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中國礦業(yè)大學2008屆畢業(yè)生畢業(yè)設計 第6頁
目 錄
1 概述……………………………………………………………………………………1
1.1 技術現(xiàn)狀…………………………………………………………………………1
1.2 刮板輸送機的發(fā)展前景…………………………………………………………1
2 主要部件的結構設計和要求………………………………………………………3
2.1 機頭部……………………………………………………………………………4
2.1.1 機頭架………………………………………………………………………4
2.1.2 鏈輪…………………………………………………………………………5
2.1.3 減速器………………………………………………………………………6
2.1.4 盲軸……………………………………………………………………7
2.1.5 聯(lián)軸器……………………………………………………………………7
2.1.6 電動機………………………………………………………………………8
2.2 機尾部……………………………………………………………………………4
2.3 中部槽及附屬部 ……………………………………………………………9
2.4 刮板鏈…………………………………………………………………………11
2.5 緊鏈裝置………………………………………………………………………12
2.6 推移裝置………………………………………………………………………14
2.7 錨固裝置………………………………………………………………………15
3 總體方案的確定……………………………………………………………………15
3.1 主要技術參數(shù)…………………………………………………………………16
3.2 電動機的選………………………………………………………………………16
3.2.1 運輸能力的計算……………………………………………………………17
3.3 總傳動比及傳動比的分配……………………………………………………17
3.3.1 總傳動比的確定…………………………………………………………17
3.3.2 傳動比的分配………………………………………………………………17
3.4各級傳動計算……………………………………………………………………18
3.4.1 各軸轉速計算………………………………………………………………18
3.4.2各軸功率計算………………………………………………………………18
3.4.3 各軸扭矩計算………………………………………………………………19
3.5軸的設計及強度校核…………………………………………………………37
3.5.1 高速軸Ⅰ軸的設計…………………………………………………………37
3.5.2 Ⅱ軸的設計…………………………………………………………………39
3.5.3 Ⅲ軸的設計…………………………………………………………………40
3.5.4輸出軸的設計………………………………………………………………41
4 減速器鍵、軸承的校核………………………………………………………………43
4.1 減速器鍵的校核…………………………………………………………………43
4.1.1 Ⅰ軸鍵的校核……………………………………………………………43
4.1.2 Ⅱ軸鍵的校核……………………………………………………………43
4.1.3 Ⅲ軸鍵的校核………………………………………………………………43
4.1.4 輸出軸鍵的校核……………………………………………………………44
4.2 減速器軸承的校核………………………………………………………………44
4.2.1 驗算Ⅰ軸軸承壽命…………………………………………………………44
4.2.2 驗算Ⅱ軸軸承壽命…………………………………………………………45
4.2.3 驗算Ⅲ軸軸承壽命…………………………………………………………46
4.2.4 驗算輸出軸軸承壽命………………………………………………………46
5 箱體及附件的設計校核……………………………………………………………48
5.1軸的強度校核……………………………………………………………………49
5.1.1軸的受力分析………………………………………………………………49
5.2齒輪詳細參數(shù)……………………………………………………………………55
6 液力耦合器概述……………………………………………………………………56
結論……………………………………………………………………………………58
附錄………………………………………………………………………………59
參考文獻………………………………………………………………………………61
英語翻譯………………………………………………………………………………62
1英文原文……………………………………………………………………………62
2中文譯文……………………………………………………………………………71
致謝……………………………………………………………………………………78
摘 要
刮板輸送機是一種撓性牽引的連續(xù)輸送機械，是為采煤工作面和采區(qū)巷道運煤布置的機械。它的牽引機構是刮板鏈，承載裝置是中部槽，刮板鏈安裝在中部槽的槽面。中部槽沿運輸路線全線鋪設，刮板鏈繞經(jīng)機頭、機尾的鏈輪接成封閉形置于中部槽中，與滾筒采煤機和輸送機推移裝置配套，實現(xiàn)落煤、裝煤、運煤及推移輸送機械化。沿輸送機全長都可向溜槽中裝煤，裝入中部槽中的煤被刮板鏈拖拉，在中部槽內滑行到卸載端卸下。
