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任務書 任務下達日期：2011年2月28日 畢業(yè)論文日期：2011年3月7日至2011年6月10日 畢業(yè)論文題目：MG400/930-AWD型交流電牽引采煤機牽引部設計 畢業(yè)論文專題題目： 畢業(yè)論文主要內(nèi)容和要求： 主要技術參數(shù)及配套設備： 采高（m）：1.6～3.5； 適應傾角（°）：≤25； 煤質硬度 : 硬或中硬； 機面高度（mm）：1250； 機重（T）：～60； 滾筒截深（mm）：800； 滾筒直徑 （mm）： 1600、1800、2000； 滾筒轉速 （mm）：25.83、29.29； 滾筒水平中心距（mm）：13719； 搖臂回轉中心距（mm）：8250； 牽引形式 ：強力輪齒—齒軌電牽引； 牽引速度(m/min)： 0～8.5～14.2； 牽引力（KN）：670～400； 搖臂回轉中心距（mm）：8250； 搖臂擺角：下擺 上擺； 牽引電機型號：YB2-250M-4-55； 裝機功率（KW）：930 （其中兩個截割電機2×200KW　兩個牽引電機2×55KW，破碎電動機20KW，共計2×200＋2×55＋20=930） 技術要求： 1. 查閱有關資料、完成該機總體方案的設計，三機配套布置； 2. 根據(jù)有關技術參數(shù)對該采煤機牽引部進行設計； 3. 對該牽引部主要傳動組件、零件進行加工圖設計； 4. 編寫完成整機設計計算說明書。 5. 院長簽字： 指導教師簽字： a． 英文原文 Harmonic Response Analysis On Cutting Part of Shearer Physical Simulation System Paper Title Abstract—Coal-rock interface recognition system mainly means collecting various response signals available from multi-sensors equipped in shearer and further analyzing and those response signals to see if it is cutting coal or rock. For this purpose, the shearer equips total five types of various distinguishing sensors to pick up these signals. Both the optimized configuration of sensors measuring points and the choices of the sensors properties are the key factors to correctly and completely collecting the manifold dynamic characteristic signals of cutting part of physicalsimulation system. Therefore, it is important and necessary to carry out the harmonic response dynamics analysis of shearer cutting part. The vibration characteristics based on frequency response is analyzed. The study not only optimizes the disposition of the vibration sensor for the maximum output amplitude signals, but also identifies the frequency range of the vibration sensor, so that it not only satisfies the condition for undistorted measurements, but also avoids that the sensors are interfered due to resonance. Keywords— cutting part finite element dynamics harmonic response coal-rock interface recognition I. INTRODUCTION Coal-rock interface recognition system mainly collects response signals of cutting force of shearer by multi-sensor and analyses this response signal for the recognition of cutting coal or rock. Therefore, it is basic premise to pick up signals. Generally there are two methods to pick up these signals: one is to collect data at the coal interface, which, however, brings a lot of difficulties as a result, and is limited to certain extent by many factors. Another method is, under meeting the similarity condition, to establish physical simulation system in the laboratory, including media and the simulation ofshearer traction-cutting mechanism. This way can adjust structural parameters, mechanical and physical performance parameters of coal or rock in large range; meanwhile, this way can strictly control the test parameters, optimize test methods to obtain the accurate and reliable results. So the physical simulation system of shearer is developed on the foundation of similarity principle. With the states of cutting different materials, arm vibration state, pressure in the raising cylinder, torque signal of input shaft, torsional vibration signal of drum shaft and cutting electrical current accordingly reflect changes in the state of