礦井提升設(shè)備的選型設(shè)計(jì)
礦井提升設(shè)備的選型設(shè)計(jì),礦井提升設(shè)備的選型設(shè)計(jì),礦井,提升,晉升,設(shè)備,裝備,選型,設(shè)計(jì)
中國礦業(yè)大學(xué)成人教育學(xué)院2007屆畢業(yè)設(shè)計(jì)論文緒 論礦山提升機(jī)是礦山大型固定機(jī)械之一,礦山提升機(jī)從最初的蒸汽機(jī)拖動(dòng)的單繩纏繞式提升機(jī)發(fā)展到今天的交交變頻直接拖動(dòng)的多繩摩擦式提升機(jī)和雙繩纏繞式提升機(jī)已經(jīng)歷了170多年的發(fā)展歷史,它是礦山井下生產(chǎn)系統(tǒng)和地面工業(yè)廣場相連接的樞紐,被喻為礦山運(yùn)輸?shù)难屎?。因此礦山提升設(shè)備在礦山生產(chǎn)的全過程占有重要的地位。一個(gè)現(xiàn)代化的礦井在提升設(shè)備的選型上尤為重要。因?yàn)樘嵘O(shè)備選型的合理與否,直接關(guān)系到礦井的安全和經(jīng)濟(jì)性,因此確定合理的提升系統(tǒng)時(shí),必須經(jīng)過多方面的技術(shù)經(jīng)濟(jì)比較,結(jié)合礦井的具體條件選擇合適的設(shè)備。根據(jù)礦井提升機(jī)工作原理和結(jié)構(gòu)的不同,可分為纏繞式提升機(jī)和摩擦式提升機(jī)。單繩纏繞式提升機(jī)是較早出現(xiàn)的一種,它工作可靠,結(jié)構(gòu)簡單,但是僅適用于淺井及中等深度的礦井,而對(duì)于井深超過300米的礦井,宜選用多繩摩擦式絞車。在國內(nèi)外,多繩摩擦式絞車飛躍發(fā)展,其發(fā)展速度遠(yuǎn)遠(yuǎn)超過單繩纏繞式提升機(jī),這是因?yàn)樗兄S多單繩纏繞式提升機(jī)無法比擬的優(yōu)點(diǎn),如提升鋼絲繩直徑較小,主導(dǎo)輪直徑及整個(gè)機(jī)器的尺寸都相應(yīng)縮小了,設(shè)備重量也減輕了,不需要設(shè)置防墜器等。下面是我針對(duì)不同的礦井的地質(zhì)、煤層等情況,進(jìn)行綜合計(jì)算分析后,本著安全、經(jīng)濟(jì)等原則對(duì)這兩種提升設(shè)備系統(tǒng)進(jìn)行的選型設(shè)計(jì)。本設(shè)計(jì)充分貫徹以下設(shè)計(jì)原則:根據(jù)國家現(xiàn)有的設(shè)備生產(chǎn)狀況,結(jié)合某些使用中的具體情況,以及經(jīng)濟(jì)角度出發(fā)盡量選用國產(chǎn)設(shè)備并力求在條件基本相當(dāng)?shù)那闆r下進(jìn)行技術(shù)的方案比較,選擇即經(jīng)濟(jì)又合理的設(shè)備。 由于本人水平有限,設(shè)計(jì)中難免出現(xiàn)錯(cuò)誤和不足之處,敬請各位老師指正。1 礦井提升設(shè)備的選型設(shè)計(jì)1. 1副井提升機(jī)的選型設(shè)計(jì)1.1.1設(shè)計(jì)依據(jù)臥牛山煤礦位于徐州市西郊九里山大彭鎮(zhèn)境內(nèi),東郊與九里山煤田比鄰,礦層界限下石盒子組和山西組以F23斷層分割,太原組以F27斷層為界。西與新河煤礦相連。礦層開采上限為-40m水平,開采下限為-550水平。井下采煤方法主要為單一長壁采煤,以傾斜煤層為主,開拓方式為立井石門開拓,是央對(duì)角式通風(fēng)。全礦區(qū)共劃分為二個(gè)水平,-150水平,-310水平。,其具體的數(shù)據(jù)為:1)原煤的密度: =0.9 噸/米2)矸石的密度: 矸 =1.35 噸/米3)含矸率: 10%4)一水平井深: -190米5)二水平井深:-350米6)最大班下井人數(shù): 260人7)坑木消耗: 9 米/千噸煤根據(jù)以上情況,假如先進(jìn)行第一水平的開采年產(chǎn)量定為40萬t,現(xiàn)對(duì)其進(jìn)行副井提升設(shè)備的選型設(shè)計(jì)。1.1.2設(shè)備類型的確定由于第一水平井不深,且年產(chǎn)量不大,決定采用單繩纏繞式提升系統(tǒng)。罐籠的選定(1)噸位的確定:罐籠的噸位按井下運(yùn)輸使用的礦井名義載重量確定。臥牛礦擬選定礦車的名義載重量為1t。因而選用罐籠的噸位為1t。(2)層數(shù)的選擇:層數(shù)的選擇應(yīng)根據(jù)運(yùn)送最大班下井工人時(shí)間不超過40min或總作業(yè)時(shí)間是否超過5小時(shí)來確定。臥牛山煤礦最大班下井人數(shù)為260,顯然選擇一層罐籠不能夠滿足工作的要求。故選用二層罐籠。其具體的技術(shù)參數(shù)如下:型號(hào):GLSY12/2 G罐籠 L-立井單繩 S-鋼絲繩罐道 Y異側(cè)進(jìn)出車 1煤車噸位 2煤車數(shù) 2層數(shù)自重:3000 Kg允許乘人數(shù):24每層底有效面積: 2.3m3罐籠總高度 4550 罐籠寬度: 1246 罐籠長度: 2550 罐籠質(zhì)量:3667Kg罐籠裝載量:3235Kg最小井筒允許直徑 3800 采用1 t 標(biāo)準(zhǔn)礦車,型號(hào)為 MG1.16自重 qc=6000N名義載煤量 1 t 有效容積 1.1m31.1.3提升剛絲繩的選型選擇原則:鋼絲繩在運(yùn)轉(zhuǎn)中受到許多應(yīng)力的作用和各種因素的影響,如靜應(yīng)力、動(dòng)應(yīng)力、彎曲應(yīng)力、扭轉(zhuǎn)應(yīng)力和擠壓應(yīng)力等。磨損和銹蝕也將損害鋼絲繩的性能,綜合考慮以上應(yīng)力因素的計(jì)算是困難的,目前國內(nèi)外都是按靜載荷近似計(jì)算的。我國是按煤礦安全規(guī)程的規(guī)定來設(shè)計(jì)的,其原則是:鋼絲繩應(yīng)按最大靜載荷考慮一定的安全系數(shù)來進(jìn)行計(jì)算的。在經(jīng)常性作業(yè)中,以提升作業(yè)載荷最重,故以此條件選擇鋼絲繩。(1)次提矸量Q:Q=2rqv=213501.12970 (kg)Rq 矸石容量1350kg/m3V 礦車有效容積 V=1.1m3(2)計(jì)算鋼絲繩每米重P P圖1-1 鋼絲繩計(jì)算示意圖 其中 Hc=Hj+Hs+Hz=14.13+190.14=204.27 m Qx 一次提升的QXg 一次提升的最大載荷,N; Qz 容器的重量,N 鋼絲繩的抗拉強(qiáng)度 QXg=2r矸V=213501.1=2970 (kg)代入數(shù)字計(jì)算得: P= N/m根據(jù)上述計(jì)算值,從鋼絲繩規(guī)格表中選取每米鋼絲繩重量等于或大于P值的鋼絲繩,選型號(hào)為:D619+1直徑為31mm的鋼絲繩。有關(guān)數(shù)據(jù)為:d=31 , , 33.83 N/m ,KN/cm2,Qq=690 KN由于實(shí)際所選鋼絲繩的r0(鋼絲繩的比重)不一定是0.09N/cm3,因而對(duì)所選鋼絲繩是否滿足安全系數(shù)的要求必須按實(shí)際所選每米繩重按下式進(jìn)行驗(yàn)算,即所選鋼絲繩的實(shí)際安全系數(shù)為: ma= (N/m) 式中: Qq為所選鋼絲繩所有鋼絲拉斷力之和N P 為所選鋼絲繩的每米重力,N/m.。經(jīng)計(jì)算: ma=9所以所選鋼絲繩可用。1.1.4選擇提升機(jī) 提升機(jī)的主要參數(shù)有:卷筒直徑D,卷筒寬度B,提升機(jī)最大靜張力Fjmax及最大靜張力差Fjc.。這里依據(jù)卷筒直徑D為依據(jù)選擇提升機(jī)的型號(hào),其它三個(gè)參數(shù)為校核參數(shù)。 為了保證提升鋼絲繩具有一定的承載能力和使用壽命,鋼絲繩在卷筒上纏繞時(shí)所產(chǎn)生的彎曲應(yīng)力不要過大,根據(jù)煤礦安全規(guī)程規(guī)定,安裝在地面的提升機(jī),其直徑與鋼絲繩的直徑的關(guān)系應(yīng)滿足:D80dD1200D為提升機(jī)卷筒直徑 mm小d 為提升鋼絲繩直徑 mm為提升鋼絲繩中最粗鋼絲的直徑經(jīng)計(jì)算D=8031=2480因而選擇提升機(jī)的型號(hào)為:XKT22.51.2B11.5其技術(shù)特征如下:(1)卷筒直徑:2.5 m(2)設(shè)計(jì)鋼絲繩最大靜張力 Fjm=70 KN(3)設(shè)計(jì)鋼絲繩最大靜張力差 Fjc=40 KN(4)減速器傳動(dòng)比I=9.5(5)傳動(dòng)效率 =0.851.1.5校驗(yàn)提升機(jī)強(qiáng)度:以提矸作業(yè)為準(zhǔn)校驗(yàn),鋼絲繩懸掛長度He=190米。最大靜張力:Fjm=Qg+Qzg+qc+PHc =29.7+30+0.03383190=66.1270KN最大靜張力差Fjc=Qg+H =29.7+0.3383190=36.1240KNFjm、Fjc的實(shí)際值均小于設(shè)計(jì)值,強(qiáng)度校驗(yàn)合格。