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MG200－487型薄煤层采煤机截割部设计【6张CAD图纸和说明书】

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摘  要


本文介绍了采煤机的发展历史、组成及工作原理，在分析煤炭工业及煤炭工业的行业背景的基础上，展望了采煤机的发展趋势，并针对采煤机的发展现状，进行了 MG200/487 型采煤机的截割部设计。

本文首先确定了设计方案和选择了基本部件并开展了传动系统的可靠性分析，MG200/487型采煤机截割部主要是由一个减速箱和四级齿轮传动组成，截割部电机放在摇臂内横向布置，电动机输出的动力经由三级直齿圆拄齿轮和行星轮系的传动，最后驱动滚筒旋转。并对所设计的齿轮和花键进行了公差分析，同时介绍了截割部的安装、维护和故障处理。本采煤机截割部具有较高的可靠性和安全维修性。


关键词：滚筒式采煤机； 截割部； 行星齿轮传动


ABSTRACT


This paper presents the development history, the composition and the principle of shearers in brief. On the foundation of analyzing the trade background of coal industry and mining equipment, look ahead the development of shearers, and according to the present development situation of shearers, we carried out the design of MG200/487-WD Shearer’s cutting unit.

   This design firstly fixed on design scheme and selected basic components, and besides, developed the reliability analysis of transmission system. The design of MG200/487-WD Shearer’s cutting unit. It is made up of a gearbox and moderate breeze gear wheel transmission that the MG200/487-WD type mining machine cuts the cutting department, Cut the electrical machinery of cutting department and put to fix up horizontally in the rocker arm, The power that the motor outputs leans on a round of transmission of department of gear wheel and planet round via the tertiary straight tooth, Urge the cylinder to rotate finally. And gears and involute splines’ tolerances of geometrical quantity were analyzed. At the same time, introduced the installation, maintenance and fault disposal of this cutting unit. The cutting unit of MG200/487-WD Shearer has reliability and installation maintainability.




