MG200－487型薄煤层采煤机截割部设计【含CAD图纸和说明书】
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编号：（ ）字 号本科生毕业设计薄煤层采煤机截割部设计 李虎 21040206机械工程及自动化04-1班题目： 姓名： 学号： 班级： 二八年六月中国矿业大学毕业设计任务书学院 应用技术学院 专业年级 机自04级 学生姓名 李虎 任务下达日期： 2008 年 03 月 16日毕业设计日期： 2008 年 03月 18日至 2008 年 06月 10日毕业设计题目： 薄煤层采煤机截割部设计毕业设计专题题目：毕业设计主要内容和要求：设计参数：总装机功率：487 KW 截割部功率：200 KW 采高范围：1.32.6m滚筒直径：1.1m滚筒截深：630 mm 滚筒转速：40 r/min电机转速：1476 r/min 额定电压：1140 V具体要求如下：1、要完成毕业设计图纸3张零号图纸；2、按学校统一要求打印、装订设计说明书，说明书正文70页左右；3、中英文摘要400字；4、参考文献20篇左右。院长签字： 指导教师签字：中国矿业大学毕业设计指导教师评阅书指导教师评语（基础理论及基本技能的掌握；独立解决实际问题的能力；研究内容的理论依据和技术方法；取得的主要成果及创新点；工作态度及工作量；总体评价及建议成绩；存在问题；是否同意答辩等）：成 绩： 指导教师签字： 年 月 日 中国矿业大学毕业设计评阅教师评阅书评阅教师评语（选题的意义；基础理论及基本技能的掌握；综合运用所学知识解决实际问题的能力；工作量的大小；取得的主要成果及创新点；写作的规范程度；总体评价及建议成绩；存在问题；是否同意答辩等）：成 绩： 评阅教师签字： 年 月 日中国矿业大学毕业设计答辩及综合成绩答 辩 情 况提 出 问 题回 答 问 题正 确基本正确有一般性错误有原则性错误没有回答答辩委员会评语及建议成绩：答辩委员会主任签字： 年 月 日学院领导小组综合评定成绩：学院领导小组负责人： 年 月 日摘 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ABSTRACTThis 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 Shearers 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 Shearers 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11.1引言11.2我国采煤机30多年的发展进程11.2.1 20世纪70年代是我国综合机械化采煤起步阶段11.2.2 20世纪80年代是我国采煤机发展的兴旺时期21.2.3 20世纪90年代至今是我国电牵引采煤机发展的时代31.2.4 国际上电牵引采煤机的技术发展状况41.3国内电牵引采煤机的发展状况61.4 结构特征与工作原理71.4.1 摇臂71.4.2 截割电动机81.4.3 牵引部92 总体方案的确定122.1主要技术参数如下：122.2传动方案的确定142.2.1 传动比的确定142.2.2传动比的分配143传动系统的设计153.1各级传动转速、功率、转矩的确定163.2齿轮设计及强度效核173.3截割部行星机构的设计计算243.3.1齿轮材料热处理工艺及制造工艺的选定253.3.2确定各主要参数253.3.3几何尺寸计算283.3.4.啮合要素验算303.3.5齿轮强度验算313.4轴的设计及强度效核423.4.1选择轴的材料423.4.2轴径的初步估算423.4.3求作用在齿轮上的力423.4.4轴的强度效核：433.4.5安全系数效核计算463.5 轴承的寿命校核483.5.1对截轴的轴承22219c和Nj419进行寿命计算483.5.2行星轮轴承寿命的计算493.6 花键的强度校核503.6.1截轴花键校核503.6.2行星轮系花键校核504 采煤机的使用和维护504.1润滑及注油514.2地面检查与试运转514.2.1试运转前的检查：514.2.2试运转时检查：514.3下井及井下组装524.4采煤机的井下操作524.4.1操作前的检查：524.4.2试运转中注意事项：524.5机器的维护与检修534.6采煤机轴承的维护及漏油的防治544.7 硬齿面齿轮的疲劳失效及对策564.8煤矿机械传动齿轮失效的改进途径594.8.1设计594.8.2选材604.8.3 加工工艺604.8.4 热处理614.8.5 表面强化处理614.8.6 正确安装运行614.8.7 润滑625总结63参考文献64英文原文65中文译文72致 谢77中国矿业大学2008届本科生毕业设计 第 12 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.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 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 ft.Types 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.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 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 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 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.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
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