cutting. So the five types of sensors to pick up these signals are equipped with. In recent years ,the researches of coalrock interface recognition are mostly focused on fusion research[1]-[3], unfortunately, little concerns about the validity and correctness of the data itself is given, which involves the disposition optimization of sensors measuring points and the choice of the sensor performances. In view of this, the vibration states of arm will be analyzed and summarized up in this paper. So the cutting part of shearer physical simulation system for finite element harmonic analysis is made, the vibration response characteristics of cutting part from the perspective of frequency response is analyzed to obtain the best point of picking-up vibration of arm, optimize the disposition of the vibration sensor measuring point and determine the due working frequency range of sensor. II. PHYSICAL SIMULATION SYSTEM OF SHEARER The testing model of shearer is based on the prototype of electric traction shearer (model: MGTY400/900-3.3D) according to the similarity theory, and is designed by the geometric ratio of one to eight. Based on the foundation of this, it is optimized and remodeled to highlight the simples of model and meet the performance, low cost, simple structure. The physical simulation system of shearer[4] is shown as figure1. Shearer model is composed of drum, arm, torsional moment sensor, motor, cylinder and body. The cutting part of model needs to complete two actions: the motor as power input mechanism drives the drum to finish cutting; and the height of arm is adjusted successively by the cylinder from the top position(angle is α=48.96°) to the bottom position (angle is β=26.69°) . The position is shown as figure 2. III. HARMONIC RESPONSE AT LEVEL POSITION Harmonic response analysis is a method used to determine the steady-state response of a linear structure to loads that vary sinusoidally (harmonically) with time. The input is the harmonic load for the known size and frequency. The idea is to calculate the structure's response at several frequencies and obtain a curve graph of some response quantity versus frequency[5]. A. Establishment of three-dimensional model When we ensure the original structure size, the quality of structure, simplify these parts what are not the focus of the study, A model of cutting part is established by threedimensional modeling software Pro/E. The main parts' sizes are drum diameter 225 mm, arm length 490 mm, height 150 mm, width 154 mm, width 735 mm and so on. B. Definition of element type and material properties After completion in three-dimensional modeling, model is imported ANSYS11.0 finite element analysis software. Based on the structure of shearer, the type of solid element solid92 is selected. This element type is suitable for meshing of the irregular grid of model established by a variety of CAD / CAM. Element is defined by 10 nodes, and is the quadratic tetrahedron element of pure displacement shape function. Second , the laboratory model of shearer is steel material, so material property is defined isotropic materials, elastic modulus is 206 Gpa, Poisson's ratio is 0.3,density is 7800 kg / m 3 .As tetrahedron element types is selected, mesh is a free