Keywords: shearer; the cutting unit; planetary gear drive


目    录


1 概述 1

1.1引言 1

1.2我国采煤机30多年的发展进程 1

1.2.1 20世纪70年代是我国综合机械化采煤起步阶段 1

1.2.2  20世纪80年代是我国采煤机发展的兴旺时期 2

1.2.3 20世纪90年代至今是我国电牵引采煤机发展的时代 3

1.2.4  国际上电牵引采煤机的技术发展状况 4

1.3　国内电牵引采煤机的发展状况 6

1.4 结构特征与工作原理 7

1.4.1 摇臂 7

1.4.2 截割电动机 8

1.4.3 牵引部 9

2 总体方案的确定 12

2.1主要技术参数如下： 12

2.2传动方案的确定 14

2.2.1 传动比的确定 14

2.2.2传动比的分配 14

3传动系统的设计 15

3.1各级传动转速、功率、转矩的确定 16

3.2齿轮设计及强度效核 17

3.3截割部行星机构的设计计算 24

3.3.1齿轮材料热处理工艺及制造工艺的选定 25

3.3.2确定各主要参数 25

3.3.3几何尺寸计算 28

3.3.4.啮合要素验算 30

3.3.5齿轮强度验算 31

3.4　轴的设计及强度效核 42

3.4.1选择轴的材料 42

3.4.2轴径的初步估算 42

3.4.3求作用在齿轮上的力 42

3.4.4轴的强度效核： 43

3.4.5安全系数效核计算 46

3.5 轴承的寿命校核 48

3.5.1对截Ⅲ轴的轴承22219c和Nj419进行寿命计算 48

3.5.2行星轮轴承寿命的计算 49

3.6 花键的强度校核 50

3.6.1截Ⅳ轴花键校核 50

3.6.2行星轮系花键校核 50

4 采煤机的使用和维护 50

4.1润滑及注油 51

4.2地面检查与试运转 51

4.2.1试运转前的检查： 51

4.2.2试运转时检查： 51

4.3下井及井下组装 52

4.4采煤机的井下操作 52

4.4.1操作前的检查： 52

4.4.2试运转中注意事项： 52

4.5机器的维护与检修 53

4.6采煤机轴承的维护及漏油的防治 54

4.7 硬齿面齿轮的疲劳失效及对策 56

4.8煤矿机械传动齿轮失效的改进途径 59

4.8.1设计 59

4.8.2　选材 60

4.8.3 加工工艺 60

4.8.4 热处理 61

4.8.5 表面强化处理 61

4.8.6 正确安装运行 61

4.8.7 润滑 62

5总结 63

参考文献 64

英文原文 65

中文译文 72

致  谢 77

1 概述

1.1引言

采煤机械的装备水平是煤矿技术水平的重要标志之一。采煤机械的选用取决于煤层的赋存条件、采煤方法和采煤工艺，而采煤机械的技术发展又促进了采煤方法和采煤工艺的更新。

采煤方法按采煤工艺可分为长壁式采煤法和房柱式采煤法两大类。我们广泛使用长壁式采煤法。

    长壁式采煤法所使用的机械设备按机械化程度分为爆破采煤机械、普通机械化采煤机械和综合机械化采煤机械三类。

    炮采工作面的机电设备较少，主要靠人力完成各项工序。破煤工序有直接打眼放炮和先掏槽后打眼放炮两种，装煤工序主要依靠人工攉煤，运煤工序依靠工作面刮板输送机来完成。

    普通机械化采煤机工作面用采煤机或刨煤机和工作面刮板输送机实现破煤、装煤和运煤工序的机械化，用单体支护设备实现人工控制顶板。

    综合机械化采煤工作面将各种相对独立的机电设备合理的组合在一起，在工艺过程中协调工作，使采煤工作面的破、装、运、支全部工序实现机械化。

1.2我国采煤机30多年的发展进程

1.2.1 20世纪70年代是我国综合机械化采煤起步阶段

    20世纪70年代初期，煤炭科学研究总院上海分院集中主要科技骨干，研制出综采面配套的MD-150型双滚筒采煤机，另一方面改进普采配套的DY100型、DY150型单滚筒采煤机；70年代中后期，制造出MLS3-170型双滚筒采煤机。20世纪70年代我国采煤机的发展有以下特点：

    1．装机功率小

    例如，MLS3-170型双滚筒采煤机，装机功率170KW；KD-150型双滚筒采煤机，装机功率150KW；DY-100和DY-150型单滚筒采煤机，装机功率100KW和150KW。

    2．有链牵引，输出牵引力小

    此时期的采煤机牵引方式都是圆环链轮与牵引链轮啮合传动，传递牵引力小，牵引力在200KN以下。

    3．牵引速度低

    由于受液压元部件可靠性的限制，设计的牵引力功率较小，牵引速度一般不超过6m /min 。

    4．自开切口差

    由于双滚筒采煤机摇臂短,又都是有链牵引,很难割透两端头,且容易留下三角煤,故需要人工清理,单滚筒采煤机更是如此.