1.1.6井塔高度Hj確定:Hj=Hr+Hg+0.75=4550+8643.5+937.5=14131mm=14.131m因而確定井塔的高度為14.13米. 1.1.7預(yù)選電動(dòng)機(jī)電動(dòng)機(jī)額定轉(zhuǎn)速: ne=60ivm/D=r/minD提升機(jī)卷筒直徑 m I為減速器傳動(dòng)比Vm:最大速度由下表查得:表1-1比動(dòng)傳Vm速轉(zhuǎn)50060075011556886826853020392549063026183270電動(dòng)機(jī)的同步轉(zhuǎn)速數(shù)為:nt=500r/min則額定轉(zhuǎn)速ne=480r/min此時(shí)相應(yīng)最大提升速度為 Vm=Dne/60i=預(yù)選電動(dòng)機(jī)的功率(按提矸作業(yè)選定)Pe=P K阻力系數(shù) K=1.15 P動(dòng)負(fù)荷影響系數(shù)取 P=1.3則: Pe=(KW)由Pe、ne選電動(dòng)機(jī)為JRQ1512-12三相交流繞組異步電動(dòng)機(jī),其技術(shù)特征參數(shù)如下:額定功率: Pe=330 KW額定電壓: 6000 KV額定電流: 44.2 A頻率: 50 HZ轉(zhuǎn)子電流: 355A轉(zhuǎn)子電壓: 595V額定轉(zhuǎn)數(shù): 490轉(zhuǎn)/分轉(zhuǎn)子飛輪轉(zhuǎn)距 GD2=29430Nm2電動(dòng)機(jī)的效率: nd=93%電動(dòng)機(jī)作用于滾筒上額定拖動(dòng)力 Fe=1000Pe*i/Vm= N1.1.8天輪的選型計(jì)算:天輪的分類:(1)井上固定天輪 (2)鑿井及井下固定天輪 (3) 游動(dòng)天輪結(jié)構(gòu)形式的分類: (1)直徑為3500mm,采用模壓焊接結(jié)構(gòu) (2)直徑小于3000mm時(shí),采用整體鑄鋼結(jié)構(gòu) (3)直徑為4000mm,采用模壓鉚接結(jié)構(gòu) 根據(jù)煤礦安全規(guī)程的規(guī)定,當(dāng)鋼絲繩對(duì)天輪的圍抱角大于90時(shí)。 Dt80d Dt1200 式中 Dt 天輪直徑,; 鋼絲繩中最粗鋼絲繩直徑,根據(jù)以上計(jì)算,選擇天輪為: Dt8030=2400 取 Dt=2500 整體鑄鋼結(jié)構(gòu)的天輪1.1.9提升機(jī)與井筒相對(duì)位置的計(jì)算1)鋼絲繩弦長Lx及偏角的確定。煤礦安全規(guī)程對(duì)偏角,弦長等有嚴(yán)格的限制,Lx過大時(shí),繩的振動(dòng)也會(huì)加大,因此將弦長Lx限制在60m以內(nèi)。一些提升機(jī)對(duì)仰角也有一定的要求,其原因(1)偏角過大將加劇鋼絲繩與天輪的磨損,因此煤礦安全規(guī)程規(guī)定,內(nèi)外偏角均應(yīng)小于1030。(2)某些情況下,當(dāng)鋼絲繩纏向卷筒時(shí),若內(nèi)偏角過大會(huì)發(fā)生“咬繩”現(xiàn)象。咬繩現(xiàn)象加劇了鋼絲繩的磨損。先按煤礦安全規(guī)程規(guī)定的最大外偏角允許值1030代入下式計(jì)算最小弦長。最小弦長Lxmin式中 卷筒寬度,m;S 兩天輪中心距,m; 兩卷筒之間的距離,m; 兩卷筒上繩圈的間隙;d 鋼絲繩直徑。代入?yún)?shù)計(jì)算得: Lxmin再根據(jù)內(nèi)偏角的允許角度曲線圖查得D=2.5m,d=0.002m的不“咬繩”允許內(nèi)偏角為10求出內(nèi)偏角符合要求的最小弦長Lx.max最小弦長Lx.max = =13.5mLx.max150 符合要求。1.1.10運(yùn)動(dòng)學(xué)參數(shù)計(jì)算:1) 罐籠提升通常采用五階段速度圖,其速度圖如下: v O t1 t2 t3 t4 t5 t a a1 t a3 圖1-2 罐籠提升五階段速度圖在豎井中采用罐籠升降人員其最大速度不得超過下式值,且最大不得超過16m/s. Vm0.5=0.5=6.9m/s2)提升加速度期a1和減速度a3的確定 (1) 根據(jù)煤礦安全規(guī)程的現(xiàn)定,豎井長降人員的加減速度不得大于0.75m/s2,最大加速度按下式計(jì)算: a1 式中: 電動(dòng)機(jī)過負(fù)荷系數(shù); Fe 電動(dòng)機(jī)額定拖動(dòng)力; Pe 電動(dòng)機(jī)額定功率; 0.75 最大拖動(dòng)的系數(shù)。代入?yún)?shù)計(jì)算得: a=0.742m/s2為了留有余地,可確定提矸與升降人員加速度相同,取a1=0.7m/s2。 (2)減速度a3確定由于付井作業(yè)種類繁多載荷變動(dòng)大,為了便于控制取a3=0.7m/s2。不同作業(yè)時(shí)減速方式不同,提矸時(shí)需電動(dòng)方式,提升人時(shí)需用機(jī)械制動(dòng)方式。在下放重載時(shí),為了確保a1、a3仍為0.7m/s2需采用電氣制動(dòng)方式,為此付井提升設(shè)備設(shè)有動(dòng)力制動(dòng)裝置。參數(shù)計(jì)算如下: 加速階段: a1=0.7m/s2 t1=s h1=22.4 m 減速階段: a3=0.7m/s2 t3= s h3=22.23m 等速階段: Vm=5.6m/s h2=Hh1h2h3=19022.422.233=142.37mt2=s爬行階段: V4=0.5m/s t4=6s h4=3m抱閘停車階段: t5一般取t5=1sh5=h5可忽略不計(jì)。一次提升時(shí)間T為: T=t1+t2+t3+t4+t5=8+25.42+7.29+6+1=47.71s1. 2主井提升機(jī)的選型設(shè)計(jì)1.2.1設(shè)計(jì)依據(jù)臥牛礦擬開采第二水平,假如產(chǎn)量大幅提升年產(chǎn)量為180萬t, 其具體數(shù)據(jù)如下:1礦井年產(chǎn)量 An=180萬噸2原煤密度 =0.9t/m33.矸石密度 =1.5t/m34.含矸率 10%5.二水平井深 -350米現(xiàn)根據(jù)以上情況對(duì)主井提升設(shè)備進(jìn)行選型設(shè)計(jì)。1.2.2設(shè)備類型的確定提升容器主要是底卸式箕斗和普通卸籠?;返膬?yōu)點(diǎn)是:質(zhì)量輕,所需井筒斷面小,裝卸可自動(dòng)化,且時(shí)間短,提升能力大。它的缺點(diǎn)是:井底及井口需要設(shè)置煤倉和裝載設(shè)備,只能提煤炭,不能升降人員、設(shè)備和材料,井架較高,需要另設(shè)一套輔助提升設(shè)備。罐籠的優(yōu)點(diǎn)是:井底及井口不需要設(shè)置煤倉,可以提升煤炭、矸石,下放材料,升降人員和設(shè)備,井架較矮,有利于煤炭分類運(yùn)輸。罐籠的缺點(diǎn)是:質(zhì)量大,所需井筒斷面積大,裝卸不能實(shí)現(xiàn)自動(dòng)化,而且時(shí)間較長,生產(chǎn)效率較低。由于現(xiàn)在井的深度比較深,年產(chǎn)量大,綜合考慮后,決定采用多繩、塔式布置的箕斗提升系統(tǒng)。1.2.3箕斗的選型1)提升高度:H=Hs+Hz+Hx式中 Hs井筒水平深度Hz裝載高度 1825m 取 Hz=20mHx卸煤高度 取Hx=13.5mH=350+2013.5=383.5 m2) 經(jīng)濟(jì)提升速度: Vm=0.4=0.419.583=7.833m/s3)一次循環(huán)提升時(shí)間初加速度估計(jì)為 a=1m/s Tx= 式中 : 20為裝卸載時(shí)間 Tx=7.833+=76.79 s4) 一小時(shí)提升量: As=式中: C不均衡系數(shù),煤炭工業(yè)設(shè)計(jì)規(guī)范規(guī)定,有井底煤倉時(shí)為1.101.15,取C=1.15Cf提升能力富裕系數(shù),煤炭工業(yè)設(shè)計(jì)規(guī)范規(guī)定,主井提升設(shè)備一般對(duì)于第一水平留有20%的富裕系數(shù),取Cf=1.2br年工作日,取br=300天t 是工作小時(shí)數(shù),取t=14 小時(shí)AN 年產(chǎn)量,噸A=591.428 t/h5)一小時(shí)提升次數(shù):ns=次6)一次合理提升量: Q= 噸/次由主井多繩箕斗規(guī)格表選擇名義裝載重量為16t的箕斗,其主要技術(shù)規(guī)格參數(shù)如下:自重 Qz=17.8t 全高 Hr=15600 有效容積 V=17.6m3提升鋼絲繩數(shù) n1=4繩間距 =300尾繩數(shù) n2=2實(shí)際載重量 Q=V=0.917.6=15.6 t1.2.4提升鋼絲繩的選擇1) 鋼絲繩的最大懸垂長度Hc 預(yù)估計(jì)井架Hj=40m. 由于Vi=7.833m/s,取Hg=13m,箕斗間距S=2050 Hh=Hg+1.5S=13+1.52.05=16.08 m 取Hn=20 m Hc=Hj+Hc+Hz+Hn=40+350+20+20=430 m2) 估算鋼絲繩每米重力P取鋼絲繩抗拉強(qiáng)度=1520n/mm2安全系數(shù) ma7.2-0.0005Hc=7.2-0.0005430=6.895P=41.06 N/m據(jù)此選鋼絲繩6(36)股(132+31+12+1.5)繩纖維芯,左右捻各二根,其每米重量=66.84N/m.直徑d=39.5.繩中最粗鋼絲直徑=2.4.全部鋼絲破斷力總和為Qd=1064385N.尾繩數(shù) n2=2根.q=133.68 N/m據(jù)此選擇(19231)8410扁鋼絲繩.其單位每米重為132.44N/m.考慮到=4-2q=466.84-2132.44=2.48N/m.而且=0.9%6.895所以所選鋼絲繩合格可用.1.2.5 選擇提升機(jī)1)考慮塔式井塔,設(shè)導(dǎo)向輪,滾筒直徑D: D100d=10039.5=3950 由此選擇 JKM4/4(I)型多繩摩擦式提升機(jī),其技術(shù)參數(shù)如下: 摩擦輪直徑 D=4m 設(shè)計(jì)最大鋼絲繩靜張力 588KN (60t)設(shè)計(jì)最大鋼絲繩靜張力差 177 kN (18t)減速器傳動(dòng)比 I=10.5傳動(dòng)效率 =0.85減速器最大輸出扭距 57tm(559KNm)提升機(jī)(包括減速器,導(dǎo)向輪)變位重力 192.4KN(19.6t)2) 驗(yàn)算提升機(jī)強(qiáng)度最大靜張力 Fjm = Q+Qz+4Hc = (15.6+17.8)9810+466.84680 = 509.458 KN 588 KN最大靜張力差Fjc=Q+H=15.69810+2.48680 = 154.72 KN177 KNFjm Fjcr 的實(shí)際值均小于設(shè)計(jì)值,強(qiáng)度校驗(yàn)合格.3) 摩擦襯墊比壓Pb的校驗(yàn) 上升側(cè)靜張力 Fs=Ffm=509.458 KN 下降側(cè)靜張力 Fx=Fjm-Q=509.458-15.69810=356.422 KN Pb=137N/cm2襯墊比壓Pb小于設(shè)計(jì)值,強(qiáng)度校驗(yàn)合格.