meshing. Meshes density meet the requirements of optimization of sensor location. the meshed model as shown in Figure 3 ,from top to bottom for the Y direction ,and up is positive; The horizontal direction for the X direction , the right is positive; forward and afterward for the Z direction ,forward is positive .the local distribution of nodes shown in Figure 4. C. Boundary conditions and Apply loads Because the stand plate of laboratory shearer hinges onthe fuselage, while the model is built to remove the fuselage the displacement constraints of all degrees of freedom are imposed on the hinged earrings. In working process of shearer cutting one coal level, the rocker arm position is fixed by the cylinder, it is equivalent to the all degrees of freedom constraints imposed hinged earrings for a cutting height of shearer. In the harmonic response analysis, loads applied is harmonic load as F= Focoswt. There are two ways to apply load: one is real-imaginary part, the other is amplitude-phase[6], in this paper, real-imaginary part is selected. The peak of load excitation force is Fo=300N, and it’s frequency range is generally 0 to 500 Hz, this is selected based on the testing data from the laboratory. The points of applying load are selected in the front face parallel to drum axis, five points are applied load in downward direction, as shown in figure 3. D. Results of harmonic analysis The purpose which the cutting part for harmonic analysis is made is to obtain its frequency response state, to test the transmission characteristic of mechanism for excitation force, to study vibration displacement in each frequency, and to acquire natural frequency and band in distortion measuring condition. Nodes 1157，20060，20044，3388，583 are selected to be investigated. The frequency-displacement curve of vibration in Y direction is shown in figure 5, it is drawn from the figure that the largest vibration displacement is of node 1157, the vibration form of the other nodes is similar to the node 1157. The resonant frequency of node 1157 appears in the 38Hz, 278Hz, and 324Hz. The distorted frequency range is nearly 38Hz to 278Hz. By analyzing the displacement of each frequency corresponding to the three nodes, the displacement of node 1157 is generally larger than other two nodes. It shows that the region of nodes 1157 possesses excellent amplification for the excitation signal, and maintains good transmission characteristics of the excitation force. It is drawn from the figure 6 that the largest vibration displacement is of node 1157 when it vibrates in Z direction. The resonant frequency of node 1157 appears in the 38Hz, 98Hz, 202Hz, 250Hz, 276Hz, and 324Hz. By the analysis above, the distorted frequency range is nearly 96Hz to 202Hz. In these three nodes, by analyzing the displacement of each frequency, node 1157 also possesses larger displacement than other two nodes, excellent amplification for the excitation signal, and maintains good transmission characteristics of the excitation force. IV. HARMONIC RESPONSE ANALYSIS AT TOP POSITION A. Preprocess model and solution The cutting part at top position for harmonic analysis is done when load is changed but other conditions. Loads are decomposed into X and Y axis