    5．工作可靠性较差

    我国基础工业比较薄弱,元部件质量较差,反映在采煤机的寿命普遍较低,特别是液压元部件的损坏比较严重。


内容简介：
计 第 1 页英文原文THE SHEARERShearerLongwall equipment consists of three major components: the hydraulically powered roof support, the chain conveyor, and the coal-cutting machine.The two different types of coal-cutting equipment used in coal mines are shearers and plows.Plows are used in low seams, 42in. or less. The unit consists of steel construction equipped with carbon-tipped bits. This passive steel unit is engaged to a guiding system on the face conveyor. An endless round link chain powered by synchronized electric drives on each end of the face conveyor pulls the plow body at speeds between 120 and 420 ft/min along the face.For the cutting process the plow has to be forced against the coal face. This is done by hydraulic cylinder attached to the gob side of the face conveyor and to the base of the supports, or by a separate hydraulic prop. Forces of between 1and 3 tons are applied per cylinder.A plow drive is attached to each drive frame of the face conveyor. Only 30% to 60% of the drive power supplied to the plow is used for cutting and loading of coal; the remainder is lost in friction. This means that the power loss is considerably higher than that of a shearer, which uses 75% to 85% of its power for the removal of the coal. As a result, rather large drives are required at the face ends.Although there are many models, the shearer has several common basic components. A double-ended ranging-drum shearer (Fig. 8. 1), for example, consists of four major components: electric motors, gearheads, haulage unit (power pack), and cutting drums.计 第 2 页The electric motor ranging from 300 to 1000 horsepower (223750kW) is the power source for the shearer. It provides power to run the hydraulic pumps in the haulage unit and the gearheads for the cutting drum. The large-capacity shearers are generally equipped with two electric motors: one for the haulage unit and one gearhead and the other for the other gearhead and other ancillary equipment. The motors can be remotely controlled.There are two gearheads, one on the left-hand the other on the right-hand side of the shearer. Each gearherad consists of a gearhead gearbox and a ranging arm.The cutting drum is laced with spiral vanes on with spiral vanes on which the cutting bits are mounted. Its diameter ranges from 34 to 72 in. (0.861.83 m) with rotational speeds from 30 to 105 rpm. The trends are toward fewer but larger bits and slower drum speed for better cutting efficiency and less coal dust production. The drums are also equipped with power cowls to increase the coal loading efficiency. The power cowl is usually located behind the cutting drum. For that reason, it can be rotated a full 180.The electric motor, haulage unit, and gearhead boxes combine to form the shearers body which is mounted on the underframe. The underframe has four sliding shoes. The face-side shoes are fitted and ride on the face-side top guide of the face conveyor pan, and the other two gob-side sliding shoes are fitted on a guide tube to prevent derailment. The tramming aped of the shearer ranges from 19 to 46 ft/min (5.814.0 m/min).In addition, the shearer is equipped with auxiliary hydraulic pumps and control valves for operating the ranging arms and power cowls, water spraying 计 第 3 页devices, cable, chain anchorage and tensioners, and so onIn selecting the shearer, mining height should first be considered; that is, the diameter of the cutting drum, body height, length of the ranging arm, and swing angle must be properly selected. For the double-ended ranging-drum shearer, the maximum mining height cannot exceed twice the diameter of the cutting drum. The mining height can be determined by (Fig.8.3)H=Hb-B/2+Lsin+D/2 Where H=seam thickness or mining heightHb=shearers body heightB=body depthL=length of the ranging arm=the angle between the ranging arm and the horizontal line when the ranging