| Based on the experiences of advanced design and manufacture of hydraulic support, great mining height, large resistance 6.2m support with two-prop shield is investigated and designed successfully using the combination of theoretical calculations, numerical simulation and experimenal measurement. In order to reach international advanced level, the researching project has solved a series of key techlonogies during the design and manufacture of high-end hydraulic support.For solving these difficulties of hydraulic support design and manufacture, the achievement and originality of the thesis are mainly presented in the following:1) The questions of over 6m synthesizing mining equipment were firstly studied. According to the hydrogeology condition and matching equipment, main technical parameters ware confirmed. With CAD/CAE and adopting overall designing idea, 6.2m hydraulic support is designed and analyzed. Dynamic simulation of virtual prototyping and interference analysis has been achieved based on Solid-Works and COSMOS 3D design. Hyperbola of support has been optimized. Though using finite element analysis, the whole strength of this support has been examined. Then the simulation of structure part, section type and key parts of support has been analyzed in terms of the strength examination. High stability and reliability of the mechanism are got efficiently.2) The welding CCT diagram of SHT900 steel was investigated by thermal simulated technique, which is Formast-D automatic expansion instrument. The phase transformation of overheated zone is studied based on the HAZ CCT, and the weld-ability of SHT900 has been calculated. The relations between preheat temperature, inter-ass temperature and weld-ability are researched depending on slit type cracking test, maximum hardness test and metallographic analysis. Process parameters is obtained by dint of testing and calculated, and the post-weld heat treatment process has been ascertained by impact test and residual welding stress test.3) Aim at in existence of low strength and severe trend of hottear of materials of Hydraulic support socket post, which can not adapt to the design of high strength,good toughness and workability of high hydraulic support. A new kind of high strength steel ZG30Cr06A has been designed by the orthogonal experimentation. The new material's thermo-physical and other parameters have been measured by heat exchange-simulation and ray attenuation methods, Addition these data to the cast CAE software MAGMA, and application simulation method for the socket post optimization process. Finally, researched on the heat treating process and weld-ability of the new material, results demonstrate that ZG30Cr06A has good mechanical performance, upstanding Weld-ability and casting properties, this material can meet the design and use requirement of high hydraulic support.4) The advanced electro-hydraulic controlling system was designed and introduced to the 6.2m hydraulic support. A new kinds of plug-in electro-hydraulic directional control valve has been developed. Therefore the drawback of poor one-way valve flow and large unloading impact problems are solved. Power bond graph of hydraulic systems is established, which can derive equation of state in the dynamic course. The dynamic simulation and optimization of the pilot valve structure are performed with Matlab/Simulink. Through research and selecting design of the electro-hydraulic control system, Support-moving speed has reached 8s/rack, which guarantee the design requirements.
|
PDF Full Text Request