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The vertical Boom-type Roadheader design
1 Introduction
Mechanical design is in the process of product design and an important part of the main links, it is followed in programme design after the design work. The vertical Boom-type roadheader (the roadheader) to the overall design of the merits of complete machine play a decisive role, and the decision of the assembly, the system, coordination between the various components of the unity and match, to obtain the high-end performance and overall better economic efficiency technology. Roadheader design, including the following: 1)According to design project description choice type and various cellular construction pattern 2) Decides the complete machine the main technical performance parameter, Including size parameter, heavy parameter, the parameter of movement and the technical economy refer parameter, 3) According to system design performance requirement, definite complete machine system composition and between them match as well as each part main technical senate parameter, 4) The necessary whole, and the mapping of transmission, hydraulic, electronic control systems, and other plans.
2 the selected models and various components and structural type, drive, and the overall layout of the reasonable
In determining the content, first task should be designed to meet the contents, especially the users of the main demands of the investigation, the two sides exchanged views repeatedly, to satisfy both users (or superior) conditions, can better meet the product development of the overall plan.
2.1 the selected models
According to roadheader use, for the coal mine tunnel boring or used for other sectors of the works, roadheader working conditions for cutting coal roadway or semi-Coal Lane, the compressive strength of coal and rock one-way (or the value of platts coefficient f) and the rock abrasion factor. At the same time the control line should be superscript MT138 ~ 1995 "cantilevered Roadheader types and parameters",
according to cutting coal and rock the biggest one-way compressive strength, the type of selected models.
2.2 the structure of the various components, the way the driver identified
Roadheader by cutting general agencies, shipping agencies, walking, hydraulic system, electronic control systems and auxiliary devices (such as dust removal devices, security devices, remote monitoring devices) and other components. 1) Cutting agencies. Cutting the drive from AC motor-driven, in the transmission system located in the general profile coupling with no mechanical overload protection device, the two planets reducer driven spindle front of the cutting head. Some sections of the working bodies boring machine has cut chain, disc-milling and cutting-such as cantilever. Cantilever due to the cutting-boring machine body flexible, relatively small, can cut a variety of shapes and sections of the roadway, and to achieve selective cutting, but cutting good effect, a higher rate of boring, so now used mainly cantilever Cutting-and has become boring machine working body of a basic pattern. By cutting head of the layout, is divided into horizontal and vertical axis of the two. The line-cutting head of the advantages are: Transmission convenient, compact and can be cut to any shape of the profile, easy access to the formation of a cross-section and is conducive to expansion in the use of cantilever, or ditch digging, in Waterloo. Cutting head the shape of a cylindrical, cone and the cone and cylindrical, as the latter two cutting head to drilling, and the cutting surface than the formation, use it more. This is the work of the shortcomings: As the longitudinal axis of cutting head in the horizontal swing at the cutting reaction force is not passed machine centres, with cantilevered form of torque to boring machine have a greater vibration, stability is poor. Therefore, the coal roadway excavation, the need to increase the body weight or support the installation of auxiliary equipment. At present, such a boring machine in some sections of the use of more boring machine. 2) Shipment of bodies. It generally from the middle loading and conveyor components. They were driven or focus may be linked, either by AC motor drive, can also be used hydraulic motor drive. Trailing claw-is to use a turn moves the rake claws to continue to rake materials and in a reprint from transport operators. This structure is simple, reliable, small form