由以上校驗(yàn)說明,所選JKM4/4型摩擦式提升機(jī)合格可用。1.2.6井塔高度Hj確定 HJ=Hr+Hg+0.75=15600+13000+0.75=30.1 m 由以上確定HJ=35 m 可取。1.2.7預(yù)選電動(dòng)機(jī)1)電動(dòng)機(jī)轉(zhuǎn)數(shù)n=392.892 r/min 取電動(dòng)機(jī)同步轉(zhuǎn)數(shù) nt=500r/min,則額定轉(zhuǎn)數(shù)ne=492 r/min 此時(shí)相應(yīng)最大提升速度Vm=2)預(yù)選電動(dòng)機(jī)功率 Pe= 式中 K阻力系數(shù),取K=1.15 動(dòng)負(fù)荷影響系數(shù) 取=1.2因而 Pe=1.2=2435.867 KW 根據(jù)ne,Pe選電動(dòng)機(jī)YR2500121215 三相繞線式異步電動(dòng)機(jī).其技術(shù)特征參數(shù)如下:額定功率 Pe=2500 KW額定轉(zhuǎn)數(shù) ne=495 r/min過負(fù)荷系數(shù) =2.38轉(zhuǎn)子飛輪轉(zhuǎn)距 GD2=97860 N/m2電動(dòng)機(jī)效率 =92%電動(dòng)機(jī)作用于滾筒上的額定拖動(dòng)力 Fe= =216615.7 N1.2.8提升系統(tǒng)總變位質(zhì)量其中 GD=GD2()2=97860()2=674316.6 N因而 =866.84430+192400+674316.6+15600+217800 =162988.6 kg =162.9886 t1.2.9提升機(jī)加減速度的確定1)(a)按電機(jī)過負(fù)荷能力a1= =1.2949 m/s2(b)按減速器允許最大輸出扭矩 a1 m/s2根據(jù)以上結(jié)論,因而本設(shè)計(jì)加速度a=0.9 m/s2 可取.2) 減速度a3確定 首先考慮自由滑行方式減速 a3= m/s2 由此a3可采用自由滑行方式減速.1.2.10運(yùn)動(dòng)學(xué)參數(shù)計(jì)算1)初加速度a0 =式中 V0箕斗脫離卸載軌時(shí)速度 取 V0=1.5m/s hx卸載曲軌長度 取 hx=3 ma0=0.375 m/s2初加速時(shí)間 t0=主加速時(shí)間 t1=主加速行程 h1=52 m減速時(shí)間 t3= 式中V4爬行速度 取 V4=0.5m/s t3=s減速行程 h3=爬行時(shí)間 t4=式中 h4爬行距離 取h4=4 m t4= 等速行程 h2=Hhxh1h3h4 =39035244.4364=286.564 m等速時(shí)間 t2=29.21 s 2)箕斗卸載休止時(shí)間由礦井提升設(shè)備表51查得16 t箕斗Q=16 s所以一次提升循環(huán)時(shí)間為:Tx=t0+t1+t2+t3+t4+Q =4+9.2+8.62+8+29.21+16 =75.03 (s)3)提升能力校核實(shí)際年提升能力 An=273.36 萬噸/年4)箕斗提升速度圖圖1-3 箕斗提升六階段圖1.2.11動(dòng)力學(xué)參數(shù)計(jì)算初加速階段 F0 = KQ+ma0=1.15156009.81+162988.60.375=237.112 KN主加速階段 F1 = F0+m(a1a0) =237.112+162988.6(0.90.375)/1000 =322.681 KN 等速階段 F2=KQ=1.15156009.81=175.991 KN減速階段 F3=0爬行階段 F4=KQ=175.991 KN1.2.12電動(dòng)機(jī)功率校驗(yàn)1)等效時(shí)間Td = a(t0+t1+t3+t4)+t2+ =4+9.2+8.62+8)+29.21+16 = 49.45 S2) 等效力 =237.11224322.68129.2175.9912(29.21+8) =2.3353191012 N2/SFd = N3) 等效功率 Pd = =2455.45 KW1.75靜防滑校驗(yàn)合格.2) 動(dòng)防滑校驗(yàn)要求動(dòng)防滑系數(shù) 1.25 提升時(shí), 上升側(cè)靜張力 Fs=509.458 KN上升側(cè)變位質(zhì)量 Ms=53 t 下降側(cè)靜張力 Fx =356.422 KN下降側(cè)變位質(zhì)量 Mx=37.4 t =1.24 1.25動(dòng)防滑系數(shù)合格.3)緊急制動(dòng)防滑校Mz NMaz=2.0588 m/s2=0.846 1 緊急制動(dòng)不合格,考慮加配重,據(jù)鋼絲繩安全系數(shù),經(jīng)計(jì)算配重,m17.825t.選配重.m=15t則 Fx=356.422+159.81=503.572 KNmx=15+37.4=52.4 tFs=509.458+159.81=656.608 KN Ms= 15+53=68 t m=162988.6+2151000=192988.6 kg根據(jù)以上數(shù)據(jù)算出:az= =1.744 m/s2= =增加配重后,動(dòng)靜防滑系數(shù)更大,所以不需要再校驗(yàn).1.2.14提升機(jī)電耗及計(jì)算1)一次提升電耗237.1124+322.6819.2+175.9913721 =104.6573 KNSW = = =37.1989 KWh/次2) 噸煤電耗WtWt= W/Q=37.11089/15.6 =2.385 KWh/ t3)一次提升有益電耗 WyWy= KWh4)提升效率= =至此提升機(jī)的選型結(jié)束。2 提升容器逆止器的設(shè)計(jì)在立井提升中,為了防止提升容器發(fā)生過卷事故造成對(duì)設(shè)備或井筒設(shè)施的破壞,在提升系統(tǒng)中設(shè)置了各種減速、限速及過卷電氣開關(guān)等,然而由于絞車司機(jī)操作失誤或電氣元件失靈仍會(huì)發(fā)生過卷事故,造成了人員傷亡和重大的經(jīng)濟(jì)損失。因此,立井提升系統(tǒng)中需增設(shè)過卷保護(hù)裝置,以確保設(shè)備和人身的安全。通常采取的保護(hù)措施是在提升系統(tǒng)的上部設(shè)置楔形罐道和防撞梁。下部設(shè)置楔形罐道進(jìn)行過卷保護(hù),但是這種保護(hù)措施只能保護(hù)上部設(shè)備不受破壞,提升容器過卷時(shí),受到楔形罐道的保護(hù)不能繼續(xù)過卷,若提升容器以10M/S的速度上升時(shí),在要0.1秒鐘停止過卷,此時(shí)提升容器的減速度為100m/s.提升容器在極短的時(shí)間停住,提升鋼絲繩受到極大的沖擊而發(fā)生斷繩,斷繩后的提升容器將以極大的速度墜落入井筒.從而會(huì)使井筒內(nèi)的設(shè)施受到極大的破壞.簽于以上的原因煤礦安定規(guī)程1992年版明確規(guī)定:在提升速度大于3m/s,的提升機(jī)構(gòu)內(nèi),必須設(shè)置防撞梁和托罐裝置-。規(guī)定不但要求保護(hù)井塔部分,也要求保護(hù)井筒部分,要求過卷保護(hù)措施更完善。提升容器逆止器的設(shè)計(jì)思想就是在這種要求下而產(chǎn)生的。就是在斷繩后在有效地托住容器,防止容器墜落,造成事故的進(jìn)一步擴(kuò)大?;纺嬷蛊饕话阊b于卸載位置以上0.5米處.當(dāng)箕斗過卷時(shí)箕斗通過逆止器住置,逆止器動(dòng)作,阻斷箕斗下墜通路,將箕斗托于罐道上,避免其因斷繩下落,將事故損失減小了最小.逆止器的設(shè)計(jì)應(yīng)充分滿足礦山安全生產(chǎn)的需要,并達(dá)到安全,可靠.而且設(shè)計(jì)控制上盡量簡單,靈活。2.1方案的確定設(shè)計(jì)所提供的原始數(shù)據(jù): 立井12t的箕斗本設(shè)計(jì)以JDS-12/110-4立井提升繩12噸為標(biāo)準(zhǔn)提煤箕斗,以及相應(yīng)的罐道尺寸為對(duì)象進(jìn)行設(shè)計(jì)的。當(dāng)安裝位置不同時(shí),可相應(yīng)改變托爪以及底座的尺寸。JDS-12/110-4技術(shù)數(shù)據(jù):自重 12 t有效面積 13.2 m3名義載重 12 t斗箱斷面 23001300 mm 相應(yīng)剛性罐道斷面 180180 mm 井筒尺寸 5500 mm將箕斗逆止器的主要支撐部件-托爪裝在卸載高度500mm以上處.當(dāng)箕斗裝載容器的底部超過托爪位置時(shí),箕斗逆止器動(dòng)作,伸出托爪,阻斷箕斗下落通路.將箕斗托于罐道上.當(dāng)箕斗斷繩故障排除后,上提箕斗.采用手動(dòng)油泵,給收爪油缸供油,使托爪上揚(yáng),箕斗恢復(fù)正常工作狀態(tài),然后排出收爪油缸中的油液,托爪恢復(fù)到工作位置.箕斗逆止器工作簡圖如圖示:逆止器工作過程:圖: 此時(shí)逆止器處于靜止?fàn)顟B(tài),托爪在水平位置,支撐在減震油缸上,彈簧處于預(yù)拉緊狀態(tài),收復(fù)爪與托爪不接觸。圖:此時(shí)箕斗處于卸載位置,托爪沿斗箱邊緣被托起,彈簧伸長,使托爪緊貼于箕斗壁。