基于应力-强度干涉理论的采煤机截割部关键零件可靠性分析
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摘要
随着中厚煤层不断开采完毕,薄煤层开采比重将不断加大,其安全、高效开采日显重要,但由于开采空间有限、条件恶劣,采煤机易出现设计结构不合理、工作状态不稳定、可靠性差等问题。以MG2~* 100/455-BWD新型薄煤层采煤机截割部为工程对象,采用Pro/E,ANSYS,ADAMS建立了该采煤机的刚柔耦合虚拟样机模型,基于破煤理论建立了采煤机螺旋滚筒的力学模型,通过MATLAB编制了相关程序解决了刚柔耦合虚拟样机模型载荷添加的问题;通过虚拟仿真获取了关键零件输出轴、壳体、行星架的Von Mises应力分布及最大应力节点应力值的时域信息,以30组不同牵引速度仿真模型的仿真结果建立了各关键零件的最大应力分布函数;以应力-强度干涉可靠性理论为基础,结合各关键零件的最大应力分布函数及所用材料强度分布函数,在考虑载荷作用次数情况下,建立各关键零件在随机载荷多次作用下的可靠度计算模型。经分析计算得到输出轴、行星架、壳体的可靠度分别为0.978,0.536及0.614,研究发现:行星架与壳体存在应力集中现象,应力最大位置分别位于行星架腹板与花键轴相交处及壳体惰轮轴孔后侧与行星减速器承载部分相交处。在对薄弱零件改进后,行星架、壳体的可靠度分别达到0.969 0和0.997 4,满足使用要求。该方法可有效缩短产品设计周期,提高采煤机关键零件的设计质量及可靠性。
With the completion of medium-thick seam mining gradually,the proportion of thin seam mining will continue to increase,and its safe and efficient mining is becoming increasingly important.Due to the limitation of mining space and harsh conditions,the shearer is prone to the problems of unreasonable structure design,instability and poor reliability.Taking new thin coal seam shearer of MG2~* 100/455-BWD cutting parts as an investigation target,the rigid flexible coupling virtual prototype model of the shearer was established by Pro/E,ANSYS and ADAMS.The mechanical model of shearer spiral drum was established based on coal breaking theory.The problem of load addition of rigidflexible coupling virtual prototype model was solved by programming with MATLAB.The maximum stress nodes' timedomain information and Von Mises stress distribution of output shaft,shell and planetary carrier were obtained by virtual simulation.Based on the simulation results of 30 sets simulation models for different hauling speeds,the maximum stress distribution function of each key part was established.Based on the reliability theory of stress-strength interference,combined with the maximum stress distribution function of each key part and the strength distribution function of the material used,the reliability calculation model of each key part under multiple random loads was established considering the cycle of loads.The reliabilities of output shaft,planet carrier and shell were cal-culated as 0.978,0.536 and 0.614 respectively.The results show that the stress concentration phenomena exist on planetary carrier and shell.The maximum stress locates at the intersection of web and spline shaft of planetary carrier,and at the intersection of backside of idler shaft hole and outside of planetary reducer of the shell,respectively.After the improvement of the weak parts,the reliability of the planet carrier and shell are 0.969 and 0.9974 respectively,which can meet the operation requirement.This method can effectively shorten the product design cycle and improve the design quality and reliability of the key parts of shearer.
With the completion of medium-thick seam mining gradually,the proportion of thin seam mining will continue to increase,and its safe and efficient mining is becoming increasingly important.Due to the limitation of mining space and harsh conditions,the shearer is prone to the problems of unreasonable structure design,instability and poor reliability.Taking new thin coal seam shearer of MG2~* 100/455-BWD cutting parts as an investigation target,the rigid flexible coupling virtual prototype model of the shearer was established by Pro/E,ANSYS and ADAMS.The mechanical model of shearer spiral drum was established based on coal breaking theory.The problem of load addition of rigidflexible coupling virtual prototype model was solved by programming with MATLAB.The maximum stress nodes' timedomain information and Von Mises stress distribution of output shaft,shell and planetary carrier were obtained by virtual simulation.Based on the simulation results of 30 sets simulation models for different hauling speeds,the maximum stress distribution function of each key part was established.Based on the reliability theory of stress-strength interference,combined with the maximum stress distribution function of each key part and the strength distribution function of the material used,the reliability calculation model of each key part under multiple random loads was established considering the cycle of loads.The reliabilities of output shaft,planet carrier and shell were cal-culated as 0.978,0.536 and 0.614 respectively.The results show that the stress concentration phenomena exist on planetary carrier and shell.The maximum stress locates at the intersection of web and spline shaft of planetary carrier,and at the intersection of backside of idler shaft hole and outside of planetary reducer of the shell,respectively.After the improvement of the weak parts,the reliability of the planet carrier and shell are 0.969 and 0.9974 respectively,which can meet the operation requirement.This method can effectively shorten the product design cycle and improve the design quality and reliability of the key parts of shearer.
