本文關(guān)鍵詞： 采煤機(jī) 截割系統(tǒng) 可靠性分析 截割系統(tǒng)動力學(xué) 截割系統(tǒng)殼體　出處：《中國礦業(yè)大學(xué)》2015年博士論文　論文類型：學(xué)位論文

【摘要】：采煤機(jī)截割傳動系統(tǒng)是采煤機(jī)完成綜采任務(wù)的重要部件,其維護(hù)工作已成為采煤機(jī)維護(hù)工作的重中之重。隨著綜采工作面開采技術(shù)的要求越來越嚴(yán)格,人們對采煤機(jī)的質(zhì)量要求越來越高,對采煤機(jī)截割傳動系統(tǒng)的性能要求也越來越高,因此對采煤機(jī)截割傳動系統(tǒng)的設(shè)計(jì)變得越來越重要�？煽啃詿o疑是采煤機(jī)截割傳動系統(tǒng)設(shè)計(jì)中的關(guān)鍵因素,因此通過對截割傳動系統(tǒng)進(jìn)行全面的可靠性評價分析,可以有效的控制故障的發(fā)生概率,提高采煤機(jī)截割傳動系統(tǒng)可靠性。同時對采煤機(jī)可靠性分析,為采煤機(jī)故障的自診斷、預(yù)測、和自修復(fù)提供基礎(chǔ),對自動化智能采煤工作面的發(fā)展提供條件。論文針對需要降低采煤機(jī)截割傳動系統(tǒng)運(yùn)行風(fēng)險的要求,提出了一套應(yīng)用于采煤機(jī)截割傳動系統(tǒng)的可靠性分析體系,并運(yùn)用其對采煤機(jī)截割傳動系統(tǒng)進(jìn)行了可靠性應(yīng)用分析。主要研究內(nèi)容如下:(1)通過對采煤機(jī)的截割傳動系統(tǒng)進(jìn)行結(jié)構(gòu)和功能原理分析,建立了采煤機(jī)截割傳動系統(tǒng)的可靠性分析模型,并且基于相關(guān)可靠性分析標(biāo)準(zhǔn),制定可靠性分析約定層次和分析流程,進(jìn)而基于FMEA(故障模式影響分析)可靠性分析方法對采煤機(jī)截割傳動系統(tǒng)進(jìn)行了可靠性分析,建立了采煤機(jī)截割傳動系統(tǒng)的故障模式庫,并生成了分析報告。(2)在對比分析FMECA(故障模式影響及危害性分析)和FTA(故障樹分析)兩種可靠性分析方法的基礎(chǔ)上,充分利用兩種分析的方法的優(yōu)點(diǎn)提出了將FMECA和FTA結(jié)合的FTF可靠性綜合分析方法,并對正向、逆向FTF分析作比較分析。論文利用正向FTF分析方法,先對采煤機(jī)截割傳動系統(tǒng)進(jìn)行FMECA分析,根據(jù)分析的結(jié)果選擇I、II類的事件中RPN值和危害度值排序較高的事件作為頂事件進(jìn)行FTA分析,得到了故障發(fā)生原因組合以及危害重要度,進(jìn)行優(yōu)先排序得到了截割傳動系統(tǒng)健康狀態(tài)評價參數(shù),提出了系統(tǒng)薄弱環(huán)節(jié)的改進(jìn)措施。(3)齒輪故障可以通過齒輪嚙合動力學(xué)參數(shù)表現(xiàn)出來,特別地,齒輪嚙合剛度和輪齒嚙合力對齒輪系統(tǒng)的故障比較敏感,所以研究齒輪動力學(xué)嚙合參數(shù)是對齒輪系統(tǒng)進(jìn)行精準(zhǔn)故障診斷的基礎(chǔ)�；诓牧狭W(xué)原理和能量原理建立了求解齒輪時變嚙合剛度的理論模型,進(jìn)一步建立了具有非等齒寬裂紋的齒輪時變嚙合剛度理論模型模型�；诮馗顐鲃酉到y(tǒng)高速區(qū)是齒輪故障高發(fā)區(qū),建立高速區(qū)齒輪9自由度動力學(xué)模型,基于此模型研究了高速區(qū)齒輪動態(tài)特性、沖擊載荷對齒輪動態(tài)特性的影響,以及不同裂紋損傷程度對系統(tǒng)動態(tài)特性的影響,結(jié)果表明齒輪系統(tǒng)的損傷存在可通過時域信號分析診斷。(4)針對煤礦井下強(qiáng)噪聲背景影響,及齒輪傳動產(chǎn)生的非線性、非平穩(wěn)振動信號,基于多傳感器信息融合建立故障診斷模型,利用小波相關(guān)特征尺度熵提取故障特征信息,SOM神經(jīng)網(wǎng)絡(luò)進(jìn)行單傳感器識別,最后利用D-S證據(jù)理論進(jìn)行多傳感器融合診斷。解決了強(qiáng)噪聲背景下準(zhǔn)確識別故障類型,消除識別不確定等關(guān)鍵問題。(5)通過ANSYS對截割系統(tǒng)殼體的有限元分析,找到了截割系統(tǒng)殼體結(jié)構(gòu)的主要應(yīng)力集中部位,合理優(yōu)化加強(qiáng)筋結(jié)構(gòu),從而提高了截割系統(tǒng)殼體的設(shè)計(jì)可靠性�；谔胤N鑄鋼材料的提高采煤機(jī)截割系統(tǒng)殼體綜合機(jī)械強(qiáng)度的研究,設(shè)計(jì)采煤機(jī)截割系統(tǒng)殼體合理和穩(wěn)定的鑄造工藝,根據(jù)鑄件力學(xué)性能需要和金屬液的充型能力選材和確定成分,有利于降低鑄造難度,鑄造出鑄件健全和綜合機(jī)械性能較高的大功率截割系統(tǒng)殼體。殼體驗(yàn)收檢驗(yàn)表明,殼體加工路線安排和機(jī)加工工藝設(shè)計(jì)滿足加工精度要求。在井下工業(yè)應(yīng)用期間,截割系統(tǒng)殼體使用性能保持良好狀態(tài),殼體綜合力學(xué)性能滿足大功率采煤機(jī)使用要求。(6)通過分析截割傳動系統(tǒng)高低速密封件的密封機(jī)理以及目前使用中存在的問題,研制了浮動油封試驗(yàn)裝置,并根據(jù)試驗(yàn)裝置和截割系統(tǒng)加載試驗(yàn)對不同廠家的密封件性能進(jìn)行了對比,篩選出了產(chǎn)品性能優(yōu)越的密封件和最佳裝配間隙,提出了改進(jìn)截割傳動系統(tǒng)高低速密封可靠性的措施和密封件損壞檢測方法及維護(hù)措施。文章最后對論文的工作進(jìn)行了總結(jié),并對相關(guān)的研究技術(shù)進(jìn)行了展望。
[Abstract]:Shearer cutting drive system is an important part of coal mining machine to complete the mining task, the maintenance work has become a priority among priorities of shearer maintenance work. With the mining technology of fully mechanized mining face of the increasingly stringent requirements, people on the quality of the coal mining machine is more and more high, the performance of shearer cutting drive system requirements more and more is also high, so the design of shearer cutting drive system becomes more and more important. The reliability is the key factors in the design of shearer cutting drive system, so the cutting drive system to conduct a comprehensive evaluation of the reliability analysis, the probability of failure can be controlled effectively, improve the shearer the reliability of transmission system. At the same time analysis of shearer reliability prediction, self diagnosis, fault shearer, and provide the basis for self repair, provide conditions for the development of the automatic intelligent coal face theory. Aiming at the need to reduce the shearer running risk transmission system requirements, proposed a set of application in system reliability analysis of shearer cutting drive system, and the use of the shearer cutting drive system for the application of reliability analysis. The main contents are as follows: (1) analyze the structure and function of the principle of shearer cutting drive system, established reliability analysis model of shearer cutting drive system, and analyze the related standard based on reliability, reliability analysis and hierarchical analysis to develop contract process, on the basis of FMEA (failure mode and effect analysis) of the reliability analysis method of