Lightweight Design And Research Of Coal Mine Hydraulic Support

Hydraulic support is the key equipment of coal mining in the "three-machine andone-support", its role is to support mine roof, protect the safety of the operating room, Pushthe coal cutter and conveyors forward. The use of hydraulic support not only improved thecomprehensive mechanization of coal mining, but also increase the coal production andcoal mining efficiency, improved the working conditions and ensured the production safety.The coal reserves in our country is more of thick coal seam, when doing the mining work,it requires large working resistance and large mining height hydraulic support. Because ofthe simple structure, high reliability and good stability of the two-pillar shield hydraulicsupport, it is widely used in comprehensive mining working face.This paper analyzes the importance of hydraulic support for coal mine safetyproduction and the actual situation of hydraulic support industry in our country, using thesoftware Solidworks established ZY12000/24/56D type three-dimensional model of thehydraulic support. And using the software Abaqus to analysis the static strength stress ofthe overall structure, simulating the stress when the support in different working conditions,summed up the stress concentration area of the support, and preliminary points out the areawhich can be optimized when taking lightweight according to the stress distribution.According to the national published "The general technical conditions of coal minehydraulic support" MT312-2000requirement, testing the prototype of hydraulic support,the main strength test takes in the five kinds of dangerous conditions which are the canopyeccentric load, the canopy torsion load, the base torsion load, the load on both ends of thebase, the load on both ends of the base and the canopy torsion load. Through measurementthe stress of the support key parts to detect whether it meets the requirements. At the sametime, detect the reliability of finite element analysis by contrast with the data of finiteelement analysis, and provide a basis for the support lightweight design.On the basis of the finite element analysis and the physical test, the softwareHyperWorks and Abaqus is used to analyze the hydraulic support lightweight design, bythe topology optimization and size optimization methods. When doing the topologyoptimization, the optimization goal is to achieve the minimum stress of the hydraulicsupport, the design variables is part structure of the support, and the constraint conditionsis volume of the hydraulic support. When doing the size optimization, the optimizationdesign on hydraulic support is conducted with minimizing weight as objective, the section thickness of main parts as design variable, strength as constraints. After two optimization,it reduced1.729×103Kg to the support’s weight, the lightweight percentage is5.195%.Through the analysis of coal mining hydraulic support, testing and optimization, theresult shows that use finite element analysis of modern design theory and methods canreplace prototype testing in traditional design. It could provide some theoretical referencefor the design、analysis and optimization of hydraulic support. When the performance ofhydraulic support is improved, it reasonably reduce the production costs and shorten theproduct design and manufacturing cycle at the same time.