respectively, it is equivalent to vertical downward load imposed on drum at top position. The equivalent load force is 300N, and is decomposed into Y axis as 196.96N, the downward of Y direction is negative based on model coordinate system, into X axis as 226.29N, the right of X direction is positive based on model coordinate system. Load is applied on model shown in figure 7. B. Results of harmonic response and analysis Nodes 1157 ， 20060 ，20044 are still selected to be investigated, the frequency-displacement curve of vibration in Y direction as shown in figure 8, it is drawn from the figure that the largest vibration displacement is of node 1157, the vibration form of the other nodes is similar to the node 1157. The resonant frequency of nodes 1157 ，20060 ， 20044 appears in the 38Hz, 278Hz, and 324Hz. The distorted frequency range is nearly 38Hz to 278Hz. It is shown in figure 8 that the cutting part of shearer at top position only appears third-order resonance, and the displacement of low-frequency resonance is the largest. So the cutting part of shearer mainly avoids noises signals of low-frequency, particularly in the three resonant frequencies. By analyzing the displacement of each frequency corresponding to the three nodes, it is shown that the region of nodes 1157 possesses excellent amplification for the excitation signal, and maintains good transmission characteristics of the excitation force as the level position. It is drawn from the figure 9 that the largest vibration displacement is of node 583 when it vibrates in Z direction at top position. The resonant frequency of node 1157 appears in the 38Hz, 98Hz, 202Hz, 250Hz, 278Hz, 324Hz and 424Hz. By the analysis above, the distorted frequency range is nearly 98Hz to 202Hz. For vibration in Z direction at top position,node 1157 possesses larger displacement than other two nodes except individual frequency. So with regard to vibration in Z direction at top position, node 1157 can still be selected to be the picking-up point for good transmission characteristics. V. HARMONIC RESPONSE ANALYSIS AT BOTTOM POSITION A .Preprocess model and solution The cutting part at bottom position for harmonic analysis is still done when load is changed but other conditions. Loads are also decomposed into X and Y axis respectively, it is equivalent to vertical downward load imposed on drum at top position. The equivalent load force is 300N, and is decomposed into Y axis as -148.59N, the downward of Y direction is negative based on model coordinate system, into X axis as -260.62N, the left of X direction is negative based on model coordinate system. Load is applied on model shown in figure 10. B. Results of harmonic response and analysis Nodes 1157 , 20060 ,20044 are still selected to be investigated, the frequency-displacement curve of vibration in Y direction as shown in figure 11, it is drawn from the figure that the largest vibration displacement is of node 1157, the displacement value is 1.11cm, the vibration form of the other nodes is similar to the node 1157. The resonant frequency of nodes 1157,20060,20044 appears in the 38Hz, 278Hz, and 324Hz. The distorted frequency range is nearly 38Hz to 278Hz. It is shown in figure 11 that the cutting part of shearer