悬臂式半煤岩掘进机总体及截割部设计
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英文原文
Discussion on key technology
of mine boom type heavy roadheade
[Abstract]:The paperproposed the key technological issues of the hard rock cutting for themine boom type heavy roadheader. In combined with the research and developmentof the EBZ300TY mine heavy roadheader, the paperdiscussed the technicalmeasuresmade. Accordingto the certain geological conditions of the client, the proposed the alternatives on the rationalmatching of theworking parameters, the cut-ter improvementdesign direction, the selected type cutting head, the stabilization and layout of the roadheader, the development of thekey parts, the orientation position, the face cross sectionmonitoring and others.
[Key words]:mine heavy roadheader; hard rock cutting; key technology
Cantilevered boring machines have made express from 1960s during the 20th century inChina, with continued research, testing and improvement in recent 50 years, the performance of machine has increased: cutting power range from 50kW to 220 kW, from light to heavy-duty models of the more than 20 kinds of products, in the coal mine coal and semi-mechanized coal-rock tunnel boring widely used in China in recent years to meet the basic the rapid development of the coal industry needs. Along with the mine working face size and the continuous improvement of production, the modernization of a large number of million-ton mine-building, especially the construction of new wells in the rock to open up the roadway, on whole-rock boring machine demand increases every year, its technical capabilities and requirements for continuing raised.
The development of cutting power reaches 300 kW, the machine to adapt to the quality of over 100t roadway section 30 ~ 50 m2, cutting of rock uniaxial compressive strength reached 120MPa heavy hard rock boring machine, it is in growing demand and rapid advancement of technology boring machine made under the premise. With the development of the past 50 years compared to the boring machine, it is not a simple local improvement, nor is it a successful model of the past, zoom in or out, boring machine technology but a far-reaching changes in many aspects. This is because some of its key technologies will be applied to other products on the boring machine, boring machine and then bring the whole technology industry. The following boring machine at home and abroad according to the present developments and the development experience of heavy hard rock boring machine for cutting the key technologies are discussed.
Cutting capacity 1
Cutting capacity is heavy hard rock boring machine restricted the use of the most important factor in the development of heavy-duty boring machine at the heart of the level of their ability are usually measured by three indicators, namely, tooth loss cut-off rate (to / m3), production capacity (m3 / h) and cutting energy consumption than the (kW • h/m3), which cut the rate of tooth loss is more decisive role. Cutting in hard rock boring machine, if the hardness of rock, or grinding teeth of a strong lead to the actual loss rate cut more than 1 / m3, then they would pick as a result of consumption of high cost and frequent replacement of the cutter and machine vibration increased increase in maintenance costs compared with the drilling and blasting method becomes uneconomical. Therefore, heavy boring machine's ability to adapt to cutting hard rock cutting is essential, for this body of work needs to choose the parameters, the type of cutting head and cutting tool, such as an in-depth study.
1 • 1 operating parameters of a reasonable match with the performance prediction
Cutting in the process, and one of the most important parameter is the most basic cutting thickness (coal cutter rock cutting depth), and the rock cutting nature of the cutting is not suitable thickness will reduce cutting efficiency and Pick of the wear and tear, resulting in more dust. Different cut-off in the rock structure, the formation of different mechanical properties. Because of the specificity of cutting hard rock, hard rock boring machine during the design, user-specific nature of the geological conditions of rock parameters for the selection and matching of heavy hard rock boring machine is designed to correct the premise. In the different rock types, such as strength, abrasion, and rock types, such as cutting tests conducted on the basis of the combination of dedicated design software for cutting optimization of operating parameters of the design, hard-rock boring machine is cutting to achieve high performance the only way .
In addition, the design parameters for performance prediction of the success of the use of boring machine is an important factor. According to research institutions abroad, the research results [2], can be forecast according to certain formula for the cut-off rate of tooth loss and to predict cutting capacity. Will be by way of cutting the rock compressive strength, cutting power, boring machine weight, diameter of cutting head as the standardization of parameters such as parameters.
