| The paper aims at a novel hydraulic pressure monitoring device with complete mechanical structure,low cost,high reliability,powerless,especially for long-distance and multi-angle observation and suitable for large-scale installation.As the key support equipments for fully mechanized coal mining,the hydraulic support realizes the coal outputted and the advancement of comprehensive mining equipment through cyclic process which consists of supporting,cutting,moving and shifting conveyors.And during the entire process,the hydraulic support gets directly interacted with the roof of the working surface so as to provide safe working space for coal mining.Considering the complex working conditions of the mine,in order to timely know the state of the roof pressing and the supporting as well as provide a reliable reference for safe and efficient operation,it is very necessary to monitor the work load of the hydraulic support.The existing conventional pressure monitoring instruments have the poor performance of moisture-proof,waterproof,anti-interference as well as used cumbersomely and monitoring long period,etc.And there is no doubt thatwires deployment and maintenance of power utilization monitoring devices will increase the production cost.Other types such as acoustic,electrical,and vibration sensors also need to demodulate the acquired signals,so that they cannot assist the on-site staff quickly to clear the status of support.And at present what important is that a very lack of a pressure monitoring device that can be viewed remotely and circumferentially.Therefore,there is an urgent need for a hydraulic pressure monitoring device that powerless,simple and convenient installation,low cost and can be remotely and multi-angle-monitored.Aiming at the need of mine,this paper designs a new type of pressure monitoring device.Firstly,the monitoring principle is determined.The determination of the birefringence effect and the interference coloration based on the anisotropic material under internal stress are made.And the stress-colored light path is established so as to determine a new method for indicating the pressure by color.Second,determining the device structure which mainly has three components: the carrier tube,the uniform carrier,and the color-displaying material.The transmission of deformation and stress from carrier tube initially applied by the pressure of column emulsion to the uniform carrier and eventually to be internal stress distributed in the color-displaying material.Based on the stress-coloration principle of the color-displaying material,the relevant kinds of colors would emrge in the circle with the miner's lamp irradiation.By observing the color,the pressure on the carriertube can be clearly defined which is same to the pressure of column emulsion.Then the sensitivity of the monitoring device is analyzed.By the respective use of Pro/E 4.0 to build the assembly model of the three components and ANSYS 14.5 to perform a static pressure analysis of 0 ~ 60 MPa to determine the relevant deformation and stress,which mainly aims to determine the stress-color relationship of color-displaying material.Secondly,the displacement response characteristics of the monitoring device under constant pressure and transient impact pressure are determined,and a protection device for the monitoring device is specifically designed.In the AMESim environment,the displacement response characteristics of the three components with no protection device at pressures of 28,38.5,60 MPa and the ones with protection device with a transient pressure of 60 MPa are analyzed,which obviosly prove the function of the protection device.Finally,the observation distance and angle of the monitoring device are determined.Through the prototype testing,it is confirmed that the sensitivity is in good agreement with the ANSYS calculation result.The reliable observation distance is determined within 20 m and the effective observation angle is 120°. |
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