一般的刮板輸送機能在25°以下的條件使用。刮板輸送機在使用中要受拉、壓、彎曲、沖擊摩擦和腐蝕等多種作用，因此，必須有足夠的強度、剛度、耐磨和耐腐蝕性。由于它的運輸方式是物料和刮板鏈都在槽內滑行，因此運行阻力和磨損都很大。但是，在采煤工作面運煤，目前還沒有更好的機械可代替，只能從結構上、強度上和制造工藝上不斷研究，使它更加完善、耐用。
刮板輸送機是與大型綜采工作面設備配套使用的液壓支架、采煤機，完成把工作面采煤機采下的煤輸送、轉運到后續(xù)運輸設備上的任務，并提供相應的連接手段。設計要求與ZY2300轉載機自移機尾配套，以實現(xiàn)在2.3米范圍內整體移動而不必拆移輸送機。與ZY2300轉載機自移機尾配合可更方便地調節(jié)皮帶機，增強了輸送機與轉載機配合的協(xié)調性。本刮板輸送機與MG300/700-WD采煤機配套使用，運量可達1000t/h，技術先進，工作可靠，是大型綜采配套設備的優(yōu)秀機型。
關鍵詞：刮板輸送機 ；減速器 ；機頭部 ；機尾部 ；液力耦合器。
Scraper conveyor
Scraper conveyor is a reprint of fully coal face ancillary equipment in the transport system an important part of the roadway in the face of the accepted face scraper conveyor unloading of coal flow, not halt the transfer to the retractable belt Conveyor boost. Bridge reversed loader with the face-scraper conveyor machine synchronous over his head, face Shearer guarantee for coal mining, and fully mechanized coal face of high yield and high efficiency operations.
Scraper conveyor is a reprint of a special structure of the scraper conveyor, powertrain and drive and scraper conveyor similar to a ramp of its fuselage and a section of the arch bridge structure and belt conveyors in the tail Paragraph above lap. In the back-alley in the coal face when the machine goes to reprint its arch bridge and all of the aircraft ended the lap belt conveyor stack of position limits, a retractable belt conveyor shortened ride Next length of the belt conveyor for the development of the shift to home-unloading nose reproduced below, can be reproduced with the face of the advance goes forward.
Reproduced large-scale machine is fully coal face with the equipment supporting the use of the Gate transmission, reproduced equipment, to complete the face conveyor sent to the coal transportation, transit facilities to follow up on the conveyor belt of tasks and to provide the appropriate means of connection. ZY2300 belt with the design requirements for supporting the tail since the shift to achieve in the 2.3 metres of the overall mobile rather than demolished shift belt machine. ZY2300 belt and the tail of the shift can be more easily cope with belt-regulation, enhance the belt-and-reproduced with the coordination. This reprint of MG300/700-WD and supporting the use of conveyor, capacity up to 1,000 tons / hour, technologically advanced, reliable, large-scale comprehensive mining equipment supporting the excellent models.
Key words：scraper conveyor； reducer； machine head； aircraft tail； hydraulic coupler。