Come to the conclusion that the hardness in cutting when the cutter reached 120MPa consumption rate of a more economical level.
1 • 2 tool to improve the design
The last 50 years, researchers in order to improve Cutting capacity rock tests done a lot of research, such as increasing the weight of the machine, the design of solid rack, a big increase in power, such as cutting. Test shows that the constraints of the main factors driving hard rock is still the pick, as the cut-off performance is good or bad teeth, the length of life boring machine a direct impact on the economy, thus cutting the need for an in-depth study tool.
At present, the extensive use of boring machine with cone-shaped alloy head pick-ho, as they have since the blade and impact resistance and have been affirmed, in a variety of boring machine has been widely used and become standardized. In addition, through the introduction of new welding technology, increasing the diameter of the first alloy and improve abrasion resistance, such as cut-off method of tooth roots, pick a larger improvement in the durability of cutter. Despite the ho-shaped cutter to carry out an in-depth research, manufacturing process has been greatly improved, but still can not economically stronger for grinding of hard rock mining. This is because when the ho-shaped cutter with the rock when the contact area, and in the higher stages of wear and tear become blunt and sharp teeth, the posterior horn of the negative, the plane of the wear and tear and extrusion of rock have a lot of rock powder, work to be larger than the energy, cutting efficiency is very low, if the pick-shaped cutter to stop rotating, then the performance of their cutting the rate of deterioration will be increased.
Shoul improve the design tools to enable the transfer to the rock through the tool of power and energy to achieve maximum value. Recently developed new tools, the United States of Geology, University of Colorado School of Mines Research Institute of the disc machine cutting tool [3], and mining services company in Australia, the development of the era of chain-shaped cutter head alloy. Before the adoption of a rotary cutting tool for cutting hard rock, due to large size tools and boring machine cutting head size is limited to use; the latter has a cutting tool than the energy stability, the extent of tool use has been a sharp remain unchanged, less dust, vibration small degree block is characterized by the more hard rock boring machine ideal choice, and the use of broad prospects.
1 • 3 types of cutting head
The design of cutting head usually meet the following requirements: tool consumption in small, even by force, good stability, high cutting efficiency. To achieve this
These requirements is the main criteria for the design of each tool rotary cutting head in a week can cut the same materials. Practice shows that in the horizontal boring machine, two kinds of longitudinal cutting head type, the horizontal boring machine is more suitable for hard rock cutting [4-5]. This is due to cut-off horizontal cutting head and cut off the small side, at the same time to participate in cutting the number of teeth less than the cut-off, the machine allows the greatest resistance to the same work, they can force the use of larger single-pole; horizontal cutting head cutting line spacing small , can be cut smaller deep, single-tooth cutting resistance on the smaller, the horizontal than the vertical axis of the high hardness cutting; forward open horizontal cut, as cutting edge and are located in traction with the cantilever axis parallel to the plane, you can take full advantage of the weight of the machine, cutting good stability, and pick and Chip of the effect of Better than the vertical axis type.
2 job stability and the whole arrangement
Evaluation of the stability of boring machine is an important indicator of performance, cutting a direct impact on the performance and reliability of machines. Affect the stability of the boring machine by many factors, such as the cutting head of the load, the balance of machine layout, grounding area, body height, cantilever rack, and other major components of the weight and stiffness, cutting head type and so on.
Heavy boring machine is designed for cutting hard rock, and its main characteristic is that the weight of big machinery, big power. The quality of a big machine for cutting the work of providing a more solid platform to effectively reduce the vibration machine, but it also brought about a balanced arrangement of hard to machine, machine ground pressure of the big problems, how to make the whole arrangement of a balanced center of gravity position reasonable is a heavy-duty design difficult.
