1 1.2 双滚筒采煤机简介 .................................................................................................. 3 1.3 截割部结构研究现状 .............................................................................................. 4 1.4 传动系统可靠性及动态特性研究现状 .................................................................. 7 1.5 存在的问题 .............................................................................................................. 9 1.6 主要研究内容 .......................................................................................................... 9 2 截割部短链传动系统设计截割部短链传动系统设计 ...................................................................................... 11 2.1 采煤机截割部故障现状分析 ................................................................................ 11 2.2 MG250/601-WD 型电牵引采煤机 ....................................................................... 13 2.3 采煤机短链传动变速截割部设计 ....................................................................... 14 2.4 齿形链的有限元分析 ........................................................................................... 24 2.5 截割部设计的优点 ................................................................................................ 28 2.6 本章小结 ................................................................................................................ 29 3 基于基于 FTA 的采煤机截割部可靠性分析的采煤机截割部可靠性分析 ................................................................ 30 3.1 故障树分析简介 .................................................................................................... 30 3.2 采煤机截割部可靠性框图的建立 ........................................................................ 32 3.3 采煤机截割部传动系统定性分析 ........................................................................ 35 3.4 采煤机截割部传动系统的定量分析 .................................................................... 40 3.5 本章小结 ................................................................................................................ 42 4 短链传动系统运行状态分析短链传动系统运行状态分析 .................................................................................. 44 4.1 采煤机截割部三维模型的建立 ............................................................................ 44 4.2 基于 ADAMS/view 采煤机截割部刚体模型的建立 .......................................... 48 4.3 负载的确立 ............................................................................................................ 54 万方数据 V 4.4 仿真结果 ................................................................................................................ 56 4.5 本章小结 ................................................................................................................ 60 5 结论结论........................................................................................................................... 61 参考文献参考文献 ..................................................................................................................... 62 作者简历作者简历 ..................................................................................................................... 68 论文原创性声明论文原创性声明 ......................................................................................................... 69 学位论文数据集学位论文数据集 ......................................................................................................... 70 万方数据 VI Contents Abstract ........................................................................................................................ II Contents ..................................................................................................................... VI List of Figure .......................................................................................................... VIII List of Table .............................................................................................................. XII Variable Comments Table .................................................................................... XIII 1 Introduction ............................................................................................................... 1 1.1 Origin、Background and Significance of Subject .................................................. 1 1.2 Introduction of Shearer with Double Drum ............................................................. 3 1.3 Research Status of Cutting Department Structure ................................................... 4 1.4 Research Status of Transmission System Reliability and Dynamic Characteristics 7 1.5 Problem .................................................................................................................... 9 1.6 Main Research Content ............................................................................................ 9 2 Cutting Section of Short Transmission Chain System Design ............................ 11 2.1 Analysis of the Current Situation of the Cutting Part of the Shearer ..................... 11 2.2 MG250/601-WD Electric Traction Shearer ........................................................... 13 2.3 Design of Variable Speed Cutting Part of Shearer Short Chain Transmission ...... 14 2.4 Finite Element Analysis of Silent Chain ................................................................ 24 2.5 Advantages of the Cutting Section Design ............................................................ 28 2.6 Summaries .............................................................................................................. 29 3 Reliability Analysis of Shearer Cutting Section Based on FTA .......................... 30 3.1 Mechanical Reliability Research .............................................................. 30 3.2 Establishment of Reliability Block Diagram of Shearer Cutting Department ....... 32 3.3 Establishment of Fault Tree ................................................................................... 35 3.4 Quantitative Analysis of Transmission System of Shearer Cutting Section .......... 40 3.5 Summaries .............................................................................................................. 42 4 Analysis of Operating Status of Short Chain Transmission System .................. 44 4.1 Establishment of 3D Model of Shearer Cutting Department ................................. 44 4.2 Establishment of Rigid Body Model Based on ADAMS/view Shearer Cutting Section .......................................................................................................................... 48 万方数据 VII 4.3 Establishment of Load ........................................................................................... 54 4.4 Simulation Results ................................................................................................. 56 4.5 Summaries .............................................................................................................. 60 5 Conclusions .............................................................................................................. 61 Reference..................................