1、 刮板運輸機的使用溫度？
一般的刮板輸送機能在25°以下的條件使用。
2、 使用場合？
刮板輸送機是與大型綜采工作面設備配套使用的液壓支架、采煤機，完成把工作面采煤機采下的煤輸送、轉運到后續(xù)運輸設備上的任務，并提供相應的連接手段。設計要求與ZY2300轉載機自移機尾配套，以實現(xiàn)在2.3米范圍內整體移動而不必拆移輸送機。與ZY2300轉載機自移機尾配合可更方便地調節(jié)皮帶機，增強了輸送機與轉載機配合的協(xié)調性。本刮板輸送機與MG300/700-WD采煤機配套使用，運量可達1000t/h，技術先進，工作可靠，是大型綜采配套設備的優(yōu)秀機型。
3、 礦用刮板輸送機的結構要求？
礦用的刮板輸送機，按工作需要，對其結構有如下要求：
⑴能用于左或右工作面；
⑵各部件便于在井下拆裝和運輸
⑶同一型號的部件安裝尺寸和連接尺寸應保證相同，同類部件應保證通用互換；
⑷刮板鏈安裝后，在正、反方向都能順利運行；
⑸有緊鏈裝置，且操作方便，安全可靠；
⑹能不拆卸用機械推移，為此，應有便于安裝推移裝置的連接點；
⑺要有足夠的強度、剛度、耐磨性；
⑻從端部卸載的 刮板輸送機，機頭架應有足夠的卸載高度，防止空段刮板鏈返程帶回煤；
⑼一般應有上鏈器，上鏈器是供刮板鏈在下槽脫出時通過它返回槽內的裝置；
⑽用于機械采煤的工作面刮板輸送機，機頭架的外廓尺寸和結構形式應便于采煤機自切開口；
⑾用于采煤機的工作面刮板輸送機，應結合技術上的需要，能裝設下列部分或全部附屬部件
4、 機頭部由什么部分組成？
機頭部由機頭架、鏈輪、減速器、盲軸、聯(lián)軸器和電動機組成，是將電動機的動力傳遞給刮板鏈的裝置。
5、機頭架由什么部分組成？
機頭架是機頭部的骨架，應有足夠的強度和剛度，由厚鋼板焊接制成
5、 減速器的選型是什么？
平行布置式、三級傳動的圓錐圓柱齒輪減速器。
6、 刮板鏈的組成都有哪些部件？
刮板鏈有鏈條和刮板組成，是刮板輸送機的牽引機構。刮板鏈的作用是刮推槽內的物料。目前使用的有中單鏈、中雙鏈、邊雙鏈三種。
7、 本次設計刮板鏈有幾條？
兩條
8、 刮板輸送機的帶長是多少？
200米
9、 輸送量是多大？
1000噸每小時
10、 選用電動機的功率是多大？
160千瓦
中 國 礦 業(yè) 大 學
本科生畢業(yè)論文
姓 名： 周春雷 學 號：21040293
學 院： 應用技術學院
專 業(yè)： 機械工程及自動化
論文題目： 刮板輸送機設計
專 題：
指導教師： 王啟廣 職 稱： 副教授
2008 年 6月 徐州
中國礦業(yè)大學畢業(yè)論文任務書
學院 應用技術學院 專業(yè)年級 機自04-3班學生姓名 周春雷
任務下達日期：2008年3月16日
畢業(yè)論文日期：2008年3月20日至2008年6月12日
畢業(yè)論文題目：刮板輸送機設計
畢業(yè)論文專題題目：
畢業(yè)論文主要內容和要求：
設計參數(shù)：
設計長度 200m
生產能力 1000t/h
鏈 速 1m/s
要求：
（1）刮板輸送機的傳動方案設計；
（2）減速器的設計；
（3）完成主要傳動組件,零件的工作圖設計；
（4）編寫完成設計計算說明書。
院長簽字： 指導教師簽字：
中國礦業(yè)大學畢業(yè)論文指導教師評閱書
指導教師評語（①基礎理論及基本技能的掌握；②獨立解決實際問題的能力；③研究內容的理論依據(jù)和技術方法；④取得的主要成果及創(chuàng)新點；⑤工作態(tài)度及工作量；⑥總體評價及建議成績；⑦存在問題；⑧是否同意答辯等）：
成 績： 指導教師簽字：
年 月 日
中國礦業(yè)大學畢業(yè)論文評閱教師評閱書
評閱教師評語（①選題的意義；②基礎理論及基本技能的掌握；③綜合運用所學知識解決實際問題的能力；③工作量的大??；④取得的主要成果及創(chuàng)新點；⑤寫作的規(guī)范程度；⑥總體評價及建議成績；⑦存在問題；⑧是否同意答辯等）：
成 績： 評閱教師簽字：
年 月 日
中國礦業(yè)大學畢業(yè)論文評閱教師評閱書
評閱教師評語（①選題的意義；②基礎理論及基本技能的掌握；③綜合運用所學知識解決實際問題的能力；③工作量的大?。虎苋〉玫闹饕晒皠?chuàng)新點；⑤寫作的規(guī)范程度；⑥總體評價及建議成績；⑦存在問題；⑧是否同意答辯等）：
成 績： 評閱教師簽字：
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中國礦業(yè)大學畢業(yè)論文答辯及綜合成績
答 辯 情 況
提 出 問 題
回 答 問 題
正 確
基本
正確
有一般性錯誤
有原則性錯誤
沒有
回答
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答辯委員會主任簽字：
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中國礦業(yè)大學2008屆畢業(yè)生畢業(yè)設計 第17頁
英語翻譯
英文原文
Scraper conveyor of the status quo and development trend of technology
Abstract: The Face scraper conveyor of the machine and its head, tail, the central trough, ring linked, soft-start devices, components of the technical status quo and development trend, and made China's development scraper conveyor Trend.