Heavy boring machine weighing more than a 100, ton although the horizontal cutting of the work agencies have good stability, but the weight of cutting big institutions, so that whole center of gravity forward, causing the front track ground pressure is too large, the need for running chassis to the rack, as well as the arrangement of special means, on the one hand, adjust the rack and track the structural design of aircraft, reasonable weight and to increase its strength and stiffness, the parameters to match the requirements on the other hand, as far as increasing ground track area to reduce ground pressure.
3 key components of development and design
Performance requirements of new technologies and the increasing weight and power of the machine by making the boring machine parts the machine can not fully meet the overall requirements, the need for a pilot study of key components. Heavy Cutting excessive body weight, the traditional slewing bearing slewing mechanism can not meet the work requirements, the need to develop new-type rotary body design. Rack and pinion has a carrying capacity of rotating bodies, and rotary constant force, vibration and strong impact resistance, smooth operation, the advantages of compact structure.
Heavy boring machine ground pressure, and makes walking traction device efficiency is not high, especially in the soft, wet ground. Telescopic cutting a large extent, solved the problem, it can be static in the machines, the machines take full advantage of gravity and track traction device of the friction with the ground, so that cutting head to promote greater traction. However, within the traditional telescopic spline and T-slot outside the telescopic structure, not only structurally complex, processing difficulties, and the relatively high failure rate, so the need for heavy-duty cantilever Cutting the characteristics of the development of strong and stable institutions of stretching.
4 Boring Machine-oriented positioning and monitoring section
Bulky heavy boring machine, the driver line of sight worse, according to the traditional approach to accurate driving and cutting cross-section to promote the right direction to ensure that it is very difficult, often boring machine drivers rely on the experience and technology, in most cases the need for duplication of ultra-cutting or patch cutting region, therefore it is difficult to control operating costs. How in the shortest possible time, the greatest precision cutting, the use of the lowest operating costs, it is hard rock boring machine needs to be resolved another difficult
Address these problems, usually boring machine automated positioning system. This is through the use of a high level of integration of computer-driven boring machine operations to complete the display, as shown in Figure 2. Display can be clearly marked on the boring machine precise position and orientation information; the design of roadway cross-section profile of the axial projection; boring machine cutting head section in an ideal location on the real-time. Through the use of the system can achieve precise control of the cross-section; to ensure that the design of roadway in accordance with the direction; raise boring machine footage; be completed roadway cutting part is not visible; automatically advanced site features such as measurement of theodolite.
5 Accessibility
5 • 1 Heading Face Comprehensive Dust Removal System technology
At present, the wet roadway dust removal system results in tunneling a major factor in the poor is that the dust removal system is not able to face boring machine, as well as the wind system for supporting effective, so a comprehensive dust removal system heading face technology research in general is supporting heavy boring machine One of the main research and development studies. In addition, the large cross-section of dust control technology studies and the role of charged dust device is controlled mechanized excavation face the spread of dust from outside air. One of the key issues and technical problems is the formation of mural mural hairdryer wind speed to determine the best effect, the need for an in-depth study on this.
5 • 2 bolt support system
Bolting is the coal mine roadway support the main form of support will bolt drilling and boring machine arm system integrated in one, the realization of a fully mechanized excavation face bolt hole drilling and bolt installation mechanized operations, a very care to improve the efficiency of the earth anchor to reduce the time for auxiliary operations, effective care to shorten the operating cycle time anchor. In addition, the anchor of care to achieve automation and control operations, further improve the efficiency of the anchor retaining staff and reducing the number of operations to improve the care of the anchor of the security operation.
6 Conclusion
1) specific nature of the geological conditions of rock to choose and match the parameters of heavy hard rock boring machine is designed to correct the premise.
2) the use of cutting energy consumption than the stable, remain the same sharpness of the new alloy ornament-shaped cutter, heavy hard rock boring machine is a better choice.