reliability analysis of shearer cutting drive system, fault pattern library the establishment of the shearer cutting drive system, and generate analysis report. (2) in the comparative analysis of FMECA (failure mode effects and criticality analysis) and FTA (fault tree Two) analysis method of reliability analysis, taking full advantage of two methods for the analysis of the comprehensive reliability analysis of FTF method FMECA and FTA combination, and the positive and reverse FTF analysis were compared and analyzed. The positive analysis method of FTF, the first FMECA analysis of transmission system of shearer. According to the results of the analysis I, and criticality values higher ranking events as the top event was analyzed by FTA RPN II value in the event of the failure reason and harm of combination of importance, prioritize the health status evaluation of cutting parameters of transmission system, the improvement measures are put forward. (the weak links of the system 3) gear fault by gear meshing dynamic parameters show, in particular, the gear meshing stiffness and meshing forces of the gear system fault is more sensitive, so the research of gear meshing dynamics The parameter is the basis for the accurate fault diagnosis of gear system. The principle of material mechanics and energy based on the principle of solving gear established theoretical model of time-varying stiffness meshing, further established with non equal tooth width of crack gear time-varying stiffness model meshing theory model. High speed cutting drive system based on region is a high incidence of gear fault the establishment of high speed gear, 9 degree of freedom dynamics model, based on this model to study the dynamic characteristics of high speed gear, impact load on the dynamic characteristics of gear, and different crack damage degree of the effect on system dynamic property, results show that the gear system can damage diagnosis by time-domain signal. (4) because of the influence of coal mine under the strong background noise, nonlinear and gear transmission the nonstationary vibration signal, multi sensor information fusion based fault diagnosis model based on using small wave. Sign scale entropy for fault feature extraction, SOM neural network for single sensor, finally using D-S evidence theory to fuse multi-sensor diagnosis. It solved the strong background noise to accurately identify the fault types, eliminate the identification of key issues of uncertainty. (5) by using ANSYS finite element analysis of the shell of the cutting system, find the section the cutting system shell structure of the main stress concentration position, optimize rib structure, thus improves the reliability of the design and cutting system of housing. Housing research comprehensive mechanical strength cutting special steel material to improve the system of Shearer Based on casting process design of shearer cutting system shell is reasonable and stable, according to the filling ability the mechanical properties of castings and metal material to liquid and determine the composition, to reduce the difficulty of casting, casting and casting and improve the comprehensive mechanical properties of high power cutting system The shell shell. Acceptance test shows that the design process of shell processing route arrangement and meet the requirements of precision machining. During the underground industrial application, cut cut system to maintain a good state of housing performance, comprehensive mechanical properties can meet the shell of large power shearer requirements. (6) transmission system of high speed sealing mechanism and problems there are currently used in cutting through the analysis section, the development of floating seal test device, and compared according to the seal performance of different test device and cutting system loading test, screened the best seal and assembly clearance of superior product performance, put forward the improvement of cutting drive system of high speed sealing reliability measure and seal damage detection method and maintenance measures. Finally, the research work was summarized, and the related research technology was prospected.

【學(xué)位授予單位】：中國礦業(yè)大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2015
【分類號】：TD421.6

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