Key words: scraper conveyor with two, components, development trends.
In recent years, with high yield and high efficiency of the rapid development of intensive mine, the coal mine in a mine to achieve a high degree of concentration of wells a production model. Face the long arm as the main transportation equipment, the scraper conveyor transport capability mainly by high yield and high efficiency of the production capacity of the mine to decide, but also determines the scraper conveyor trend of development.
1 Technology status
Since the 1980s, both at home and abroad scraper conveyor to the large volume, long distance, high-power, high-intensity, high reliability and long life direction. At present, the largest foreign Fully-face scraper conveyor to transport volume has reached 6000 t / h, installed power 4 × 800kW, distance 450 m. Domestic independent research and development of the scraper conveyor transport volume has reached 3500 t / h, installed power 3 × 700kW, distance 300 m. With God East, and other large coal base 400 m face the emergence of China-made scraper conveyor will be moving in the direction of more large-scale. However, volume, distance and the increase of power by many factors. First of all, the height of the central trough should not be too high, otherwise they will be affected with coal effect. Second, the conveyor's length should not be too long, Will reduce the rate of advance. Then the most important factors is also key components of the technical performance and life expectancy. Therefore, the scraper conveyor to the development of large-scale, high-performance components of the R & D will become the next scraper conveyor focus on the development, soft-start technology, the status of testing, running state control the use of mechanical and electrical integration technology will be Scraper conveyor into the future development of an important symbol
2 Yuan parts of the technical status quo
2.1 Head
With the fully mechanized coal face of rapidly increasing production apacity, scraper conveyor-unloading has been difficult to meet the requirements of domestic and foreign large volume of heavy scraper conveyor adopt cross-lateral institutions unloaded, the agency after several generations of improvements in the ability to offload , Efficiency, life and other aspects of a big increase. At the same time, unloading a high degree of reduced support for the fully mechanized coal mining has brought convenience.
2.2 Tail
For long distance, high-power scraper conveyor, the chain tension need greater flexibility trip, both at home and abroad using retractable tail, and is divided into manual and automatic tight chain tight chain. Manual tight chain system is regularly measured by the chain of artificial tension, stretching the tail, which can not guarantee the chain will always be in the best state of tension and the automatic system is the ideal tight chain of tension, as shown in Figure 1. The system in the chain and the nose, tail drive sprocket chain from the bottom, a tension sensor placement, in accordance with the actual chain of take-up tension control the fuel tank. This automatic use of the tight chain, conveyor chain operation will always maintain the best state of tension, to extend the life of the chain, reducing downtime.
Figure 1 automatically tensioning system
2.3 Sprocket components
Sprocket scraper conveyor components is the key component, and its development trend of improving the reliability of sprocket components, the price increase sprocket accuracy, improving heat treatment process to extend the life of sprocket.
At present sprocket components in the structure of use of double-row tapered roller bearings, light oil lubrication, nose and tail of the sprocket components are the same, through different gear reducer coupling connection with the replacement of underground Reducer, not demolition; sprocket using high-strength alloy steel, of quenching the hardness to eat HRC55, effective hardening depth of 10 mm and above, the service life of up to 400 to 5 million t of the media.
In addition, from sprocket on the tooth to be improved, for example, a company design the GR-sprocket and there is great difference between conventional sprocket, which always has three sprocket tooth led the entire load. 3 tooth contact will inevitably reduce the wear chain and sprocket, thereby extending the life of the chain and sprocket, reducing the chain elongation, power transmission efficiency is higher.
2.4 Soft-start devices
Foreign advanced conveyor transmission use of soft-start technology, in scraper conveyor on the successful use of the soft-start main valve control device-filled hydraulic coupler, CST controllable start and the exchange of electrical transmission system, such as Frequency Control . Because there is no domestic mature technologies and products, the China-made high-power scraper conveyor used in soft-start device for all imported products. Figure 2 was developed by Germany-filled hydraulic valve control DTP coupler.
2.4.1-filled hydraulic valve control coupled with the principal technical characteristics
⑴ can achieve the empty scraper conveyor start and overload protection;
Change can be achieved through
⑵ scraper conveyor the frequent start, without limitation start frequency;
⑶ through hydraulic coupler divisions will also re-order the multi-drive can be achieved under the load balancing;
⑷ slow post-mortem can be linked;
⑸ dual-chamber design, compact, power transmission components without mechanical contact, high reliability.