arm is raised to its maximum heightD=diameter of the cutting drumFor example, for the Eichhoff EDW-170 L double ranging-drum shearer, Hb=4.3 ft, L=3.90 ft, =52，and D=5.3 ft. Its maximum cutting height is H=9.2 ftTypes of modern shearersSince its first appearance in 1954,the shearer has undergone continuous changes both in capability and structure. It is now the major cutting machine in longwall coal faces. There are two types of shearers, single-and double-drum. In the earlier models, the drum in the single-drum shearer is mounted on the shearers body and cannot be adjusted for height. Therefore it is not suitable for areas where there are constant changes in seam thickness and floor undulation. Thus the single-ended fixed-drum shearer is used mostly for thin seams.计 第 4 页Figure 6.10 shows a single-drum shearer with a ranging arm. The cutting drum is mounted at the very end of the ranging arm. The ranging arm can be raised up and down by hydraulic control to accommodate the changing seam thickness and floor undulation. But when the seam exceeds a certain thickness, the single-drum shearer cannot cut the entire seam height in one cut and a return cutting trip is necessary to complete a full web cut. Furthermore, since the drum is located on the headentry side, it generally requires a niche in the tailentry side. A niche is a precut face end, one web deep and a shearers length long. With a niche at the face end the shearer can turn around.Nowadays, the double ranging-drum shearers are used predominantly. The shearer cuts the whole seam height in one trip. The two drums can be positioned to any required height (within the designed range) during cutting and lowered well below the floor level. The arrangement of the drums enables the whole seam to be cut in either direction of travel, thereby ensuring rapid face advance and shortening roof exposure time. There are various types of double ranging-drum shearers. Based on the location of the drums, there are two types: one with one drum mounted on each side of the shearers body and the other with both drums mounted on one side of the machine. The former type is the most widely used. Its advantage is that with one drum on each side of the shearer, it can sump in either direction. During the cutting trip, the leading drum cuts the upper 70% of the seam height while the rear drum cuts the lower 30% and cleans up the broken coal on the floor. The two drums are approximately 2333 ft (710m) apart. When the shearer is traveling in the opposite direction to that of the face conveyor, the coal cut by the leading drum has to pass under the shearers body, which increases the moving resistance of the shearer and the face conveyor and could cause a “crowding” condition. If the broken coal is too large, it may block the shearer and stop the operation. In general, when the shearer and the face conveyor are traveling in the opposite directions, approximately 70% of the coal taken by the leading drum will pass under the shearer. But when they are traveling in the same direction, the coal taken down by the rear drum together with the float coal from the floor constitute the approximately 30% of the coal that has to pass under the shearer. The former case consumes 25% more power than the latter. As compared to the single-ended shearer, the underframe of the double-ended shearer is higher, thereby ensuring a sufficient cross section for 计 第 5 页coal passage.Based on the method of adjusting the height of the cutting drum, there are also two types of shearers: ranging-arm shearer and gearhead shearer. The former one is commonly used, whereas the latter one is a recent development. The advantage of the gearhead shearer is that the haulage unit is located at the center of the shearers body and mounted on the underframe. On both sides of the haulage unit, there is a gearhead. Each gearhead contains an electric motor and a speed-reduction unit. The gearhead