3) In order to better adapt to cutting hard rock, heavy use of hard rock boring machine horizontal cutting way, with production capacity, and job stability, and lower than the energy consumption characteristics.
4) heavy-duty boring machine according to the characteristics of the balanced arrangement of parts, and a reasonable weight.
5) heavy-duty boring machine according to the characteristics of the development of strong and stable cutting telescopic slewing mechanism and heavy-duty.
6) the use of boring machine-oriented cross-section location and surveillance systems, to improve the performance of heavy boring machine.
7) to heavy boring machine for the technology platform, can also be used to eliminate dust and equipment automatic bolting device and system to enhance the safety of staff, efficiency of mechanized excavation face.
中文译文
悬臂式重型掘进机关键技术探讨
【摘 要】:提出了悬臂式重型掘进机硬岩切割的关键技术问题,并结合EBZ300TY重型掘进机的研制开发,对所采取的技术措施进行了探讨。提出了根据用户特定地质条件进行工作参数合理匹配、刀具改进设计方向、截割头选取的类型、整机稳定性及布置、关键部件的开发和导向定位及断面监视等方案。
【关键词】:重型掘进机;硬岩切割;关键技术
我国悬臂式掘进机是20世纪60年代发展起来的,经近50年的研究、试验和改进,机器性能不
断提高,已开发出截割功率50~220 kW,从轻型到重型的20多种型号的系列产品,在煤矿井下煤及半煤岩巷道的机械化掘进中广泛应用,基本满足了近年来我国煤炭工业快速发展的需求。随着我国矿井规模和工作面单产的不断提高,大批千万吨级现代化矿井的建设,特别是新井建设中岩石巷道的开拓,对全岩掘进机的需求逐年增加,对其技术能力和要求也持续提高。
研制截割功率达到300 kW,机器质量超过100t适应巷道断面30~50 m2,截割岩石单轴抗压强度达到120MPa的重型硬岩掘进机,正是在不断增长的需求和掘进机技术快速进步的前提下提出的。同过去50年研制的掘进机相比,它不是简单的局部改进,也不是以往成功机型的放大或缩小,而是掘进机技术一次意义深远的多方面变革。这是因为它的一些关键技术将会推广应用到其他掘进机产品上,进而带动整个掘进机行业的技术进步。下面根据目前国内外掘进机的发展动态和开发体会,对重型掘进机硬岩切割的关键技术进行初步探讨。
1 截割能力