⑹ with water as a working fluid, safe and convenient and cheap, through pipes or water supply, drainage tube through the pump row, row of pressure from the main hydraulic motor-driven cycle produced by the pilot of the portfolio directly to the valve To control the water cycle;
⑺ without affecting the power transmission circumstances, * Change to heat through.
Figure 2 DTP-valve-controlled oil-filled hydraulic coupler
2.4.2CST controlled transmission system activated the main technical characteristics
⑴ in any load can track any launch curve, the speed of plus or minus any adjustment;
⑵ relative speed hydraulic coupler, the transmission efficiency;
⑶ an arbitrary controlled under the conditions of parking capacity；
⑷ can be driven to achieve more balance of power between the high-precision, balance accuracy up to 98 percent;
⑸ conveyor of all mechanical, electrical system overload protection, the protection system fast response;
⑹ be running low on time, and cashing in on the trend post-mortem chain;
⑺ scene debugging simple, it is easy to modify the parameters online and debugging.
2.4.3 AC motor technology the main technical characteristics
⑴ and other soft-start mode compared to the full realization of electrical soft-start control, scraper conveyor drive system and power supply system to maximize the simplification;
⑵ start-up time can be loaded with self-regulation;
⑶ achieved a scraper conveyor loaded with empty and the smooth start-up;
⑷ significantly reduce the starting current and improve the quality of electricity supply grid, power grid to reduce impact.
2.5 Central groove
Central trough conveyor of the whole face of the trunk, its life is a measure of an important indicator of life. At present the central trough use of Σ trough-shaped cross section for the whole cast back cover welding structure, life expectancy has reached 10 million t. To further improve the service life of the major manufacturers of domestic and foreign central trough of form, structure and materials have done a great deal of research. Such as Germany of a company through research and development, be that in different sections of the mine shafts for a large number of Central Test and eventually found, and Σ trough-shaped cross section for comparison, curved section slot for the scraper to help with the trough in contact with the side of the small, thereby reducing friction and reduce power consumption, extend the central slot and scraper life. Σ scraper and arc-shaped cross section and the section for surface trough comparison shown in Figure 3.
Figure 3 scraper and Σ arc-shaped cross section and the section for surface trough comparison
From top to bottom for a slot on the design, shown in Figure 4, from top to bottom slot for the same, you can choose any thickness and width of the plate in the central trough design makes for greater flexibility. Slot for each board and the central slot between the two Weld, the central side of the trough of four seam, only on the inside of the tank to help withstand the wear and tear a seam, even if it was polished welds , The central trough can maintain a high degree of stability.
Figure 4 4-steel tank to help design and wear contour
Help create a slot on the Rolling materials, steel rolling on the surface than the smooth casting of steel, small friction. Central tank plate using high-strength steel hardening Wear-resistant, wear little. Rolling in the central trough lateral welding dumbbell Block, will not help reduce the thickness of groove. Forging dumbbell on the design and ensure that the central trough Yaling not Block damage, and the youngest is basically breaking strength of 1.5 times the dumbbell, so the fault is always the first dumbbell.
Another trough of the central structure of the tank from top to bottom-of-duplication, this form can be set from top to bottom groove and the failure of different conditions for different structural design and material selection, and easy on the replacement tank, will help improve strength and Life. The central trough in the form of SGZ880 / 2 × 400-type double-stranded in the cross-side dumping in the face scraper conveyor has been successfully applied.
2.6 Ring linked
Circle as a scraper conveyor chain of traction, its tensile strength directly related to the reliability of. At present, China's largest ring linked to φ42 mm × 146mm compact chain, tensile strength of 2270 kN, the largest foreign ring linked to φ48 mm × 152mm compact chain, tensile strength of 3550 kN. With the ring linked the increasing size of the central trough of higher and higher, conveyor magnificent performance declined, the gateway if not thorough clean-up will also affect passage of conveyor. So ring linked the direction of development is to improve tensile strength and reduce the high degree of Central legislation.
