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The hydraulic pressure support development with first gazes
[ Key word ] hydraulic pressure support; Control; Intellectualization
1 hydraulic pressure supports development
The hydraulic pressure support is take the high-pressured liquid as a power, by certain hydraulic pressure part (cylinder, pipe accessory) one kind of strut and the control roof mining coal working surface equipment which becomes with some steel work combinations. Has the intensity high, the travelling speed quick, support the performance good, safe is reliable and so on the characteristic. Since the 20th century 50's, the hydraulic pressure support has gradually become the mining coal working surface core equipment, in the world mainly produced the coal country to invest the massive manpower physical resource and the financial resource carries on the research development to it. At present, support tends to take the hydraulic pressure support as the main body maturely, in the world has produced makes several hundred kind of frames and the up to ten thousand kind of models hydraulic pressure support, meets each kind of coal bed mining support need. On the century 60's, our country once has also developed 10 kind of hydraulic pressure supports, because all sorts of reasons have not obtained the promoted application, the hydraulic pressure support is in the development, the experimental stage; The 70's successively from England, Germany, Poland, former Soviet Union and so on mainly produce the coal country to introduce several 10 sets of hydraulic pressure supports. After the unceasing exploration, the use, the digestion and the summary, make each kind of type the support, it is the beginning which the domestically produced hydraulic pressure support develops; The 80's hydraulic pressure support research and development is in the innovation to enhance the stage, develops 30 kind of new frames one after another, makes the ZZ series, the XY series, the ZD series and so on the different specification, and widely uses in the state-owned large and middle scale coal mines, obtains the good economic efficiency; 90's special hydraulic pressure support development obtains the rapid development, the mechanized shop net support, the water granulated substance fills the support, the reason support, the force support, puts goes against the coal support and so on to be published one after another; This century along with the computer technology, the automated technology popularization and the application, the hydraulic pressure support control obtains unprecedentedness to progress, gradually to the procedure control, the numerical control, the remote control and the automated control makes great strides forward.
2 domestic and foreign hydraulic pressure supports difference
The domestically produced support in the manufacture technology, the material quality performance, the processing craft, the control system and in the sealing property compares with the overseas advanced countries has the very big disparity.
2.1 processings manufactures aspect
According to the related synthesis picks the engineers and technicians to reflect that, the domestically produced hydraulic pressure support craft technology, the service life, the operational performance, use the material quality so far not yet to achieve in 1979 introduced 100 sets of supports the technical levels. If structural material: Germany uses the ST52 material it yield strength is 500 MPa, but our country uses 16 Mn material yield strength is only 350 MPa; Valve class: Overseas always uses the copper alloy valve shell and the high strength stainless steel valve core, our country is the 45# steel adds surface heat processing; In processing craft: The overseas cylinder endophragm is duplicate plates, the domestic product for does not plate, causes the column premature to appear the spot in the use process, scratches and so on the seal leaks the fluid phenomenon, affects support the effect. The domestically produced hydraulic pressure support and the overseas production hydraulic pressure support compares the average to reduce 2 ~ 3 a service life.
2.2 control systems aspect
The domestically produced hydraulic pressure support control system research and development is at backwardness condition, seriously restricted the support to move supposes the speed the enhancement and the synthesis picks the economic efficiency the display. In the world several mainly produce the coal great nation throughout to enhance the support control system achievement the synthesis to pick the economic efficiency the important method, the 20th century 60's use manually straight control the operating system; The 70's use the forerunner control system, along with it England first proposed the development electrohydraulic control system, the eighty's tends to maturely; The 90's ladders company develops the entire working surface electrohydraulic control system, follows closely after that Wister to cut down the advantage Asia - shell Switzerland special company to develop more advanced P - M3, P - the M4 electrohydraulic control system. Presently country and so on US, Germany, England, Australia basically all is the programmable electrohydraulic control, but our country still used the hand control system.