imposed sinusoidal excitation force at bottom position only appears third-order resonance, and the displacement of lowfrequency resonance is the largest. So the cutting part of shearer mainly avoids noises signals of low-frequency, particularly in the three resonant frequencies. It is drawn from the figure 12 that the largest vibration displacement is of node 583 when it vibrates in Z direction at bottom position. The resonant frequency of node 1157 appears in the 40Hz, 98Hz, 202Hz, 250Hz, 276Hz, 324Hz and 424Hz. By the analysis above, the distorted frequency range is nearly 98Hz to 202Hz, the displacement unit is meter. VI. CONCLUSION The cutting part of shearer for harmonic response analysis at level, top, and bottom position is done to acquire the vibration displacement law corresponding to frequency. It concluded: (1) With the vibration in Y direction, node 1157 retains excellent amplification for the excitation signal, and maintains good transmission characteristics of the excitation force. So the region of node 1157 is suitable picking-up point monitoring the vibration in Y direction. (2) The sensors installed for vibration in Y direction should possess good transmission characteristics of the excitation force in the frequency range of 0 to 265Hz, for vibration in Z direction, the frequency range should be 0 to 200Hz. (3) It is shown that output signals for harmonic response analysis zoom out unlimitedly in the resonant frequencies, yet the signals of other frequencies retain good amplification; meanwhile, the signals of resonant frequencies should be filtered to avoid zooming out unlimitedly and interfering the normal output signals of coal-rock state. It is drawn that the picking-up point of the largest amplitude is obtained, and the placement point of accelerometer sensor is optimized; meanwhile. Frequency band of sensors is studied, the sensor also possesses the filtering effect. The reliability of physical experiment is well verified in the simulation testing. b.中文翻譯 截割部諧波響應分析的物理仿真系統(tǒng) 文摘-煤-主要是巖石界面識別系統(tǒng)收集各種響應信號可以從多傳感器并進一步分析的裝備和反應信號,來看看它是否在切割煤巖體。為了達到這個目的,這些裝備總共五種類型的各種識別傳感器獲取這些信號。兩個傳感器的優(yōu)化配置問題測量分和選擇的傳感器性能的關鍵因素能正確、全面收集在靜聽著的松林之間動態(tài)信號特征的截割部的物理仿真系統(tǒng)。因此,這是重要而且必不可少的進行諧響應動力學分析的剪切截割部。　基于頻率的振動特性響應進行了分析。本研究不僅優(yōu)化配置振動傳感器的最大的輸出振幅信號,但也會辨識出語句的振動的頻率范圍傳感器,因此它不僅滿足條件如實的測量的工具,而且也避免了,由于傳感器干擾對共振。 關鍵詞--截割部 有限元動力學 諧響應 煤和巖石的識別 1. 介紹 煤和巖石的識別系統(tǒng)主要是多傳感器收集的希勒切削力的響應信號和對這些信號的分析。因此,它是獲取信號號的基本前提。通常有兩種方法：一種是在煤的界面收集數(shù)據(jù)，但卻帶來很多困難的結果，而且許多因素在某個程度上來說是有限的。另一種方法是在相似條件下在實驗室建立物理仿真系統(tǒng)，　包括媒體與模擬的工具牽引-切割機制,這種方式可以在很大的范圍內(nèi)調整煤巖體機械物理性能結構參數(shù)。同時，這種方法能嚴格控制試驗參數(shù)，　優(yōu)化試驗方法獲得準確、可靠的結果。所以物理模擬系統(tǒng)開發(fā)的剪毛的的基礎上相似原則。在切割不同材料時，搖臂的狀態(tài)、升降氣缸的壓力、輸入軸的扭矩信號、　滾筒軸的扭轉振動信號和切割電流的變化反應出切割狀態(tài)的不同。所以要配備這五種類型的傳感器來獲取這些信號。最近幾年，大家都把對煤和巖石的識別的研究工作的注意力放在融合研究上。不幸的是，很少關注到有效性數(shù)據(jù)本身的正確性提供的參考依據(jù)。　這牽涉到傳感器測量分的配置優(yōu)化傳感器測量分傳感器性能的選擇。鑒于此,本文將是對搖臂振動狀態(tài)的分析和總結。所以截割部機進行物理模擬系統(tǒng)是由有限元諧波分析振動響應的特點,從截割部頻率響應分析的角度來取得手臂振動的最佳契合點，優(yōu)化振動傳感器測量點，決定傳感器的最終工作頻率范圍。 2. 物理仿真系統(tǒng)的工具 測試模型是根據(jù)相似理論基于原型電牽引采煤機(模型:MGTY400/900-3.3D)，并且是以1:8的比例設計的。在這基礎上,這是重新進行了優(yōu)化,并突出的簡便性模型和達到要求的性能、低成本、簡單的結構。 的物理仿真系統(tǒng)以數(shù)字[4]表示： 1.采煤機模型是由滾筒、搖臂、扭轉力矩傳感器、電機、液壓缸和機身組成。截割部需要完成兩種運動：以電機作為動力驅動滾筒完成切割;由液壓缸來調整搖臂從上頂板到下地板的高度。 3.