圖: 當(dāng)箕斗過卷時(shí),托爪受自身的重力和復(fù)位彈簧的作用而恢復(fù)到水平位置?;窋嗬K下落將被托于托爪之上,減震油缸減緩沖擊,從而托住箕斗,不使箕斗下落,防止了事故的進(jìn)一步擴(kuò)大。圖:當(dāng)箕斗提升鋼絲繩修好后,上提箕斗,用油泵約收爪油缸沖油,抬起托爪,下放箕斗,恢復(fù)正常工作。把油排到油箱,復(fù)位彈簧使托爪復(fù)位,重新進(jìn)入工作準(zhǔn)備狀態(tài)?;纺嬷蛊髟诠薜乐械牟贾梦恢萌鐖D所示:圖中為井筒剖視圖,逆止器一共八個(gè),分布在箕斗兩側(cè),使之受力均勻,每個(gè)逆止器受到1/4沖擊載荷。托梁穿入井筒壁固定,托爪,減震油缸、底座均固定于托梁上,托梁中間部分都與罐道接觸部分采用焊接。圖2-2 井筒剖視圖2.2 托爪的設(shè)計(jì)2.2.1托爪的結(jié)構(gòu) 初步根據(jù)井筒布置尺寸,確定托爪長度為500。其中支撐箕斗部分長度為100。減震油缸支撐點(diǎn)在距轉(zhuǎn)軸中心190處,如圖示托爪受力圖。圖2-3 托爪受力圖FRBRA初步確定托爪轉(zhuǎn)軸中心位置為距端部50處。為A點(diǎn)。減震油缸支撐處為B點(diǎn),箕斗用力處為C點(diǎn)。2.2.2托爪的受力據(jù)井筒布置知,每個(gè)箕斗共安裝有4個(gè)托爪,則F= G 式中 G 箕斗自重及其負(fù)載總重。因而 F=6 t=6104 N由托爪受力圖知:RB190 = F(190+160+50) RB= 因?yàn)閅=0 因而 RA+F-RB=0RA=RB-F=12.63104-6104 =6.63104 N畫剪力圖6104Q圖 6.63104圖2-4 剪力圖畫彎矩圖M圖 圖2-5 彎矩圖其中Mmax=(12.631040.190.21)0.4=1.2588104Nm2.2.3托爪截面面積 由于max=N/A=6.631042/19.6106=6.7510-3m32.2.4彎曲應(yīng)力 由=My/Iz式中 Ymax=h/2 Zz=bH3/12 h托爪矩形斷面高度 b托爪矩形斷面寬度根據(jù)材料力學(xué)性能,受彎梁力學(xué)分布,截面寬和高最佳比例為: b:h=2:3所以 =(Mh/2)/(bh3/12)=9M/h3=91.26104/h3=179.5 mm在剪切應(yīng)力計(jì)算中,A=bh=h2=6.676510-3m2 h100.73mm2.2.5確定托爪截面尺寸 據(jù)以上結(jié)果,查機(jī)械設(shè)計(jì)手冊確定: h=200 mm b=135 mm2.2.6驗(yàn)算安全系數(shù)抗壓安全系數(shù): ma=s/=s/(my/Iz) =0.1350.22=25.21抗剪安全系數(shù): ma= =0.1350.8=71.87托爪強(qiáng)度校驗(yàn)合格2.2.7托爪尺寸圖 注: 為防止箕斗正常工作時(shí),托爪卡在箕斗上,所以托爪支撐端底部設(shè)計(jì)為以R180為半徑的圓弧。為連接安裝復(fù)位彈簧,在圖弧中心處焊接掛鉤。具體尺寸如下圖所示: 圖2-6 托爪尺寸圖2.2.8確定轉(zhuǎn)軸尺寸轉(zhuǎn)軸主要受到剪切應(yīng)力 N=6.63104/2=3.315104N選擇材料為45#鋼,安全系數(shù)取MA=15 =23.53 Mpa =11.76 Mpa由= A=2.8188710-3 m2 D59.9 mm 查機(jī)械設(shè)計(jì)手冊,取D=63 2.3 復(fù)位彈簧的設(shè)計(jì)計(jì)算由于本設(shè)計(jì)的復(fù)位彈簧只起復(fù)位作用,無具體的要求,只要在初位置有一個(gè)預(yù)緊力,在終端位置不會(huì)因受力太大而發(fā)生永久形變即可,取預(yù)拉伸長度L=10。而初位置時(shí)L1=252.所以彈簧自由長度為242。當(dāng)彈簧處于終端位置時(shí)L2=305。彈簧d=4,D2=20,c=5 L0=nd+1.5D2=4n+30 n=(242-30)/4=53L1=L0+ =252-242=10=式中-彈簧受載后軸形變形量 G-彈簧材料剪切彈性模量查機(jī)械設(shè)計(jì)手冊取G=80000 F0=60.3773 Nmax= 式中Fmax-彈簧受到最大拉力max-彈簧終端位置時(shí)變形量max=L2-L1305-252=53Fmax=+60.3773=380.375 N因而彈簧的幾何尺寸確定為: 中徑 D2=20 外徑 D=D2+d=20+4=24 內(nèi)徑 D1=D2-d=20-4=16 節(jié)距 t=d=4 自由長度 L0=242彈簧剛度 Kf=6.0377 N/ L1=252 時(shí) F1=Kf(L1-L0)=60.377 N L2=305 時(shí) F2=Kf(L2-L0)=380.375 N2.4 收爪油缸的設(shè)計(jì)2.4.1油缸位置的確定收爪油缸在本設(shè)計(jì)中無太多的要求,只要它能支撐起托爪重力和彈簧的拉力的合力即可.由于結(jié)構(gòu)關(guān)系,托爪油箱放置位置如圖,它的活塞桿長度應(yīng)使托爪不致于阻礙箕斗下放.圖2-7 托爪結(jié)構(gòu)圖2.4.2收爪油缸受力分析當(dāng)托爪處于正常工作位置(水平位置)不受力,當(dāng)手動(dòng)油泵給油缸注油時(shí),看需力為: Nc= 式中 F2-彈簧在終極位置時(shí)接力 Y-F2到轉(zhuǎn)軸中心力臂G-托爪重力,估算為G=gv V=()135 =12.399103kg/m3因而 G=944.2 N Z-油缸到轉(zhuǎn)軸中心力臂注: X,Y,Z 由比例圖上大致量為60,175,59所以 Nc=3187.3 N2.4.3收爪油缸尺寸確定1)根據(jù)實(shí)際需要,查液壓系統(tǒng)設(shè)計(jì)手冊選擇內(nèi)徑D=302)計(jì)算壁厚: 式中 - 液壓缸壁厚 Py - 實(shí)驗(yàn)壓力取工作壓力1.3倍 D - 液壓缸內(nèi)徑內(nèi)徑 - 材料許用應(yīng)力 選擇鑄鋼材料 =105 MP 工作壓力P=4.511 Mpa 1.34.5110.03/105=0.00167m=1.67 取 =33)缸蓋厚度確定 前端蓋: t0.433D 式中 : t-缸蓋有效厚度 d0-缸蓋孔直徑 t=6.36查機(jī)械設(shè)計(jì)手冊取t=6.54)最小導(dǎo)向長度確定H取 H=30 式中: L-液壓缸最大行程 L=140 D-液壓缸內(nèi)徑5)活塞寬度B=(0.61.0)D=(0.6-1.0)30=18-30 取出B=20缸蓋滑動(dòng)支撐面寬度L1L1=(0.6-1.0)D=18-30 取出L1=20隔套長度CC=H-106)收爪油缸結(jié)構(gòu)圖: 圖示如下:2.5 緩沖油缸設(shè)計(jì)2.5.1估取油缸的內(nèi)徑 D=1402.5.2活塞桿直徑確定工作壓力 P=8.21 Mpa7 MPa查液壓系統(tǒng)設(shè)計(jì)手冊則 d/D=0.7d=0.7140=98 取 d=100校驗(yàn)其強(qiáng)度 Mpa選擇45#鋼 =325 Mpa Ma=所以活塞桿滿足強(qiáng)度要求。2.5.3液壓缸壁厚和外徑計(jì)算 壁厚 =158.210.14106/2105106=8.21取 =14查機(jī)械設(shè)計(jì)手冊得液壓缸外徑D1=D+2=140+214=168 2.5.4缸蓋厚度確定t0.433D16.95取t=202.5.5 最小導(dǎo)向長度確定H=75取H=802.5.6活塞寬度B確定 由于 D80 所以 B=(0.61.0)d=(0.61.0)100=(60100)取 B=802.5.7油量壓縮值 液壓缸初油壓為0.5MPa 終油壓為: 8.21MPa油缸連接皮囊式貯能器NXQ0.6型,技求指標(biāo):容積: 0.6L壓力: 10MPa重量: 4.5 Kg油缸充油量為0.1L,此終油壓為:8.21Mpa 由Pv為常數(shù)1.10.6=(1.1+0.5)V V=0.425L1.10.6=(1.1+8.21)VV=0.07089L所以四個(gè)油缸中的油流到貯能器中為: V=0.425-0.07089=0.35411每個(gè)油缸去油量V=0.08852 L所以下降高度為: x=8.852 減震油缸剖視圖2.6底座設(shè)計(jì)及計(jì)算2.6.1底座設(shè)計(jì)方案底座設(shè)計(jì)是根據(jù)實(shí)際需要進(jìn)行的。底座上需要固定減震油缸,收爪油缸,復(fù)位彈簧及托爪.底座是焊接在托梁上所以只需校核軸孔強(qiáng)度即可。底部凹槽為固定減震油缸用,由于緩沖油缸只受徑向力,所以油缸只需放入槽中即可,收爪油缸焊在底座上。2.6.2軸孔校核 軸孔受拉面積為: (108-63)45=2025 2 兩軸孔總受拉面積為: A=22025=40502 由以前計(jì)算知轉(zhuǎn)軸處受力為: Ra=6.63104 N所以 F/A =6.63104/405010-6=16.37 Mpa底座選擇鑄鋼 45# 鋼 則: =320 Mpa安全系數(shù) Ma=/=19.547915因此底座軸孔強(qiáng)度符合安全要求.2.6.3 底座示意尺寸圖如下 圖2-10 底座示意尺寸圖2.7托梁強(qiáng)度校核2.7.1托梁受力分析N1N2F1N1” F2圖2-11 托梁受力分析圖由于托梁兩邊受力為對(duì)稱,因而可簡化為:N2N1275275 圖2-12 受力簡化圖已知力F1=F2=6104 N由m=0 F1(2750-575)=N22750 得 N2=4.7104 N由Y=0 N1+N2-F1=0 N1=6104-4.7104=1.25104 N所以N1=N1=1.25104 N F1=F2=6104N N2=2N2=9.49104 N2.7.2托梁的Q圖及M圖 Q圖:M圖:2.728104Nm2.728104NmMmax=2.728104Nm圖2-13 Q圖和M圖托梁和罐道相交處采用焊縫厚度的方法焊接。