2.6.1 Materials and Technology
In order to improve the roundabout chain of tensile strength, the current foreign Grade C and D-linked ring in the large-sized materials with 23 MnNiCrMo54, 23MnNiCrMo54 and 23 MnNiCrMo64 scouring steel, tensile strength limit ≥ 1600 ~ 1800 MPa. Welding Technology: the use of advanced welding equipment, welding and the use of flash returns processing technology, successfully resolved the surfacing of the process of overheating, such as a burning issue. In quality testing, the use of scanning stretch fracture fracture of cables used to pre-tension ring linked to strengthen technology, greatly enhancing the carrying capacity and fatigue.
2.6.2 form and geometry
In 1985 the first to create a company 38 mm × 137mm flat chain. Flat is linked each of the chain is still ring-Central, Central was "squeezed" the flat ring. Flat chain link sliding work to reduce the size of the increase in the chain of slot pressure on the units and improve the legislation of the Central wear resistance; reduce its high level of the chain more easily through the sprocket, but can also reduce the capacity of power transmission and Bays of a high degree. Modern high-performance conveyor are generally involved in supporting a flat chain.
Figure 5 conventional chain and a new wide-body linked flat
In 2003, the company has developed a wide-body at a flat linked, as shown in Figure 5. It is a high-intensity, low-chain, has the following characteristics:
⑴ using this chain can reduce the high scraper chain, thereby reducing the central trough height, eventually reduce the use of high-mining, coal mining to meet thin.
⑵ using this chain can reduce the use of power, or power in the same circumstances, increase the length of face, it will greatly reduce the workload of opening up, reducing the number of face move.
⑶ this forging of wide-body flat link chain has increased the contact area, can improve the chain link at the same time reduce the intensity of the wear and helps to maintain the rigidity of chain link. Such as a flat 42 mm chain can take 2 × 855kW of installed power, and 50 mm wide-body flat can be linked up to 3 × 1000kW bear the installed power.
2.6.3 intelligent conveyor chain
As unable to accurately predict the failure of the chain, according to conventional practices are generally ahead of the replacement of the chain. In 2005 a company with a number of research institutes to study the development of a conveyor chain-detection system, as shown in Figure 6. This is a combination of integrated sensor technology of intelligent conveyor chain, it will stress the chain of real-time record, the help of micro-electronics technology devices, from computers that the chain of life remaining before the fracture. It also can detect the chain of preload, is conducive to life during the period in the chain to achieve the best use of state, improve safety and avoid accidents.
2.7 The link chain
The link chain-rings are used for the link chain and ring for legislation to link the two in recent years has tended to adopt legislation to link the ring, then such a chain link through the sprocket and not linked A round of contacts, so there will not be worn.
Blockmaster the link chain is a new legislation for a flat linked to the Central chain link shown in Figure 7, because of their extreme length of closure, at the time of installation without relaxation chain; their innovative design concept, two-way installation, do not have to consider the direction of transmission, There is the possibility of anti-loaded, the link chain block in central lock can be avoided chain kink, but also increased the strength of the link chain, such as 42 mm × 146mm Blockmaster the link chain of broken Rally of 2500 kN.
Figure 6 smart conveyor chain
2.8 High-power transmission gear
Scraper conveyor of the low-speed transmission is characterized by heavy, impact resistance, small in size but poor lubrication and cooling. In order to obtain high-performance gear transmission device, to be constantly raise the level of product and manufacturing standards involved.
Figure 7 Blockmaster the link chain
2.8.1 raising the level of design
Raise design standards to improve the design means first of all, the use of advanced design techniques. At present, some companies developed based on the load and deformation of the tooth contour design and calculation software and books used in high gear shift, with the bending stress on the tooth for finite element analysis to improve the shape of teeth with the transition to full gear in case meshing State be greatly improved and increased contact with strength,elasticity and the use of finite element of the planetary gear transmission mechanism for load analysis, contained both the structure more scientific and rational, adopt a flexible flow of dynamic pressure lubrication analysis of gear mating area of friction and heat Film state. The advanced design of a gear transmission, gear designed to meet the high technical indicators.