水平位置上的諧波響應 諧響應分析是一種用來確定穩(wěn)態(tài)響應線性結構的負荷隨著時間不斷變化的方法。輸入是諧波負載為已知的大小和頻率?！∵@個想法是計算了結構的反應在幾個不同頻率和獲得一個曲線圖的數(shù)量與一些反應頻率。 a. 建立三維模型 當我們確保原結構的尺寸時，結構的質量，簡化了的非重點研究的部件，一個用三維切削部分建模軟件Pro / E建立的模型。他主要零件滾筒的直徑是　225毫米，長490毫米,高150毫米，寬154毫米或者寬735毫米等等。 b. 元素類型和材料性能的定義 完成三維建模后，用ANSYS11.0軟件對模型進行有限元分析?；跐L筒的結構，solid92固體元素的類型是選定的?！∵@個元素類型適用于嚙合由多種CAD /CAM建立的不規(guī)則網(wǎng)格模型。元素節(jié)點所定義的是十二次四面體元素的純位移形函數(shù)。第二,采煤機的實驗模型材料是鋼，所以材料的性能是由各向同性材料決定的，彈性模量是206 Gpa, 泊松比0.3,密度是7800 kg / m 3。作為四面體單元類型被選中，網(wǎng)格是一個自由的嚙合。網(wǎng)格密度能夠滿足傳感器位置的優(yōu)化的需求?！∪缱髨D所示的網(wǎng)狀模型圖3, 　從上到下為Y方向,是正方向; 水平方向X軸方向,向右是正方向；前后的Z方向，向前是正方向。節(jié)點分布如圖4。 c. 邊界條件和適用的負載 　 因為采煤機的滑靴取決于機身，而建立模型,可以有效的去除所有強加在鉸鏈上的位移約束的自由度。采煤機在工作過程中切割一煤水平, 搖臂桿位置是由氣缸固定的,它通過鉸接點限制所有自由度來使采煤機截割部達到一定高度?！　≡谥C響應分析,荷載應用作為F= Focoswt諧波負載。　有兩種方法可以適用負荷: 一種是虛構部分，另一種是相。本文，選擇了虛構部分。負荷的峰值是F= 300N激振力，它的頻率范圍一般0到500赫茲，這是從實驗室基于實驗數(shù)據(jù)的選擇。　應用載荷點的被選擇在滾筒前面的平行線上。應用負荷在向下方向的五點如圖3所示。 D．諧波分析的結果 截割部分的諧波分析的目的獲得它的頻率響應狀態(tài)，測試傳輸特性的機理，研究在每個頻率振動位移,并獲得固有頻率和樂隊在變形的測量條件。選擇節(jié)點1157、20060、20044、3388、583用于調查。振動的頻率位移曲線在Y軸方向是顯示在圖5中, 　這是來自保持的最大的振動位移的節(jié)點1157，它振動形式的其他節(jié)點是相似的節(jié)點1157。諧振頻率的節(jié)點1157出現(xiàn)在38Hz,278Hz的,324Hz。扭曲的頻率范圍接近于278Hz到38Hz。通過分析相應于這三節(jié)點的位移值的頻率, 　位移節(jié)點的1157總體上大于其它兩個節(jié)點。它顯示的地區(qū)的節(jié)點1157具有良好的放大的激勵信號,并且維持良好的激振力的傳遞特性。這是來自圖6, 當它在Z方向移動時，最大的振動節(jié)點的位移是1157?！≈C振頻率的節(jié)點,出現(xiàn)在38Hz、98Hz 、202Hz、 276Hz、250Hz、276 Hz和324Hz。　通過以上分析，被扭曲的頻率范圍幾乎是202Hz到96Hz。在這三個節(jié)點,通過分析位移值頻率, 也擁有更大、節(jié)點位移比1157其他兩個節(jié)點,準確的放大的激勵信號,并且維持良好的傳播特性激振力。 Ⅳ.最高的點的諧波響應分析 a. 預處理模型和解決方案 在切割部最高點的諧波分析是在其他條件不變，負載進行更改時。荷載分解為X和Y軸分別就相當于垂直向下的荷載施加在滾筒頂點位置。該等效負載力是300N，并分解到Y軸為196.96N，Y方向的基礎上下調為負模型坐標系，將X軸為226.29N，右X方向為正基于模型坐標系。負載時在圖7所示的模型。 b.諧波響應和分析的結果 節(jié)點1157、20060、20044仍然被選擇來做研究，振動頻率位移曲線Y方向，如圖8所示，從圖中繪制的最大振動位移是節(jié)點1157，其他節(jié)點的振動的形式是類似于節(jié)點1157。節(jié)點1157 、20060、20044的諧波共振頻率出現(xiàn)在38Hz，278Hz，324Hz。扭曲頻率范圍是接近于38Hz到278Hz。這顯示在圖8，該采煤機在截割部頂點的位置只出現(xiàn)第三階共振，以及低頻位移共振是最大的。因此，采煤機截割部大部分避免了低頻噪聲信號，尤其是在第三共振頻率。通過分析位移每個頻率所對應的三個節(jié)點，它表明在節(jié)點1157，該區(qū)域的節(jié)點具有優(yōu)良為激勵信號放大，并保持著良好作為激振力的水平傳輸特性位置。 這是圖9，最大振動位移是節(jié)點583在最頂點的位置在Z方向振動的位移。節(jié)點1157的共振頻率出現(xiàn)在38Hz，98Hz，202Hz，250Hz，278Hz，324Hz和424Hz。通過上述分析，扭曲的頻率范圍是接近98Hz至202Hz。對于最高點在Z方向振動時，1157節(jié)點擁有大于其他兩個節(jié)點位移除個別頻率。因此，對于在最高點位置沿Z方向的振動，節(jié)點1157仍然可以被選擇為良好的傳輸特性的采摘行動點。 Ⅵ．在最低點位置的諧響應分析 a.一個預處理模型和解決方案 截割部底部位置的諧波分析是當負載改變，但其他條件不變時。荷載也分別分解為X和Y軸上，相當于垂直向下的荷載施加于滾筒頂部位置。等效負載力是300N，是到Y軸分解為- 148.59N，對Y向下方向為負基于模型坐標系，到X軸為- 260.62N，X的方向向左為負的基礎上模型坐標系。負載時所顯示的模型圖10。 b.諧波響應和分析結果 節(jié)點1157、20060、20044仍然被選擇來做研究，振動頻率位移曲線Y方向，如圖11所示，從圖中繪制，最大振動位移，節(jié)點1157的位移值1.11厘米，對其他振動形式類似于節(jié)點1157。諧振頻率節(jié)點1157、20060、20044出現(xiàn)在38Hz，278Hz，324Hz。扭曲的頻率范圍接近于38Hz到278Hz。它是在圖11所示的采煤機割的一部分在底部位置施加正弦激振力只出現(xiàn)三階共振，以及低頻位移共振是最大的。因此，削減部分采煤機主要是避免了低頻噪聲信號，特別是在三個共振頻率。 這是圖12，最大的振動位移是當它在底部位置沿Z方向振動的節(jié)點583。節(jié)點1157的共振頻率出現(xiàn)在40Hz，98Hz，202Hz，250Hz，276Hz，324Hz和424Hz。通過上述分析，扭曲的頻率范圍是接近98Hz到202Hz，位移單位是米。 Ⅵ.結束語 用于在采煤機截割部頂部、底部和水平位置的諧波響應分析，是為了獲得 振動頻率對應的位移定律。這結論是： （1）隨著Y方向振動，節(jié)點保留1157準確的激勵信號放大，并保持 良好的傳輸特性激振力。因此，1157區(qū)域的節(jié)點適合采摘，注冊點監(jiān)察在Y方向的振動。 （2）安裝在Y方向的振動傳感器須具備良好的傳輸特性激振力在0至265Hz頻率范圍內(nèi)，為在Z方向的振動，其頻率范圍應為0至200Hz時。 （3）研究表明，輸出信號的諧波響應分析無限放大，在共振頻率，但對其它頻率的信號保持良好擴增;同時，共振頻率的信號應篩選，以避免無限縮小和干擾煤巖國家正常的輸出信號。這是獲得的最大的振幅的采摘行動點，并且對安置點加速度傳感器進行了優(yōu)化。傳感器的頻率波段進行了研究，該傳感器還具有過濾效果。在物理實驗的可靠性將在模擬試驗中驗證。