2.7.3托梁強(qiáng)度校核1)剪應(yīng)力校核中部截面為受前力最大截面,而截面面積小受力N2=9.5104N 面積為 A=210h 式中h托梁高。選擇鑄鋼材料。 =320Mpa =/2=160 Mpa由于受到巨大的沖擊載荷,而緩沖油缸抵消大部分沖擊,所以安全系數(shù) M10 F/A=9.4909104N/210h ma=10 9.4908104/210h16 MPa h 0.0282m=28.22)彎曲應(yīng)力校核 W= M=2.728104 Nm = ma=10 32 MPa h715.5 根椐以上計(jì)算結(jié)果,查機(jī)械設(shè)計(jì)手冊取h=126.3 提升機(jī)信號(hào)聯(lián)鎖系統(tǒng)的改造31原信號(hào)聯(lián)鎖系統(tǒng)的缺陷在礦井提升系統(tǒng)中,提升信號(hào)可與各種提升電控系統(tǒng)進(jìn)行接口配套.完成各種礦井的主副井單水平及多水平的提升信號(hào)系統(tǒng)的任務(wù)。信號(hào)閉鎖的保護(hù)、安全保護(hù)要符合煤礦安全規(guī)程的要求。使用罐籠提升的立井,井口、井底和中間運(yùn)輸巷的安全門必須與罐籠和提升信號(hào)連鎖,在信號(hào)系統(tǒng)中,采用了由一個(gè)按鈕打多種信號(hào)的方式,既安全又可靠。臥牛礦原先使用的信號(hào)聯(lián)鎖系統(tǒng),是早期天津電器設(shè)備廠生產(chǎn)的,距今已有三十多年,設(shè)備陳舊老化嚴(yán)重。它是利用JZ7-44繼電器和JS7-2A空氣式時(shí)間繼電器工作的??諝馐綍r(shí)間繼電器是利用空氣阻尼作用而達(dá)到延時(shí)的目的。由于該繼電器在正常的運(yùn)行中容易出現(xiàn)很多的問題,其觸點(diǎn)開關(guān)存在著一些固有的缺點(diǎn),如機(jī)械磨損,觸點(diǎn)的電蝕損耗,易河南理工大學(xué)萬方科技學(xué)院本科畢業(yè)論文附錄:外文資料與中文翻譯外文資料:Research on Detection Device for Broken Wires of Coal Mine-Hoist CableWANG Hong-yao1, HUA Gang1, TIAN Jie21School of Information and Electrical Engineering, China University of Mining & Technology, Xuzhou, Jiangsu 221008, China2School of Mechanical Electronic and Information Engineering, China University of Mining & Technology, Beijing 100083, ChinaAbstract: In order to overcome the flaws of present domestic devices for detecting faulty wires such as low precision,low sensitivity and instability, a new instrument for detecting and processing the signal of flux leakage caused by broken wires of coal mine-hoist cables is investigated. The principle of strong magnetic detection was adopted in the equipment. Wires were magnetized by a pre-magnetic head to reach magnetization saturation. Our special feature is that the number of flux-gates installed along the circle direction on the wall of sensors is twice as large as the number of strands in the wire cable. Neighboring components are connected in series and the interference on the surface of the wire cable, produced by leakage from the flux field of the wire strands, is efficiently filtered. The sampled signal sequence produced by broken wires, which is characterized by a three-dimensional distribution of the flux-leakage field on the surface of the wire cable, can be dimensionally condensed and characteristically extracted. A model of a BP neural network is built and the algorithm of the BP neural network is then used to identify the number of broken wires quantitatively. In our research, we used a 637+FC, 24 mm wire cable as our test object. Randomly several wires were artificially broken and damaged to different degrees. The experiments were carried out 100 times to obtain data for 100 groups from our samples. The data were then entered into the BP neural network and trained. The network was then used to identify a total 16 wires, broken at five different locations. The test data proves that our new device can enhance the precision in detecting broken and damaged wires.Key words: wire cable; broken wire; signal processing; detection deviceCLC number: TB 421 IntroductionIt is well-known that coal mine-hoist cables are an important part in coal mine-hoists or transportation systems. Wires are, in fact, subjected to breakage due to wear, corrosion and fatigue. The extent of damage and the carrying capacity of wires are directly related to the safety of equipment and staff. At present, there are many detection devices for broken steel cables manufactured in China, but most devices do not meet the conditions ideally required in practice. The reasons are largely the complex structure of wires, bad working conditions, the multiplicity and uncertainty of broken wires. It is therefore quite difficult to detect signs of broken wires as well as to analyze and process detected signal of broken wires in cables 1.A new instrument for broken wires detection and procession of coal mine-hoist cables was investigatedfor this paper. With the special structure of a detection transducer, the interfering signal from the leakage field of wire twists can be filtered efficiently. After the extraction of dimensional contraction and characteristic values of multi-ways signals, a quantitative BP neural network recognition for broken wires in steel cables was realized. The test results are