引文
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[12]赵丽娟,马永志.基于多体动力学的采煤机截割部可靠性研究[J].煤炭学报,2009,34(9):1271-1275.ZHAO Lijuan,MA Yongzhi.Reliability research on shearer cutting unit based on multi-body dynamics[J].Journal of China Coal Society,2009,34(9):1271-1275.
[13]赵丽娟,刘旭南,马联伟.基于经济截割的采煤机运动学参数优化研究[J].煤炭学报,2013,38(8):1490-1495.ZHAO Lijuan,LIU Xunan,MA Lianwei.Optimization research on shearer’s kinematic parameters based on economical cutting[J].Journal of China Coal Society,2013,38(8):1490-1495.
[14]赵丽娟,田震.薄煤层采煤机截割部动态特性仿真研究[J].机械科学与技术,2014,33(9):1329-1334.ZHAO Lijuan,TIAN Zhen.Simulation on dynamic characteristics of cutting unit for thin seam shearer[J].Mechanical Science and Technology for Aerospace Engineering,2014,33(9):1329-1334.
[15]赵丽娟,李佳,田震,等.新型薄煤层采煤机截割部建模与仿真研究[J].机械传动,2013,37(1):47-50.ZHAO Lijuan,LI Jia,TIAN Zhen,et al.Reliability analysis of a new shearer cuting unit in shin coal seam[J].Journal of Mechanical Transmission,2013,37(1):47-50.
[16]李佳.新型薄煤层采煤机截割部可靠性研究[D].阜新:辽宁工程技术大学,2013.LI Jia.Reliability Study of new shearer cutting unit working in thin coal seam[D].Fuxin:Liaoning Technical University,2013.
[17]王丹玉,王启佳,孙维.采煤机牵引速度的分析与选择[J].煤矿机械,2012,33(10):201-203.WANG Danyu,WANG Qijia,SUN Wei.Analysis and selection of shearer haulage speed[J].Coal Mine Machinery,2012,33(10):201-203.
[18]曾波.某航空发动机涡轮叶片动态可靠性建模与分析[D].成都:电子科技大学,2013.ZENG Bo.Dynamic Reliability modeling and analysis of an aeroengine turbine blade[D].Chengdu:University of Electronic Science and Technology of China,2013.
[2]陈鹏.基于全寿命周期理论的滚筒采煤机可靠性工程技术研究[D].太原:太原理工大学,2011.CHEN Peng.Research on reliability engineering technology of drum shearer based on life cycle theory[D].Taiyuan:Taiyuan University of Technology,2011.
[3]张义民,黄婧,朱丽莎,等.采煤机摇臂传动系统可靠性稳健优化设计[J].煤炭学报,2015,40(11):2540-2545.ZHANG Yimin,HUANG Jing,ZHU Lisha,et al.Reliability-based robust optimization design of the transmission system of a shearer ranging arm[J].Journal of China Coal Society,2015,40(11):2540-2545.
[4]周笛,张旭方,杨周,等.采煤机牵引部传动系统动态可靠性分析[J].煤炭学报,2015,40(11):2546-2551.ZHOU Di,ZHANG Xufang,YANG Zhou,et al.Vibration reliability analysis on tractive transmission system of shearer[J].Journal of China Coal Society,2015,40(11):2546-2551.
[5]赵津.采煤机潜在故障预测和可靠性分析[D].太原:太原理工大学,2016.ZHAO Jin.The potential failure prediction and reliability analysis of drum shearer[D].Taiyuan:Taiyuan University of Technology,2016.