factor, loading good effect, the application is widespread. However, such institutions loading width restricted (because boring machine running track when agencies generally do not arouse). To expand the loading width, will shovel the entire harrow board, together with the claw agencies in the level of swing, or design dual rake claws, to expand the scope of loading. Institutions than the rake-wheel-claw simple, high intensity, reliable, but with less bulk materials. Loading agency programme is not only the installation of the claw-rake-wheel can also be installed, the two can be used interchangeably. Usually, the choice rake claw-loaded, but considering loading width of the problem, may choose to double rake claws, can also be designed to rake claw-round interchangeable with the loading mechanism. Some sections boring machine use of scraper chain conveyor agencies. Transmission organizations to adopt an independent driver, is about to motor or hydraulic motor layout away from the machine side, driven by slow delivery agencies. This mode of transmission drive layout simple, and filling the campaign Hubuyingxiang. However, due to transmission and more dynamic components, the point of failure has increased. At present, the two transportation agencies are used, as appropriate, the design should be identified. General loading and institutions often use the same drive. Loading agencies can use motor-driven, can also be used hydraulic motor drive. However, in consideration of the working environment and wet with mud, optional hydraulic motor drive for good. 3) Run institutions. Walking agencies tracked the general pattern, crawler-run institutions apply to the floor is uneven or soft conditions, no road track laying. Traction with large capacity, good mobility, reliability, flexibility and mobility on the floor adaptability of the advantages of good. But its complex structure, components
and wear more serious. At present cross-section of the boring machine is usually used crawler-run institutions. Walking agencies tracked the general pattern, the two tracked separately by the respective power to drive, to achieve in situ. Caterpillar is the driving force of two motors and hydraulic motors, motor driver is generally set up a walking speed, hydraulic motor-driven large low-speed torque motor can be driven directly tracked sprocket, or used in the hydraulic motor speed Reducer led the drive sprocket track, it can achieve Promise governor. Tracked structure of a sliding and rolling two, when the speed machine to mobilize ≤ 10 m / min in the light Roadheader, should adopt the structure of sliding when the mobilization of speed machines> 10 m / min of heavy, severe Roadheader should be used Rolling structural type. 4) The hydraulic system. Hydraulic systems use of open-way valve system more centralized control (direct or remote control manipulation) way. Domestic and foreign use of the past, gear pumps, hydraulic system in recent years Roadheader used piston pump have increased the trend. 5) Electronic control system. Electronic control systems, including some power, control and inspection of the part. Electronic control system must be in accordance with the requirements of coal mine explosion-proof design, manufacture, testing, GB3836-2000 must meet the standards of the relevant provisions and requirements. In order to improve operations at the Roadheader in the security, operational flexibility and mechanical transmission part of the fault diagnosis and monitoring functions, from the practical point of view, the installation of the necessary machines from a remote control device, monitoring pressure, temperature, level and key parts the fault diagnosis device.
2.3 Layout
General layout of the contents include the following: 1) Identify the components in complete machine said the location, shape and size of the request; 2) To identify the parts, components and the connections between complete machine; 3) estimates complete machine weight and the weight of all components requested; 4) layout of the manipulation of institutions, the driver's seat;
5) examination of moving parts of the movement space, rule out the possibility of interference in the campaign.
2.4 specific requirements
Boring machine in the general layout, the need to pay attention to the following questions: 1) institutions into the reducer reducer, as far as possible to coax axis; 2) cantilever and spade-suited to the size of relations, not only conducive to loading, to avoid cutting the first shovel cutting board; 3) the level of cantilever and vertical position can swing the center coincidence, can not overlap. From the increased stability of the machine, these are highly swing should be reduced. In the cantilever is not guaranteed to interfere with other agencies under the conditions of swing centres are located should try to rely on, but must ensure that the machines in the centre plane of vertical symmetry; 4) When all the major components designed after. Checking should be carried out, does not meet requirements to be adjusted just so that the focus in track and less than the former center Shaopian L / 6 (L grounding for the track length). In addition, the center of gravity position in the demand for cutting bodies turret after the centerline, and Yuediyuehao high center of gravity to enhance stability when operating machinery. 5) the overall layout should consider the weight of symmetrical left and right and take care of work habits and to facilitate the operation. General driver in the left side of the fuselage and the fuselage in the rear, driver seat height should ensure that the people's attention, what good control of their machines, cutting out the rules of the roadway; 6) Caozong Tai position should be appropriate, should ensure that drivers easy manipulation, and effort. Instruments showed that the location devices for drivers to observe, not scattered normal operation of the driver's attention.