硬岩切割能力是重型掘进机使用范围受限制的最主要因素,也是重型掘进机研制的核心所在,其能力高低通常有3个指标来衡量,即截齿损耗率(把/m3)、生产能力(m3/h)和截割比能耗(kW·h/m3),其中以截齿损耗率更具决定作用。在掘进机切割硬岩时,如果岩石硬度高或者研磨性很强导致截齿实际损耗率超过1把/m3,那么就会由于高昂的截齿消耗费用,以及经常更换截齿和机器的振动加剧增加的维护费等与钻爆法相比变得不经济。因此,使重型掘进机的截割能力适应硬岩切割至关重要,为此需要对工作机构的参数选择、截割头类型和截割刀具等进行深入研究。
1·1 工作参数合理匹配与性能预测
在掘进机截割过程中,一个最重要且最基本的参数是切削厚度(截齿截割煤岩体的深度),与被截割岩石性质不适合的切削厚度只会降低截割效率,增加截齿的磨损,产生更多的粉尘。在岩石截构各异,形成的力学性质千差万别。由于切割硬岩的特殊性,在进行硬岩掘进机设计时,针对用户特定地质条件的岩石性质来进行参数选择和匹配是重型硬岩掘进机正确设计的前提。在针对不同岩石类型,如强度、磨蚀性、岩石类型等进行截割试验的基础上,结合专用设计软件来进行截割工作参数的优化设计,是使硬岩掘进机达到高截割性能的必由之路。
此外,对设计参数的性能预测是掘进机成功使用的一个重要因素。根据国外研究机构的研究成果[2],可根据一定的预测方程式对截齿损耗率和截割生产能力进行预测。将所截割岩石的单向抗压强度、截割功率、掘进机重量、截割头直径等参数作为标准化参数。
得出的结论是在截割硬度达到120MPa时截齿消耗率达到较经济的水平。
1·2 刀具改进设计
近50年来,科研人员为了提高掘进机截割岩石的能力做了大量的试验研究,比如增加机器的重量,设计坚固的机架,增大截割功率等。试验表明,制约硬岩掘进的主要因素仍是截齿,由于截齿性能的好坏、寿命的长短直接影响掘进机的经济性,因此就需要对截割刀具进行深入研究。
目前,在掘进机上大量使用的带锥形合金头的镐形截齿,由于其所具有的自刃性、耐冲击性而得到了肯定,在各种掘进机上被广泛使用并趋于标准化。另外,通过采用新的焊接技术、增大合金头直径和提高截齿根部抗磨性等方法,较大改善了镐形截齿的耐用性。尽管对镐形截齿进行了深入研究,制造工艺也有了极大的改善,但仍然无法经济地用于研磨性较强的硬岩挖掘。这是由于当镐形截齿工作时与岩石的接触面积大,在磨损较高的阶段齿尖变钝时,会产生负的后角,大的磨损平面挤压岩石并产生大量的岩粉,工作时需较大的比能,截割效率很低,如果镐形截齿停止旋转,那么其截割性能恶化速度还会加剧。
应该改善刀具的外形设计,使通过刀具转移给岩石的力和能量达到最大值。最近研制的新型刀具,有美国科罗拉多矿业大学地质机械研究院研制的圆盘截割刀具[3],还有澳大利亚时代矿业服务公司开发的锒形合金头截齿。前一种刀具通过旋转截割用于硬岩切割,由于刀具的外形尺寸大而掘进机截割头尺寸小使用受到限制;后一种刀具具有截割比能耗稳定,刀具使用中锐利程度一直保持不变,粉尘少、震动小、块度大的特点,是硬岩掘进机较理想的选择,并具有广阔的使用前景。
1·3 截割头类型
截割头的设计通常满足以下要求:刀具消耗小,受力均匀,稳定性好,截割效率高。要实现这些要求,主要的设计准则就是每个刀具在截割头旋转一周时能够切下相同的物料。实践表明,在掘进机的横、纵轴2种型式的截割头中,横轴掘进机更适合硬岩切割[4-5]。这是由于横轴截割头截割断面小,同时参加截割的截齿数量少,在机器允许最大工作阻力相同时,就可以采用较大的单刀力;横轴截割头截线间距小,可以采用较小的截深,单齿截割阻力就较小,因此横轴式比纵轴式的截割硬度高;横轴式前进开切时,由于截割力和牵引力都位于与悬臂轴线相平行的平面内,可以充分利用机器的重量,截割稳定性好,且截齿的受力和排屑效果都较纵轴式好。
2 工作稳定性和整机的布置
稳定性是评价掘进机性能的一项重要指标,直接影响着截割性能和机器的可靠性。影响掘进机稳定性的因素有很多,如截割头的载荷、整机布置的均衡、接地面积、机身高度、机架和悬臂等主要构件的重量及刚度、截割头型式等等。