presented.2 Basic Structural Principle of the On-Line Detection Instrument for Coal Mine-Hoist CableThe structural principle of the on-line detection device for wire cables studied by us is shown in Fig. 1.The detection transducer is composed of two semicircle cylindrical structures which can be opened or closed. The magnetic sensing unit is a fluxgate unit made of a single magnetic core and is single-winding. Some magnetic sensing units are evenly arranged around the inner wall of the transducer, the number of which is twice as many as the number of the wire strands in the inspected cable. As well, two neighboring units are connected in series to a detection channel.Consequently, the number of detection channels of the detection instrument is equal to the number of wire strands in the cable.Fig. 1 Structural principle of detection instrument for broken wires in coal mine-hoist cables.After being filtered and reshaped, the detection signal from each channel is sent to the signal processing unit. The analog detection signal is converted into adiscrete dimensional sequence of sampling values by multi-channel A/D conversion, followed by a characteristic extraction, a BP neural network recognition and the output of the result. When viewed separately, the leakage field signal detected by each single fluxgate unit is the leakage field intensity in the steel cable where the corresponding fluxgate units are located. That is, the outputsignal Zjk of any jth test unit is:Where FC is the structural parameter of the fluxgate, the width of the drive square-wave, s the saturated magneto-conductivity rate, B c, j the magneticinduction intensity of the leakage field produced by broken wires, Br, j the magnetic induction intensity of the leakage field produced by wire cable twists, Zf j the signal value of broken wires and Z r, j the value of the interference signal produced by wire cable twists.After , F C ,a , us , Fare assured, F is a constant.After the wire cables are deeply magnetized, the numerical value of sis very small. As a result, the value of c, j is larger and there is no need to magnify and process the detection signal again. When the sensor is operating along wire cables at a specified speed, the signals detected by each of the magnetic fluxgate units can effectively show the three-dimensional distribution status of magnetic flux leakage, generated at the surface of wire cables24.3 Filtration of the Wavelike Oscillation Interference Signal Produced by Cable Wire TwistsThe signal of broken wires from wire cables obtained by a single fluxgate detection unit of the transducer (formula (1) contains all kinds of interfering signals. The effect of the wavelike oscillation magnetic flux leakage B r, j due to the special structure of the steel cables is largest, which directly affects the detection of broken or damaged wires, especially in coal mine-hoist cables. We should consider the possibility of filtering the interference signals. In formula (1), the interference signal r, j caused by a wavelike oscillation shows up as periodic variation. This kind of wavelike oscillation interferencesignal can be regarded approximately as a sine wave,as shown in Fig. 2.Fig. 2 Wavelike oscillation interference signalproduced by the cable twistOver the length direction of wire cables, its variation period T is a Lay length of cable wire strands. At the circle direction of the wire cable, its variation period is the reciprocal of the number of outer wire strands of the circle length of the wire cable. Therefore, the wavelike oscillation interference signal of the jth detection channel can be expresse d as: jWhere a is the Direct Current Component of the wavelike oscillation signal, m the Alternating Current Component magnitude of the wavelike oscillartion signal, T represents the value of periods, y is the position of the detection unit, starting from the initial spot, j the initial phase of the wavelike oscillation signal, N the number of wire strands of the steel cable, and is the number of detection units. cObviously when c , i.e., when the number of detection units doubles the number of outer strands of the wire cable, the wavelike oscillation signal contained in the leakage magnetic field signal inspected by any two neighboring detection units is in a reversal phase. Therefore, when the