2.5 types and power transmission components choice
transmission patterns and components should follow the principle of choice 1) the advanced nature of technology: machines to improve performance, increase productivity; 2) economic rationality: drive system as simple as possible, fewer components and easy processing, low price, easy maintenance, long life;
3) reliability of the work: the transmission system reliability performance for the life of components, as well as component quality requirements; 4) adaptation: the drive system components should be adapted to load, working conditions and environmental conditions of the request. Agencies to the transmission system requirements and the choice of transmission patterns . Boring machine cutting, loading, transport, walking and other institutions generally are respectively transmission, all parts of the state and subject to different working conditions, thus driving patterns have different requirements. 1) institutions require a greater short-term Guozainengli, motor oil is very sensitive to the impact load, the loading capacity of low-impact cutting head for normal functioning. Therefore, the boring machine working body should adopt the motor-driven mechanical transmission type. Should make use of small size, power, a strong capacity for electric motors, and equipped with reliable electrical protection device. According to the compact body of work features, usually work in the reducer cantilever, an integral part of a cantilever. Cutting the first governor general way with a round peg for the method of transmission organizations to simple. 2) rake with institutions transmission device is characterized by: reducer be installed in the limited size of the lower part of the shovel plate, thus design a smaller space, poor working conditions. Reducer often soaked in muddy coal and rock in the cards when the material easy to overload. Trailing equipment, transportation agencies the use of mechanical transmission, for the larger motor, not the end of the conveyor installation, the shovel is generally installed on both sides of the board two motor, with a rake, a common power transmission organizations, such bound to make the Slowdown me the size of the increase in the spade under the board layout more tense. In addition, consider the claw and rake boards linked linked overload situation, to protect the motor did not burn, the general needs of internal security in reducer friction-clutch. Trailing equipment, transportation agencies the use of motor oil transmission gear, as small size, light weight, will enable the two separate drive, thus simplifying transmission device, for the spade under the board layout, designed for good results sealed mechanical seal or reducer And shovel plate separation, while achieving automatic overload protection.
3) walk the track-driven approach and a motor-driven motor oil in two ways. Respectively, through mechanical devices or directly from the slowdown in motor oil led the initiative sprocket running track. Mechanical transmission of the walking track, with General Motors will be tracked in two reducer rear, the brake hydraulic braking by mechanical means way. This transmission mode drive high reliability and low prices of motor, easy maintenance, but not speed, slow me larger, Lin Shui major roadway, the motor easily exposed to moisture and burned. Tracked walk to adopt hydraulic transmission patterns, simple system, better performance and advanced technology. Hydraulic transmission of the walking mechanism, in the form choice and hydraulic motor speed control mode design, there are different options. The use of low-speed torque motor-driven, characterized by the system simple, small size, light weight, to achieve stepless speed regulation and automatic overload protection. However, hydraulic motor drive complex, the high cost of manufacturing, maintenance more difficult. Gear used motor oil, the volume of high efficiency, performance and impact-resistant, easy maintenance, low cost, a 10 KW around the motor gear oil prices only with the power of the radial-Sema Da 1 / 10; small size, light weight. A 10 KW gear around the weight of motor oil, with the only major power low-speed torque motor of 1 / 18, the weight of the motor 1 / 13. Gear used motor oil, although lower-speed reducer size large torque motor, but a small electric (MRH-S50-13-type plane reducer transmission ratio i = 328). So can easily be motors, reducers, hydraulic Zhidong Fa, tight chain devices installed in the middle-tracked. In this way than on the technical performance of mechanical transmission, the economic indicators better than the low-speed torque motor drive. So has a unique advantage. The walking speed in two ways: one is a variable pump. The other is the use or diversion of the flow and speed control programmes, such as the MRH-S50-13 type aircraft, that is, in the rapid mobilization of machinery, to stop carrying motor oil, only to run motor oil so that the boring machine has two Walking speed.
3 determination complete machine main technology senate parameter
Mechanical Roadheader complete machine main technical parameter including size senate parameter (length ×width ×highly); weight parameter, parameter of movement and dynamic parameter.