2.3 hydraulic pressure parts aspect
The hydraulic pressure part research and development speed lags by far to the hydraulic pressure support need to develop. The hydraulic pressure support reliability mainly relies on the hydraulic pressure part reliability, the hydraulic pressure support in the coal mine production applies whether succeeds, the key lies in the hydraulic pressure part the technical performance whether does meet the requirements. Overseas at present uses the great current capacity safety valve, the fluid much controls the cone-way valve, the cut-off valve, initially supports the strength maintenance valve and the column quickly returns at once the fluid valve. To the hydraulic pressure part structural style, the geometry size, the choice of material, the heat treatment method and the surface treatment and so on various aspects have conducted the thorough research and the development. Develops one batch of sealing property well, the sensitivity high, enters the row of fluid ability to be big, the anti- impact load strong each kind of hydraulic pressure part, adapts the hydraulic pressure support operating performance request. But our country kind of hydraulic pressure part research and development lags regarding this, at present still continued to use the century for 80's the product, has not formed the hydraulic pressure part universalization, the seriation, the standardization
3 hydraulic pressure supports prospects for development forecast
In view of the fact that the science and technology high speed development, new technical, the new craft, the new method, the new material unceasing application and the computer technology unprecedented expansion, the hydraulic pressure support future development will have the extremely attractive prospect.
3.1 designs ideas renewal, the hydraulic pressure support develops a revolution
Must consider the environment in the hydraulic pressure support design the attribute. Because the hydraulic pressure support working condition is bad, the person, machine the environment reciprocity question appears importantly. The green design is the choice of material, the product structure, the technique, the outward appearance modelling and the color matches according to the certain rule, adopts artistic the method to perform ingeniously to fuse, fully manifests the man-machine environment system the harmonious unification. The unwieldy hydraulic pressure support image safe, reliable, is been easy to service, lowly to consume energy, the high efficiency, the modelling artistic substitutes. This kind of green design, it not only Filters the environment and the resources both must meet the economical development needs, and must meet the human survival development needs, is the humanity sustainable developmental strategy in support design manifesting. For example: The hydraulic pressure support uses the multi- goals fuzzy design in the design process, requests to support the strength in a big way, moves a speed quickly, weight light, the timber wood are few and so on, each goal determined a function, namely many designs objective function, then the combination optimizes, determination preferred plan.
3.2 will adopt the pure water hydraulic pressure technology, the hydraulic pressure support becomes the green machinery
The pure water hydraulic pressure technology is the hydraulic pressure domain development front. It not only has good anti- burns the nature, the radiation, moreover the price also cheaply, does not have the pollution, since the long-time hydraulic pressure support in Surface under has worked, because the use actuating medium is the emulsion, and has many chemical additives (emulsifier, guards against rust medicinal preparation, antiseptic, partner mixture and so on), the micro environmental pollution is extremely serious to the surface below, therefore, the hydraulic pressure support use pure water hydraulic pressure technology, to reduces the coal mine the production cost, protects the environment is beneficial, and may greatly improve the mine pit the work and the security condition. Unceasingly progresses along with the society, the people had a higher request to the dependent survival environment, hoped has a security, the environmental protection, the highly civilized green environment. The time request summoned the hydraulic pressure transmission (to origin in 1605 discovered the Pascal's law) this ancient brand-new technology resurfaced, and received the world the attention. At present, the western nation concentrates the strength to study this technology, and makes the unprecedented progress. For example: The lubrication attrition question, reasonably selects rubs the vice- material, has the engineering plastics, the structure ceramics, the high polymer material, guards against rust anticorrosion coating and so on. The structure ceramics have the resistance to wear, the anti- cavitation performance is good, the good chemical stability, characteristic and so on lower friction factor, prepares is favoured. Replaces the partial metals material in the hydraulic pressure part with the structure ceramics, big improvement its performance. In brief, the new material success develops and applies, precisely processes technical the unceasing progress, as well as each kind of new structure hydraulic pressure part making, all will become the hydraulic pressure support to use the pure water hydraulic pressure technology to enter the strict non- pollution domain, will provide the extremely attractive application prospects for development.