neighboring detection units along the inner wall of the cylinder of the transducer structure are connected forward into a test channel in series two by two, it is equivalent to adding the (j+1)th test channel signal to the jth test channel signal. Thus the strand peak value of the wavelike oscillation signal compensates for the strand value for the moment. That is, at this moment, the only remaining wavelike oscillation signal is the Direct Current ComponenAt this moment, the magnetic field signal of leakage from any of the inspection channels made up of the fluxgate array should be:of this formula can be eliminated when the zero detection position is adjusted. Therefore, we considered that the wavelike oscillation interference signal of cable wires is filtered by formula (4). After this pretreatment, each leakage from broken wires, shown by magnetic field signals from the transducer, becomes a channel sample value by A/D conversion, as shown in Fig. 3.Fig. 3 Multi-channel sampling value of broken wiresignals from wire cables4 Extraction of Characteristic Value of Signals from Broken WiresAs is shown in Fig. 3, the N-channel inspection signals from the transducer becomes its sampling sequence by A/D conversion. If the number of samples of the signals of broken wires is K, the sequence of broken wire sample signals of the jth channel can be expressed as a row vector with K elements.The N-channel signal sequence will make up a N-dimensional series vector group of broken wiresignals:At this moment, Z is a characteristic matrix of broken wires and it contains all the information on the status of the broken wires. NK Given the analysis of repeated experiments, the width of the diffused leakage from the magnetic fieldon the surface of wire cables created by broken wires is not larger than 20 mm. When the speed of the inspected wire cable is 3 m/s and the sampling interval is 1.2 mm, the number of samples K is 16 at most. When the number of inspection channels is N=4, Z should be a 416 matrix. If the analysis of the characteristic matrix of broken or damaged wires Z were directly carried out, the analytical process would be very complex and would need to be carried out as acomparison and judgment of the sequential value of each line. So instead, we carried out a reduction in the order processing of formula (6), i.e., we carried out a dimensional contraction. According to a lemma of theoretical linear algebra Z can also be expressed as:Where are arbitrary, independent base vectors. h is the characteristic vector of one-dimensional broken wires expected to be obtained after dimensionalcontraction. So long as the appropriate t is found, h can be derived:According to the L-K transformation principle, when the value of t is the latent vector of the covariance matrix z P of Z, the transformation error is a minimum, i.e., t satisfies the characteristic equationWhere j is the characteristic value of z and I is an identity matrix. Represented by formula (8), the expected characteristic vector h of the broken wires could be obtained via the dimensional contraction. The process of transformation of the dimensional contraction is, in fact, a conversion from a N-dimensional characteristic vector to a one-dimensional vector. P The average of the one-dimensional h sequence is regarded as an eigenvector which represents each state of the N-channel broken wire signals:5 ConclusionsOur detection of broken wires in steel cables is a quantitative inspection method. It will identify not only whether there are broken wires or not, but also will identify the position and number of broken wires. By combining transducer detection technology and computer technology and using advanced signal processing technology, we can effectively enhance theprecision and sensitivity of detection devices to realize the automation and the intellectualization of the detection equipment.中文翻譯:對(duì)煤礦礦井提升機(jī)鋼絲繩損毀的鋼絲檢測裝置的研究王宏姚,華崗, 田杰 1信息和電氣工程系,中國礦業(yè)大學(xué),江蘇徐州221008 ,中國2機(jī)械電子信息工程系,中國礦業(yè)大學(xué),北京100083 ,中國摘要:為了克服目前國內(nèi)鋼絲故障檢測設(shè)備的缺陷,如低精度,低靈敏度和不穩(wěn)定,一個(gè)新的由煤礦-提升機(jī)鋼絲繩所造成的漏磁信號(hào)的檢測和處理裝置已經(jīng)研制出。強(qiáng)磁場檢測的原理應(yīng)用在該設(shè)備中,鋼絲由前磁頭磁化強(qiáng)度達(dá)到飽和。我們特別的特點(diǎn)是安裝在沿圓圈方向上傳感器的內(nèi)壁數(shù)目通量是在鋼絲繩中兩倍大的數(shù)目。周邊組件系列地連接在一起并且由于鋼絲的通量域所產(chǎn)生的滲漏對(duì)鋼絲繩的表面干擾有效地被過濾,斷絲所產(chǎn)生的采樣信號(hào)序列,其特點(diǎn)是在線纜的表面上由一個(gè)三維分布漏磁場通量,可以立體簡明和根據(jù)特性提取。