2.8.2 raising the level of manufacturing
Scraper conveyor gear more than a surface treatment of advanced hardening of low carbon steel materials, the hardening process are: carburizing, nitrogen and surface hardening. With the increase in power transmission gear, the relative size decreases, Chilian contact stress and teeth with a substantial increase in bending stress. Gear crystal material between the impurities often become the source of fatigue crack initiation. At present, the major international manufacturers scraper conveyor widely used vacuum smelting furnace of the more high-quality low-carbon steel alloy gear. Gear heat treatment using computer monitoring and control equipment carburizing atmosphere, and strictly monitor the furnace temperature, carbon potential, control gear and equipment parts used mainly CNC machining centers manufacturing, processing benefit substantially improve accuracy, domestic and foreign companies gear manufacturers in China can reach a GB100095 - 88 "involute gear machining accuracy" standard 6-6-5 level and above.
3 China scraper conveyor direction of development
With coal mine production of intensive development, has a long wall face fully mechanized coal mining equipment and technology has been to the high-end development, to meet the production capacity, a high degree of automation, safety and reliability of production requirements. At present, China's scraper conveyor of the design and manufacture close to the level of similar foreign models, but in the life of key components, reliability and innovation in such areas as compared with foreign countries there are still many gaps, particularly soft-start, overload protection And the chain automatically tensioning device, such as high-end technology products.
中文譯文
工作面刮板輸送機技術現(xiàn)狀與發(fā)展趨勢
摘要：闡述了工作面刮板輸送機整機及機頭、機尾、中部槽、圓環(huán)鏈、軟啟動裝置等元部件的技術現(xiàn)狀與發(fā)展趨勢，并提出了我國刮板輸送機的發(fā)展方向。
關鍵詞：刮板輸送機；元部件；技術現(xiàn)狀；發(fā)展趨勢。
近年來隨著高產高效集約化礦井的迅速發(fā)展，煤礦都在爭取實現(xiàn)一礦一井一面的高度集約化生產模式。作為長臂工作面的主要運輸設備，刮板輸送機的輸送能力主要由高產高效礦井的生產能力來決定，同時也決定了刮板輸送機的發(fā)展趨勢。
1整機技術現(xiàn)狀