[6]张义民,王婷,黄婧.采煤机摇臂系统行星轮系疲劳可靠性灵敏度设计[J].东北大学学报自然科学版,2016,37(10):1426-1431.ZHANG Yimin,WANG Ting,HUANG Jing.Fatigue reliability-based sensitivity design of planet gear for shearer rocker arm system[J].Journal of Northeastern University(Natural Science),2016,37(10):1426-1431.
[7]王正,谢里阳,李兵.随机载荷作用下的零件动态可靠性模型[J].机械工程学报,2007,43(12):20-25.WANG Zheng,XIE Liyang,LI Bing.Time-dependent reliability model of component under random load[J].Chinese Journal of Mechanical Engineering,2007,43(12):20-25.
[8]赵丽娟,刘旭南,刘鹏.截齿排列方式对采煤机工作性能的影响[J].机械科学与技术,2014,33(12):1838-1844.ZHAO Lijuan,LIU Xunan,LIU Peng.Picks arrangement mode’s influence on shearer’s working performance[J].Mechanical Science and Technology for Aerospace Engineering,2014,33(12):1838-1844.
[9]刘旭南,赵丽娟,冯认金,等.薄煤层采煤机运动学参数最佳匹配问题研究[J].机械科学与技术,2017,36(11):1701-1707.LIU Xunan,ZHAO Lijuan,FENG Renjin,et al.The research on kinematic parameter optimum matching of thin coal seam shearer[J].Mechanical Science and Technology for Aerospace Engineering,2017,36(11):1701-1707.
[10]赵丽娟,董萌萌.含硫化铁结核薄煤层采煤机工作机构载荷问题[J].煤炭学报,2009,34(6):840-844.ZHAO Lijuan,DONG Mengmeng.Load problems of working mechanism of the shearer in containing pyrites and thin coal seam[J].Journal of China Coal Society,2009,34(6):840-844.
[11]刘旭南.采煤机、掘进机动力学仿真及控制中若干关键技术研究[M].沈阳:辽宁科学技术出版社,2017.
[12]赵丽娟,马永志.基于多体动力学的采煤机截割部可靠性研究[J].煤炭学报,2009,34(9):1271-1275.ZHAO Lijuan,MA Yongzhi.Reliability research on shearer cutting unit based on multi-body dynamics[J].Journal of China Coal Society,2009,34(9):1271-1275.
[13]赵丽娟,刘旭南,马联伟.基于经济截割的采煤机运动学参数优化研究[J].煤炭学报,2013,38(8):1490-1495.ZHAO Lijuan,LIU Xunan,MA Lianwei.Optimization research on shearer’s kinematic parameters based on economical cutting[J].Journal of China Coal Society,2013,38(8):1490-1495.
[14]赵丽娟,田震.薄煤层采煤机截割部动态特性仿真研究[J].机械科学与技术,2014,33(9):1329-1334.ZHAO Lijuan,TIAN Zhen.Simulation on dynamic characteristics of cutting unit for thin seam shearer[J].Mechanical Science and Technology for Aerospace Engineering,2014,33(9):1329-1334.
[15]赵丽娟,李佳,田震,等.新型薄煤层采煤机截割部建模与仿真研究[J].机械传动,2013,37(1):47-50.ZHAO Lijuan,LI Jia,TIAN Zhen,et al.Reliability analysis of a new shearer cuting unit in shin coal seam[J].Journal of Mechanical Transmission,2013,37(1):47-50.
[16]李佳.新型薄煤层采煤机截割部可靠性研究[D].阜新:辽宁工程技术大学,2013.LI Jia.Reliability Study of new shearer cutting unit working in thin coal seam[D].Fuxin:Liaoning Technical University,2013.
[17]王丹玉,王启佳,孙维.采煤机牵引速度的分析与选择[J].煤矿机械,2012,33(10):201-203.WANG Danyu,WANG Qijia,SUN Wei.Analysis and selection of shearer haulage speed[J].Coal Mine Machinery,2012,33(10):201-203.
[18]曾波.某航空发动机涡轮叶片动态可靠性建模与分析[D].成都:电子科技大学,2013.ZENG Bo.Dynamic Reliability modeling and analysis of an aeroengine turbine blade[D].Chengdu:University of Electronic Science and Technology of China,2013.
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