重型掘进机主要是为切割硬岩而设计, 它的主要特点是机器重量大,功率大。大的机器质量可以为截割提供更加稳固的工作平台,有效降低机器的震动,但同时也带来整机均衡布置难,机器的接地比压大的问题,如何使整机布置均衡,重心位置合理是重型机设计的一项难点。重型掘进机重量超过了100 ,t虽然采用横轴式截割机构具有良好的工作稳定性,但截割机构的重量大,使整机重心靠前,致使履带前部接地比压过大,需要对机架以及行走底盘的布置采取特殊手段,一方面调整机架和履带架的结构设计,合理配重,并增加其强度和刚度,另一方面在参数匹配要求范围内,尽量增大履带接地面积以降低接地比压。
3 关键部件的开发设计
新的技术性能要求以及不断增加的机器重量和功率,使以往掘进机的部件已经不能完全满足机器整体要求,需要对关键部件进行试验研究。 重型掘进机截割机构重量过大,传统的回转支承无法满足回转机构的工作要求,需开发设计新型回转机构。齿轮齿条回转机构具有承载能力大、回转牵引力恒定、抗冲击振动能力强、运转平稳、结构紧凑等优点。
重型掘进机接地比压大,使得行走牵引装置效率不高,尤其是在松软、潮湿的地面上。伸缩式截割在很大程度上解决了这个问题,它可以在机器静止的情况下,充分利用机器的重力及履带牵引装置与地面的摩擦力,使截割头产生更大的推进牵引力。然而,传统的花键内伸缩和T型槽外伸缩结构,不仅结构复杂、加工困难,而且故障率比较高,因此需要针对重型掘进机截割悬臂的特点开发坚固稳定的伸缩机构。
4 掘进机导向定位及断面监视
重型掘进机体积大,司机视线差,按照传统的掘进方法去精确切割断面并确保推进方向正确是非常困难的,常常依靠掘进机司机的经验和技术,大多数情况下需要重复切割或修补超切区域,因此操作成本很难控制。如何在最短的时间、最大切割精确度、使用最少的操作成本,是硬岩掘进机需要解决的又一个难点。
解决上述问题,通常采用掘进机自动化定位系统。这是通过使用一个高集成度计算机驱动的掘进机操作显示器来完成的,如图2所示。显示器可以清晰标出精确的掘进机位置和方向信息;设计巷道断面的轴向投影轮廓;掘进机切割头在理想断面上的实时位置。通过使用该系统可以实现精确的断面控制;保证巷道按照设计方向推进;提高掘进机进尺;可以完成不可见部分巷道切割;自动超前测量经纬仪站点等功能。
5 辅助功能
5·1 掘进工作面综合除尘系统总体配套技术
目前湿式除尘系统在掘进巷道使用效果不佳的一个主要因素就是,除尘系统没有能和掘进机以及工作面供风系统进行有效的配套,所以掘进工作面综合除尘系统总体配套技术研究也是重型掘进机研制中的一个主要研究内容。另外,大断面控尘技术的研究及控尘装置的作用,是控制综掘工作面含尘气流向外扩散。其中的关键问题和技术难点就是附壁风筒形成附壁效应最佳风速的确定,需要对此进行深入研究。
5·2 锚杆支护系统
锚杆支护是目前煤矿井下巷道支护主要支护形式,将锚杆钻臂系统与掘进机集成于一体,实现了综掘工作面锚杆孔钻进和锚杆安装的机械化作业,极大地提高锚护效率,减少辅助作业时间,有效缩短锚护作业循环时间。另外,锚护作业自动化控制的实现,进一步提高了锚护效率并减少了作业人员数量,提高了锚护作业的安全性。
6 结 语
1)针对特定地质条件的岩石性质来进行参数选择和匹配是重型硬岩掘进机正确设计的前提。
2)采用截割比能耗稳定,锐利程度保持不变的新型锒形合金截齿,是重型硬岩掘进机较理想的选择。
3)为了更好地适应硬岩切割,重型硬岩掘进机采用横轴式截割方式,具有生产能力大、工作稳定性好、比能耗低的特点。
4)应根据重型掘进机的特点对各部件均衡布置,并合理配重。
5)根据重型掘进机的特点,开发坚固稳定的伸缩式截割机构和重载回转机构。
6)采用掘进机导向定位及断面监视系统,改善重型掘进机操作性能。
7)以重型掘进机为技术平台,采用
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