20世紀80年代以來，國內外刮板輸送機都在向大運量、長運距、大功率、高強度、長壽命與高可靠性方向發(fā)展。目前，國外綜采最大的工作面刮板輸送機，去運量已達6000t/h，裝機功率4×800kW，運距450m。國內自主研發(fā)的刮板輸送機運量已達3500t/h，裝機功率3×700kW，運距300m。隨著神東等大型煤炭基地400m工作面的出現(xiàn)，國產刮板輸送機將朝著更大型的方向發(fā)展。但是運量、運距和功率的增大受到諸多因素的限制。首先，中部槽的高度不宜太高，否則會影響裝煤效果。其次，輸送機的長度也不宜太長，會降低推進速度。然后最主要的影響因素還在于關鍵元部件的技術性能和壽命。所以，在刮板輸送機向大型化發(fā)展的同時，高性能元部件的研發(fā)將成為今后刮板輸送機的發(fā)展重點，軟啟動技術、工況檢測、運行狀態(tài)控制等機電一體化技術的運用將成為今后刮板輸送機發(fā)展的重要標志。
2元部件的技術現(xiàn)狀
2.1機頭部
隨著綜采工作面的生產能力迅速提高，刮板輸送機端卸載已經(jīng)難以滿足要求，國內外大運量重型刮板輸送機均采用交叉?zhèn)刃遁d機構，該機構經(jīng)過幾代改進，在卸載能力、效率、壽命等方面都有了很大的提高。同時，卸載高度的降低也為綜采配套帶來了便利。
2.2機尾
對于長運距、大功率刮板輸送機，鏈條張緊需要較大的伸縮行程，目前國內外均采用可伸縮機尾，并分為手動緊鏈系統(tǒng)和自動緊鏈系統(tǒng)。手動緊鏈系統(tǒng)是靠人工定時測量鏈條張力，伸縮機尾，所以不能保證鏈條始終處于最佳張緊狀態(tài)；而自動緊鏈系統(tǒng)才是理想的張緊方式，如圖1所示。該系統(tǒng)在鏈條與機頭、機尾驅動鏈輪分離后的鏈道下方安置有張力傳感器，根據(jù)鏈條的實際張力控制張緊油缸。使用了這種自動緊鏈系統(tǒng)，輸送機運行時鏈條將始終保持最佳張緊狀態(tài)，延長了鏈條的使用壽命，縮短了停機時間。
2.3鏈輪組件
鏈輪組件是刮板輸送機的關鍵元件，其發(fā)展趨勢時提高鏈輪組件的可靠性，提高鏈輪的價格精度，改進熱處理工藝，延長鏈輪的使用壽命。
圖1自動張緊系統(tǒng)
目前鏈輪組件在結構上多采用雙列圓錐滾子軸承，稀油潤滑，機頭和機尾的鏈輪組件是一樣的，通過不同的齒輪聯(lián)軸器與減速器聯(lián)接，在井下更換時不用拆卸減速器；鏈輪采用高強度合金鋼，吃面淬火硬度達到HRC55，有效硬化層深度達10mm以上，使用壽命可達到400～500萬t過媒量。
另外，從鏈輪的齒形上加以改進，例如，某公司設計的GR型鏈輪與常規(guī)鏈輪就有很大區(qū)別，這種鏈輪始終有3各輪齒帶動整個載荷。3個輪齒接觸必然會降低鏈輪和鏈條的磨損，從而延長鏈輪和鏈條的使用壽命，減小鏈條伸長率，功率傳輸效率也較高。
2.4軟啟動裝置
國外先進的輸送機傳動裝置多采用軟啟動技術，目前在刮板輸送機上成功使用的軟啟動裝置主要有閥控充液式液力耦合器、CST可控啟動傳輸系統(tǒng)和交流電機變頻調速等。因國內尚無成熟的技術和產品，所以國產大功率刮板輸送機采用的軟啟動裝置全部為進口產品。圖2為德國研制的DTP閥控充液式液力耦合器。
圖2DTP閥控充液式液力耦合器
2.4.1閥控充液式液力耦合器的主要技術特點
⑴可以實現(xiàn)刮板輸送機的空載啟動和過載保護；
⑵通過換水可以實現(xiàn)刮板輸送機的頻繁啟動，而不必限制啟動頻率；
⑶通過告便液力耦合器的重也順序可以實現(xiàn)多機驅動下的負載平衡；
⑷可以實現(xiàn)慢速驗鏈；
⑸雙腔設計，結構緊湊；功率傳遞部件無機械接觸，可靠性高。
⑹以清水作為工作液，安全方便而且廉價，可以通過水管或水箱供水，通過排液泵管排水，排液壓力由主電機帶動的液力循環(huán)產生，通過本安型先導組合閥直接對 水循環(huán)進行控制；
⑺在不影響功率傳輸?shù)那闆r下，通過換水來散熱。
2.4.2CST可控啟動傳輸系統(tǒng)的主要技術特點
⑴在任意載荷下可以跟蹤任何啟動曲線，加減速度任意調節(jié)；
⑵相對調速型液力耦合器而言，傳動效率高；
⑶具有任意條件下的可控停車能力。
⑷可實現(xiàn)多點驅動之間高精度的功率平衡，平衡精度可達98%；
⑸對輸送機所有機械、電器系統(tǒng)提供過載保護，保護系統(tǒng)響應速度快；
⑹可以上時間低速運行，實現(xiàn)免俗驗鏈；
⑺現(xiàn)場調試簡單，可以很方便地在線進行參數(shù)修改與調試。
2.4.3交流電機變頻調速技術的主要技術特點
⑴與其他軟啟動方式相比，全部實現(xiàn)了電器軟啟動控制，刮板輸送機傳動系統(tǒng)和供電系統(tǒng)得到最大的簡化；
⑵啟動時間可隨負載自行調節(jié)；
⑶實現(xiàn)了刮板輸送機滿載及空載的平穩(wěn)啟動；
⑷大幅度降低了啟動電流，提高電網(wǎng)供電質量，減少電網(wǎng)沖擊。
2.5中部槽
中部槽是整個工作面輸送機的軀干，其使用壽命是衡量整機使用壽命的重要指標。目前中部槽多采用∑形斷面槽幫、整體鑄焊封底結構，壽命已達1000萬t。為了進一步提高使用壽命，國內外主要生產廠商對中部槽外形、結構及材料等方面有進行了大量的研究。如德國某公司通過研究和開發(fā)，撥那個在井下對不同斷面的中部槽進行大量試驗，最終發(fā)現(xiàn)，與∑形斷面槽幫相比，弧形斷面槽幫使刮板與槽幫內側面接觸液力小，從而減小摩擦
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