is raised and lowered by an adjustable hydraulic ram. The adjustable range of cutting height is large. It can reach up to 4.6 ft(1.4m).Based on the mounting relation between the shearer and the face conveyor, there are also two types: the regular type which rides on the conveyor and the in-web shearer which moves on the floor in front of the conveyor. The in-web shearer is used mainly for the thin seams. As it moves along the face, the leading drum cuts the coal, making a sufficient space for the passage of the passage of the shearers body.Haulage of the shearerThere are two types of shearer haulage: chain and chainless. These are discussed separately in the following paragraphs.(1)Chain haulageThe haulage chain is a round-link chain which extends along the whole face width and is fixed on both ends at the head and tail drives of the face chain conveyor, respectively. The chain also passes through the driving and deflecting (or guiding) sprockets in the haulage unit of the shearer. As the driving sprocket rotates, its teeth trap to the matching chain links and move along the nonmoving haulage chain, thereby pulling the shearer along. When the driving sprocket rotates counterclockwise, the shearer moves to the right. Conversely, when the sprocket rotates clockwise, the shearer moves to the left. That part of the chain in front of the moving shearer is generally tight or on the tensioned side whereas the other side, behind the moving shearer, is slack or on the slack side.The total resistance encountered by a cutting shearer consists mainly of the cutting resistance of the drum, coal loading resistance, and the frictional resistance between the conveyor and the shearer. The summation of the three types of resistance is the total haulage resistance of the shearer. The haulage unit 计 第 6 页must provide sufficient haulage power to overcome the total haulage resistance so that the shearer can move along smoothly. In Fig. 6.15 the tensile force in the tensioned side is P2 and that in the slack side is P1. Since the haulage force(P2) is the summation of P1 and P, if the chain on the slack side is completely slack, P1=0, then the tensile force in the tensioned side will be the required haulage force, P2=P. Under such conditions, although the chain is subjected to relatively small tension, the driving sprocket can not pass out the chain smoothly and may easily cause chain “stuck” or sudden tensioning of the chain. Thus in actual operation, the slack side normally maintains a small tension, i. e. , P2=P1+P. Only when the tensile force in the tensioned side is sufficient to overcome the total haulage resistance and the tensile force in the slack side, the shearer will be able to move.When the shearer starts cutting from one end of the coal face, the haulage chain is relatively slack. As the shearer moves along, the chain is gradually tightened. When the shearer is near the other end of the coal face, the tensile force in the haulage chain is greatest. At this time the chain is most easily broken. In order that the tensile force on the tensioned side is not too high and that there is a sufficient tensile force on the slack side, most shearers are equipped with tension takeup systems. The tension takeup system is mounted at one end or both ends of the face conveyor depending on whether unidirectional or bidirectional cutting is employed. The haulage chain is connected to the tension takeup system. There are many types of tension takeup systems. But the basic principles are about the same.The problems associated with chain haulage are chain sticking, chain breakage, and chain link tangling. They are due mainly to the fact that the haulage chain is lengthened and becomes loose after some periods of usage.