BP神經(jīng)網(wǎng)絡(luò)的模型已經(jīng)被建立和BP神經(jīng)網(wǎng)絡(luò)的算法是用來定量分析地確定有多少鋼絲損毀。在我們的研究,我們用了6 37 +FC, 24毫米線纜作為我們的測試對(duì)象。隨機(jī)人為地以不同程度破壞和損壞數(shù)根鋼絲,實(shí)驗(yàn)共進(jìn)行了100次,以為來自我們的樣本的100組對(duì)象獲取數(shù)據(jù), 然后將數(shù)據(jù)輸進(jìn)BP神經(jīng)網(wǎng)絡(luò)進(jìn)行處理。然后該網(wǎng)絡(luò)用來識(shí)別共計(jì)16鋼絲,打破了5個(gè)不同地點(diǎn)。測試數(shù)據(jù)證明我們的新裝置可以提高檢測破碎和損壞的鋼絲的檢測精度。 關(guān)鍵詞:鋼絲繩;損壞的鋼絲;信號(hào)處理;檢測裝置中圖分類號(hào)TB 421引言煤礦提升機(jī)鋼絲繩是煤礦提升或運(yùn)輸系統(tǒng)的重要組成部分,這是人所共知的。事實(shí)上鋼絲是,由于磨損,腐蝕和疲勞而受到破損,。鋼絲的損害程度和承載能力直接關(guān)系到設(shè)備和員工的安全。目前, 很多在中國制造的檢測損壞的鋼絲繩裝置,但大多數(shù)設(shè)備不能理想地滿足實(shí)踐需要,原因主要是鋼絲的復(fù)雜結(jié)構(gòu),惡劣的工作條件,鋼絲損毀的多重性和不確定性。因此,檢測到鋼絲損毀的跡象是相當(dāng)困難,以及作以分析和處理在鋼絲繩 1 里檢測到的鋼絲損毀的信號(hào)也是如此 。在此論文中,一套新的煤礦-提升機(jī)鋼絲繩和斷絲檢測設(shè)備已經(jīng)深入探討,用傳感器檢測的特殊結(jié)構(gòu),從鋼絲扭曲而產(chǎn)生的泄漏領(lǐng)域的干擾信號(hào),可以有效地過濾。在之后提取多途徑的信號(hào)的三維收縮和特征值, BP神經(jīng)網(wǎng)絡(luò)在鋼絲繩對(duì)斷絲的識(shí)別得已定量地實(shí)現(xiàn),該測試結(jié)果將會(huì)顯示出來。 2聯(lián)機(jī)的煤礦提升機(jī)鋼絲繩檢測儀的基本結(jié)構(gòu)原理我們研究的該聯(lián)機(jī)的鋼絲繩檢測裝置的結(jié)構(gòu)原理在圖 1中已經(jīng)表明 。 檢測傳感器由兩個(gè)可開啟或封閉的半圓圓筒形結(jié)構(gòu)組成,磁傳感單元是一種由一個(gè)單一的磁芯組成磁通門單元并且是單一繞組。一些磁性傳感單元均勻地安排靠近轉(zhuǎn)換器的內(nèi)壁,它的數(shù)量是檢測鋼絲繩鐵絲網(wǎng)的兩倍以及,兩個(gè)相鄰的單元有系列地聯(lián)接在一項(xiàng)檢測通道。 因此,該檢測儀的檢測通道的數(shù)量與絲股在線纜的數(shù)量相等。如下列圖表1:煤礦提升機(jī)鋼絲繩鋼絲損毀檢測儀的結(jié)構(gòu)原理,經(jīng)過過濾和重塑,從每個(gè)通道發(fā)出的檢測信號(hào)送到信號(hào)處理單元。通過多渠道的A / D轉(zhuǎn)換,模擬檢測信號(hào)轉(zhuǎn)化為二維離散序列的采樣值,然后通過BP神經(jīng)網(wǎng)絡(luò)的識(shí)別和結(jié)果的輸出特點(diǎn)提取。檢測時(shí),另外,通過每個(gè)單磁通門單元檢測到的漏磁場信號(hào)是泄漏在鋼索的地方相應(yīng)的磁通門單元的電場強(qiáng)度, 那就是,任何jth測試單元的輸出信號(hào)Zcj是:在該公式中,CF是驅(qū)動(dòng)器方波的磁通門 寬度的結(jié)構(gòu)參數(shù), S 是額定定磁導(dǎo)率, Bcj鋼絲損毀漏磁場所產(chǎn)生的應(yīng)強(qiáng)度,Brj是鋼絲繩曲折所產(chǎn)生的漏磁場的磁感應(yīng)強(qiáng)度, Zfj損毀鋼絲的信號(hào)值,和Zrj是的鋼絲繩扭曲所產(chǎn)生干擾信號(hào)值,公式中系數(shù)在Cf,a,s,D確定以后,是一個(gè)常數(shù)。 線鋼絲繩深感磁化后, US的數(shù)值 是很小的。因此, Zcj的值會(huì)更大,因此,沒有必要再次去放大和處理的檢測信號(hào)。 當(dāng)傳感器是在指定的速度下沿鋼絲繩運(yùn)行,每一項(xiàng)磁通門單位檢測到的信號(hào),能有效地顯示磁泄漏三維立體分布狀況,在鋼絲繩表面產(chǎn)生 2-4 。3.鋼絲繩扭曲所產(chǎn)生的干擾信號(hào)的波形振蕩的過濾由一個(gè)單一的磁通門檢測單元所獲得的鋼絲繩損毀鋼絲的信號(hào), (公式( 1 )包含各種干擾信號(hào)。由于鋼絲繩特殊結(jié)構(gòu)產(chǎn)生的磁通量泄露強(qiáng)度Bjb的波形振蕩影響是最大地,這直接影響到檢測的破碎或損壞的鋼絲,特別是在煤礦-提升機(jī)的鋼絲繩。我們應(yīng)該考慮過濾干擾信號(hào)可能性。在公式( 1 ) ,波形振蕩所造成的干擾信號(hào)Zrj周期地顯示。這種波形振蕩干擾信號(hào),可算是大約作為一個(gè)正弦波,如圖圖2所示:圖2鋼絲繩扭曲波形振蕩所產(chǎn)生的干擾信號(hào)通過鋼絲繩的長度方向,其震蕩周期T是一個(gè)奠定長度電纜絲。在鋼絲繩的循環(huán)方向,其震蕩周期是鋼絲繩圓周長度的外鋼絲數(shù)目的倒數(shù), 因此,jth檢測通道的波形振蕩干擾信號(hào)Zrj可表示為:這里Ra是振蕩直流電信號(hào)組成部分,Rm是波形震蕩信號(hào)的交流電組成量,T代表周期值, Y是檢測單元的位置,從最初的位置開始,初期階段波形振蕩信號(hào), n的數(shù)目絲股的鋼索,以及數(shù)是檢測單位。N是鋼絲繩中的鋼絲根數(shù)Nc是檢測單元的個(gè)數(shù). 顯然,當(dāng)Nc= 2 n ,即,當(dāng)檢測單元的數(shù)目是鋼絲繩外部鋼絲數(shù)目的雙倍,由任何兩個(gè)鄰的檢測單位產(chǎn)生的漏磁場信號(hào)的波形振蕩信號(hào)是在一個(gè)還原階段。因此,當(dāng)周邊的檢測單位,沿傳感器的結(jié)構(gòu)圓柱內(nèi)壁兩個(gè)兩個(gè)地系列連接著成為一個(gè)測試頻道,這是相當(dāng)于向jth測試通道信號(hào)添加了j+1次測試通道信號(hào)。因此,鋼絞線波形振蕩信號(hào)的峰值補(bǔ)償為鋼絞線的價(jià)值是當(dāng)務(wù)之急。這是,在這一刻,剩下的唯一波形振蕩信號(hào)是直流電量的組成部分此時(shí),從任何檢查的渠道泄漏的磁場信號(hào),組成了該磁通門陣列應(yīng)該是:當(dāng)零檢測位置被調(diào)整時(shí),這個(gè)公式的Zr可以被減掉,因此,我們可以認(rèn)為鋼絲繩的波形振蕩干擾信號(hào)是被式( 4)過濾了。這預(yù)處理后,損毀鋼絲的每個(gè)泄漏,由傳感器所表現(xiàn)出的磁場信號(hào),由A / D轉(zhuǎn)換,變成一個(gè)渠道采樣值,顯示在圖3 圖3來自鋼絲繩的斷鋼絲信號(hào)的多渠道的采樣值4. 從損毀的鋼絲信號(hào)的特征值提取正像圖3所表示的那樣,來自傳感器N通道檢查信號(hào)通過A / D轉(zhuǎn)換成為其采樣序列,如果損壞的鋼絲信號(hào)的采樣數(shù)值是K, jth渠道的損壞鋼絲樣本信號(hào)序列,可以表示為一個(gè)與K有關(guān)的行向量.N通道信號(hào)序列將組成損壞鋼絲的信號(hào)的一個(gè)n維向量組:此時(shí), Z是一個(gè)具有損毀鋼絲的矩陣的特點(diǎn),它包含所有損毀鋼絲的程度的信息。鑒于反復(fù)試驗(yàn)分析, 鋼絲繩表面上損壞的鋼絲所造成的擴(kuò)散泄漏磁場的寬度斷絲不大于20毫米。當(dāng)檢測到鋼絲繩的速度是3米/秒和采樣間隔是1.2毫米,樣本數(shù)目K至多是16。 當(dāng)檢查渠道數(shù)目是N = 4時(shí), Z 應(yīng)該是一個(gè)4 16矩陣。如果破碎或損壞的鋼絲z的特征矩陣分析直接進(jìn)行,分析過程將十分復(fù)雜,將需要對(duì)該序列每一行的值進(jìn)行作為比較和判斷。因此,相反,我們減少了一項(xiàng),在指令處理公式( 6 ) ,即,我們進(jìn)行了維收縮。根據(jù)一項(xiàng)引理理論線性代數(shù),z也可以表示為:其中, , , ,是任意的,獨(dú)立的基體。 h是該損毀鋼絲的一維特征向量,預(yù)計(jì)在三維收縮后將取得。因此,只要找到適當(dāng)?shù)膖, h可以得出:根據(jù)該L-K轉(zhuǎn)換的原則, 當(dāng)t值為是協(xié)方差矩陣的Z的潛在的基體,是轉(zhuǎn)型錯(cuò)誤最低一個(gè)情況,即:t滿足特征方程:其中,是的特征值,I是一單位矩陣。由公式( 8)所代替,損壞鋼絲的 期望的特征向量h可以通過三維收縮得到。 這個(gè)三維收縮的轉(zhuǎn)變過程,實(shí)際上就是一個(gè)從一個(gè)N維特征向量向一個(gè)維向量的轉(zhuǎn)換。平均一維空間h序列被視為一個(gè)特征向量代表N通道斷絲信號(hào)的每個(gè)狀態(tài):5.結(jié)論我們對(duì)鋼絲繩中損毀的鋼絲的檢測是一個(gè)定量檢測方法。它將不只是確定否有鋼絲損毀,也將確定損毀鋼絲的位置和數(shù)目。 結(jié)合傳感器檢測技術(shù)及計(jì)算機(jī)技術(shù)和使用先進(jìn)的信號(hào)處理技術(shù),我們可以有效地提高檢測裝置的精度和靈敏度,從而實(shí)現(xiàn)檢測設(shè)備的自動(dòng)化和智能化。20
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