矿井液压支架立柱的立式拆装机设计研究.docx

矿井液压支架立柱的立式拆装机设计研究摘 要　　　　液压支架作为煤矿综采工作面上重要的支护装置，直接决定着矿井的安全生产，立柱作为液压支架的重要组成部分，主要作用是调整支架高度并支撑综采工作面上方的煤层，其质量决定了液压支架的可靠性而综采工作面工作环境十分恶劣，会严重损坏立柱，影响液压支架的安全可靠性，缩短其使用寿命为了保障安全生产，在完成一个工作面的开采后，需要对立柱进行拆装维护和保养 　　　　立柱导向套拆卸是立柱拆卸中的一个难点问题，且常规卧式拆装立柱会产生导向套螺纹损坏、缸体损坏和密封件压坏等问题因此 设计了一种立柱立式拆装机，实现拆装立柱方便，改善立柱的拆装质量和效率完成了以下研究工作：　　　　（1）针对立式拆装机需要实现的功能，进行了整体结构设计根据立式拆装机各个机构的实现作用，详细介绍各个机构的组成、功能及关键部件结构设计　　　　（2）采用液压系统为立式拆装机的动力系统，对液压元件进行设计选型对执行元件液压缸进行了设计，对执行元件液压马达和动力元件液压泵进行了计算选型，确定可靠的的液压回路并优选了相应的控制和辅助元件，最后确定液压原理图　　　　（3）运用有限元法对关键零部件进行静力学分析,以保证立式拆装机关键零部件的刚度和强度。

静力分析结果表明，旋转盘和升降架的刚度和强度满足要求，棘轮盘在进行结构改进后满足要求　　　　（4）在满足刚度和强度的前提下，运用有限元法对旋转盘和升降架进行轻量化优化设计根据拓扑优化的结果，对旋转盘和升降架进行轻量化设计，再对优化完成后的旋转盘和升降架进行静力学分析，分析结果表明，旋转盘和升降架在轻量化后不仅减轻了质量，节约了成本，同时还满足刚度和强度的要求　　　　通过设计该立式拆装机，能够顺利拆卸立柱导向套，即使遇到腐蚀锈死的导向套也能完美拆卸立式拆装机使拆装立柱的效率和质量有很大的提高，同时能够降低劳动强度　　　　关键词：立式拆装机；整体设计；液压系统设计；有限元分析及优化　　 　　Abstract　　　　As an important supporting device on the coal mining face, the hydraulic support directly determines the safe production of the mine. The column is an important part ofthe hydraulic support. The main function is to adjust the height of the support and support the coal seam above the fully mechanized mining face. The quality of columndetermines the reliability of the hydraulic support . The working environment of the fully mechanized mining face is very bad, which will seriously damage the column, affectthe safety and reliability of the hydraulic support and shorten its service life. In order to ensure safe production, after the completion of mining of a working face, the column needs to be dismantled and maintained.　　　　The column guide sleeve disassembly is a difficult problem in the column disassembly, and the conventional horizontal disassembly column will cause problems such as guide sleeve thread damage, cylinder damage and seal crushing. A column vertical disassembling and installing machine is designed to facilitate the disassembly and assembly of the column and improve the disassembly and assembly quality and efficiency of the column. Completed the following research work:　　　　(1) The overall structural design was carried out for the functions that the vertical disassembling and installing machine needs to implement. According to the realizationof the various mechanisms of the vertical disassembling and installing machine, the composition, function and key component structure design of each mechanism areintroduced in detail.　　　　(2) The hydraulic system is the power system of the vertical disassembling and installing machine, and the hydraulic components are designed and selected. The hydraulic cylinder of the actuator is designed, the actuator hydraulic motor and the hydraulic pump of the power component are calculated and selected, the reliable hydraulic circuit is determined and the corresponding control and auxiliary components are selected, and the hydraulic schematic is finally determined.　　　　(3) Static analysis of key components by finite element method, in order to ensure the rigidity and strength of key components of vertical disassembling and installing machine. The static analysis results show that the stiffness and strength of the rotating disc and the lifting frame meet the requirements, and the ratchet disc meets the requirements after structural improvement.　　　　(4) Under the premise of satisfying the rigidity and strength, the finite element method is used to optimize the design of the rotating disc and the lifting frame. According to the results of topology optimization, the rotating disc and the lifting frame are lightly designed, and then the static analysis of the rotating disc and the lifting frame after optimization is carried out. The analysis results show that the rotating disc and the lifting frame not only reduce the quality after being lightweight.saving costs, while also meeting the requirements of stiffness and strength.　　　　By designing the vertical disassembling and installing machine, the column guide sleeve can be successfully disassembled, and the guide sleeve can be perfectly disassembled even if it encounters corrosion. The vertical disassembling and installing machine greatly improves the efficiency and quality of the disassembly and assembly column, and at the same time reduces the labor intensity.　　　　Key words:vertical disassembling and installing machine; overall design; hydraulic system design; finite element analysis and optimization。

　　　　1、绪论　　　　1.1、课题来源　　　　本课题来源于企业项目：液压支架立柱立式拆装机的研发　　　　1.2、课题研究背景　　　　我国经济发展的主要能源为煤炭，其极大地促进了我国的经济发展煤炭占一次能源生产量的65%和消费总量的67%因此，煤炭在未来一段时期内仍在我国能源结构中处主导地位[1-2]然而，我国煤炭总储量的53%埋藏在地表下近来资源和能源的日益紧缺，国民经济和社会发展对矿物资源的需求不断增加，开采地表下的煤炭已成为我国发展的重要战略选择，煤矿综合机械化采煤应运而生[3-5]目前我国大部分使用煤矿综合机械化的方式进行采煤，简称为煤矿综采煤矿综采能够减少采煤时的劳动力，与此同时增加采煤时的安全性，从而提高采煤的效率、增加煤矿产量，降低能源的消耗煤矿综采由三个主要装置组成，分别是采煤机、液压支架及刮板输送机[6]　　　　采煤机作为煤矿综采的主要装置之一，如下图1-1中（1）所示，分别为截割部分、装载部分、行走部分、操控部分和辅助部分组成采煤机要有高的生产能力，需要有充分的功率来产生充足的动力用于切割坚硬的煤层，并且能够适应地质的变化切割不同硬度的煤层。