(2)Chainless haulageIn response to all the disadvantages associated with the chain haulage, the chainless haulage was developed. According to the haulage principles, the chainless haulage can be divided into three types: drive chain-rackatrack, drive wheel-rackatrack, and ram propulsion. The wheel-rackatrack haulage is the most popular type.Figure 6.16 is a double-ended ranging-drum shearer equipped with the wheel-rackatracd haulage system. The haulage driving unit is similar to the 计 第 7 页conventional ones. The driving sprocket matches an idler sprocket, which in turn rides on the rail track made of steel peg rods. Thus, the driving system of power transmission is highly efficient. The rack is made of sections that have the same length as the conveyor pan, but they are installed in such a way that the center of each section is directly above the connection line between two adjacent pans. This will ensure maximum vertical and horizontal flexibility of the pans and keep the pitch deviation in the gap between two rack sections within admissible limits. Two methods are used to connect the line pans with the rack sections: one is to tie the rack sections to the sides of the line pans with screws and the other is to set the rack section on the sliding channel. Only the rack sections on both ends of the conveyor are fixed, so that a limited amount of flexibility in the conveyor direction is permitted. In Fig. 6.17 (b), the hook shape anchor on the rack section locks and slides on the guide tube of the line pans. This method is good for converting chain haulage to chainless haulage.Figure 6.18 is another model of the wheel-rackatrack chainless haulage system. The driving sprocket is engaged directly to a special sprocket called Rollrack which has five hardened steel rollers spaced equally around the circumference. As the special sprocket or Rollrack rotates, the steel rollers engage on the teeth track of the rack and pull the shearer. Thus it is also called Roller-Teeth Rack chainless haulage.计 第 8 页中文译文采煤机滚筒式采煤机长壁工作面的设备包含三个主要部分：液压支架，刮板运输机和破碎机。被用于煤矿的两种不同类型的割煤设备是：滚筒式采煤机和刨煤机。刨煤机被用于低煤层，42 英寸或者更少。刨煤机由装配渗碳刀尖的齿轮组成。这些钝化的齿轮单元与工作面输送机上的控制系统相连。由位于工作面输送机两端的同步电机驱动无级圆环链牵引刨煤机以每分钟 120 至420 英尺的速度沿工作面移动。在切割进程，刨煤机必须强迫对抗煤层表面。动力由装在工作面运输机底部的液压油缸提供，每一个油缸提供 1 至 3 吨的动力。工作中的刨煤机 并不是把全部的动力用来刨煤 ，只有 30%到 60%动力被用来切割和装运煤；剩余部分在摩擦中消耗。这就意味着动力损耗要比滚筒式采煤机高。滚筒式采煤机动力的 75%到 85%用于割煤的。结果，要想获得大功率采煤效果就不得在工作面机尾提供相当大的动力。虽然有许多部件，但是滚筒式采煤机有几种基本部分。举例来说，一台双滚筒可调高摇臂采煤机（图 8.1） ，由四个主要部分组成：电动马达，机头，牵引部分（电动机）和截割部。图 8.1 采煤机的组成电动机为采煤机提供 300 到 1000 马力的动力源，并且为牵引部的运转的液压泵提供动力和机头服务于截割滚筒。大功率采煤机通常装备两台电动机：一台用于牵引部和一个机头，另一台用于另外一个机头和其它辅助计 第 9 页装备，这些电动机是可以远距离操纵的。这两个机头一个在采煤机的左边，一个在采煤机的右边，每个机头都是由齿轮箱和摇臂组成。截割滚筒的截齿安装的是螺旋叶片，它的直径范围从 34 到 72 英寸（0.861.83m） ，回转速度从 30 到 105rpm。它的发展趋势朝着少数但个大的且滚筒速度较低的截割效率比较好，并且可以减少粉尘的产生。滚筒之所以加挡煤板是为了增加煤的装载效率，挡煤板通常安装在截割滚筒的后面，由于这个原因，它可以旋转 180。电动机、牵引部和机头箱组合成采煤机的机身安装在底托架上，底托架有四个滑履，用在工作面的滑履是固定的，它骑在刮板输送机溜槽工作面的顶道轨上，另外两个采空区滑履与道管配合是为避免出轨。采煤机的输送速度范围在 1946ft/min（5.814.0m/min） 。此外，采煤机的装备还有辅助液压泵、可操作摇臂的控制阀、挡煤板、喷水装置、电缆、链条、锚固和张紧装置等等。在选择采煤机时，采煤高度应是首先被考虑的因素；那是因为，滚筒直径，主体高度，摇臂长度，和摇摆角度都必须选择适当。对于双滚筒可调高摇臂采煤机，最大的采煤高度不能超过滚筒直径的两倍。采煤高度可以通过（图 8.3）来决定H=Hb-B/2+Lsin+D/2 其中 H=煤层厚度或者采煤高度Hb=采煤机主体高度B=主体深度L=摇臂长度=当摇臂升高到它的最大高度时摇臂和水平线之间的角度D=滚筒直径图 8.3 采煤机采高举例来说，对于 EDW-170L 双滚筒可调高摇臂采煤机，Hb=4.3 英计 第 10 页尺, L=3.90 英尺, =52，D=5.3 英尺。它的最大截割高度为 H=9.2 英尺。现代采煤机的种类采煤机在 1954 年诞生的，在性能和构造上经历了连续的变化。它主要应用在走向长壁采煤工作面上。采煤机有两种类型，包括单滚筒采煤机和双滚筒采煤机。在早期使用的采煤机中，单滚筒采煤机的滚筒是在采煤机的躯干上，并且不能调高，所以不适合用于煤层厚度和水平波动大的区域，因此单滚筒采煤机主要适用于薄煤层。图 6.10 中显示单滚筒采煤机的摇臂范围，截割滚筒处于摇臂的最末端，摇臂通过液压控制能够升起和下降，可用在煤层厚度和水平波动大的区域。但是当煤层超过某一厚度时，单滚筒采煤机就不能一次切割全部的厚度，需要回来再切一次才能完成全部工作。此外，因为滚筒位于采煤机侧面，它通常要求放在采煤机一适当的侧面，这一适当的位置在切割工作面的末端，要有合适的深度和长度，采煤机可以在这个位置掉转方向。现今，双滚筒采煤机使用很广泛，它可以切割整个煤层厚度。在切割和下降到最低位置期间，两个滚筒的位置可以按照规定的要求调整高度（设计范围之内） 。滚筒的布置能够切割整个煤层厚度和移动方向，从而保护工作面快速推进和缩短顶板暴露时间。双滚筒采煤机有各种型式，根据滚筒的位置可分为两种类型：一种是两个滚筒在采煤机的两侧，另一种是同时都在采煤机的一侧。前一类型使用很广泛，它的优点是在滚筒的两侧割煤，可以在任一方向上。在切割时，上面的滚筒切煤层厚度的 70，下面的滚筒切煤层厚度的 30和清理顶板的碎煤。两滚筒距离大约有2333ft(710m)，当采煤机平移反向到工作面运输机时，滚筒截煤不得不在采煤机的下面，是采煤机增加移动的阻力和工作面输送机和状态条件。如果掉落的煤也是巨大的，
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本文标题：MG200－487型薄煤层采煤机截割部设计【6张CAD图纸和说明书】
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