3.1 size parameters
Complete machine length, width of the size directly related to its turning radius, Recommended light-length ≤ 7.5 m, medium-length ≤ 8.5 m, heavy machine ≤ l0m, the corresponding width were ≤ 1.6 m, ≤ 2.5 m, ≤ 3 m. The complete machine relates its tendency, the static stability highly directly, the adaptation scope and passes quality, therefore lower better. The current development trend of Chinese and foreign models is the dwarf models, medium and heavy-high 1.6 ~ 2 m, special light, light machine the height of 1.4 ~ 1.6 m. Roadheader to dig the biggest section of roadway, the minimum height and width should be designed to meet the requirements of the mission. Undercover depth of 250 ~ 400 mm, ground clearance C = B/13 +84 (mm), B for the two track distance). Middle-long conveyor entrance to the expected high degree of the best 400 mm, length of track ground with the center distance L B ratio for L / B ≤ 1.6.
3.3 movement parameters
Cutting the movement parameters: cutting head of the average cutting speed V: on the one-way coal and rock compressive strength of σ c ≤ 40 MPa, V = 3 ~ 3.5m / s;
σ c ≤ 60MPa, V = 2 ~ 2.5m / s, σ c > 60MPa. V = l ~ 2m / s. But eventually cutting
speed by cutting technology to determine.
3.4 dynamic parameters
Roadheader-driven power sources are used Motors. Cutting power body size. In fact the general use of analogy, combined with roadheader some personality and
experience factors to determine. Roadheader in the operating process, the vertical axis and the horizontal axis-of the need for adequate cutting edge and push forward swing (horizontal and vertical) force. According to Russia (the former Soviet Union) in the laboratory test results that the cutting of coal and rock platts hardness f = 4 ~ 6 (equivalent to 0 C = 40 ~ 60MPa), grinding coefficient F = 5 ~ 7mg/mm2. Cutting the shaking force (traction) Pv = (1 ~ 1.34) P, P = M / Rcp, in the P-cutting head for the average cutting edge; Rcp cutting head for the average radius; M for cutting the head of the rated torque. Cut the feeding of (axial thrust) R; (1.8 ~ 2.5) Pv, this force should be no larger than the floor slippery track at the limits of traction.
3.5 technical and economic indicators
Q = (m3/min), in the sx-cutting head for the verticalcross sectional area, m2: Vn for the cutting head of cutting swing speed, m / min. Roadheader designed life, in the international advanced products up to 3 to 5 years, during which the need of major repair or wells, the general domestic product for 1 to 2 years.
4 in accordance with design requirements. Determine the parameters of the main components and their relationship between the connector
4.1 cutting agencies and technical parameters of the established link between
1) Cutting-agency technical parameters of cutting the head with the general pick for the double-headed or three spiral layout. Cutting head speed n = 20 ~ 65r/min, a sharp pick cutting the average speed V = 1.5 ~ 2.5m / s, cutting swing speed Vn = 0.8 ~ l0m / s. Cut-off line from t = 20 ~ 50mm, (when cutting coal from the value of all-time for small value). Average single-pole/double-throw force should reach: f4 grade coal and rock F ≥ 2500 N, f6 grade coal and rock F ≥ 5000 N, f8 grade coal and rock F ≥ 12000 N, pick the best angle for the installation of 45 ° ~ 48 °. 2) Cutting the link .Cutting agencies cantilever Chaxing-installed in front of the fixed-Chaxing rotary table, the turret to the rack. According to cutting agencies in the course of operating the force and torque, the application of MT475-1996 "cantilevered Roadheader rotary bearing type, the basic parameters and technical requirements" selected rotary bearing the structural type, determined by calculating
slewing ring size specifications. If the user does not require a cantilever stretching structure, is generally not recommended.
4.2 shipping agencies determine the parameters
1) Loading mechanism Loading bodies and Middle conveyor used linkage or single-action mode, loading the bodies rake claws speed is generally 25 ~ 48 r / min. Sta