3.3 high tech applications, the hydraulic pressure support tends to the intellectualization
The advanced science and technology application is mutually seeps each kind of technology, mutually unifies in the foundation mutually assists, mutually promotes and the enhancement, fully uses each kind of related technical the superiority, enhances strong points and avoid weaknesses, after causes the combination the overall function to be bigger than the composition whole sum of each part of function comprehensive interdisciplinary studies.. The many kinds of technologies unceasingly seep to "the mechanical parent substance - hydraulic pressure support", including technical and so on machine, electricity, fluid, light, magnetism servosystem. Specifically said that, is the strength, the speed which outputs by the hydraulic pressure support are a goal, constituted from has output to the input closed-loop system, was involves sensing the technology, the computer control technology, the signal processing technology, the mechanical drive technology, the hydraulic transmission technology and so on. Because fast operating speed, formidable memory function and keen logical judgement function, thus has realized the man-machine dialogue, causes it operation maintenance conveniently, the entire machine function to be strong. The hydraulic pressure support application function unceasingly expands, unceasingly strengthens to the mine pit coal bed geology condition compatibility, production benefit to equipment dependent degree increasingly big, the operational reliability is more important. The breakdown diagnosis technology (including signal examination, breakdown judgement, failure detection, content and so on fault analysis) along with the high tech development theory (for example wavelet technology, nerve network, artificial intelligence and so on) will enter the hydraulic pressure support the early diagnosis, the prevention and the reduced accident occurrence, service blindness and the maintenance time, will lengthen the support service life, will enhance the production efficiency.
4 concluding remark
In summary, the hydraulic pressure support at present develops the main tendency is: Two columns shields type, enhances the hydraulic pressure support intensity, the design factor, moves a speed, the improvement individual part structure (overall top-beam, width center distance and so on), hydraulic pressure pipe accessory seriation, standardization, universalization, high working resistance, redundant reliability, with micro electron technology realization machine electrohydraulic integration digital gathering, operating mode monitor, breakdown diagnosis and automatic control.
液壓支架的發(fā)展與前瞻
[關(guān)鍵詞] 液壓支架; 控制; 智能化
1 液壓支架發(fā)展概述
液壓支架是以高壓液體為動力,由若干個液壓元件(油缸、閥件)與一些金屬構(gòu)件組合而成的一種支撐和控制頂板的采煤工作面設(shè)備。具有強度高、移動速度快、支護性能好、安全可靠等特性。自20世紀50年代以來,液壓支架已逐步成為采煤工作面核心設(shè)備,世界上主要產(chǎn)煤國家投入了大量的人力物力和財力對其進行研究開發(fā)。目前,以液壓支架為主體的支護趨于成熟,世界上已生產(chǎn)制造出數(shù)百種架型和上萬種型號的液壓支架,以適應(yīng)各類煤層開采支護需要。上世紀60年代,我國也曾開發(fā)了10余種液壓支架,由于種種原因未得到推廣應(yīng)用,液壓支架處于研制、實驗階段;70年代先后從英國、德國、波蘭、前蘇聯(lián)等主要產(chǎn)煤國家引進數(shù)10余套液壓支架。經(jīng)不斷的探索、使用、消化和總結(jié),制造出各種類型的支架,它是國產(chǎn)液壓支架發(fā)展的起點; 80年代液壓支架研發(fā)處于創(chuàng)新提高階段,相繼開發(fā)出30余種新架型,制造出ZZ系列、XY系列、ZD系列等不同規(guī)格,并廣泛用于國有大中型煤礦,取得良好的經(jīng)濟效益; 90年代特種液壓支架的研制獲得迅速發(fā)展,機械化鋪網(wǎng)支架、水砂充填支架、端頭支架、強力支架、放頂煤支架等相繼問世;本世紀隨著計算機技術(shù)、自動化技術(shù)的普及與應(yīng)用,液壓支架的控制獲得突破性進展,逐步向程序控制、數(shù)字控制、遙控和自動化控制邁進。
2 國內(nèi)外液壓支架差異
國產(chǎn)支架在制造技術(shù)、材質(zhì)性能、加工工藝、控制系統(tǒng)及密封性能上與國外先進國家相比有很大差距。
2.1 加工制造方面
據(jù)有關(guān)綜采工程技術(shù)人員反映,國產(chǎn)液壓支架的工藝技術(shù)、服務(wù)年限、使用性能、所用材質(zhì)到目前為止尚未達到。1979年引進100套支架的技術(shù)水平。如結(jié)構(gòu)材料:德國采用ST52材料其屈服極限為500 MPa,而我國使用16 Mn材料屈服極限僅為350 MPa;閥類:國外一直使用銅合金閥殼和高強度不銹鋼閥芯,我國則是45#鋼加表面熱處理;在加工工藝上:國外油缸內(nèi)壁是復(fù)鍍,國產(chǎn)則為不鍍,導(dǎo)致立柱在使用過程中過早出現(xiàn)斑點,劃傷等密封漏液現(xiàn)象,影響支護效果。國產(chǎn)液壓支架與國外生產(chǎn)的液壓支架相比平均縮短2～3 a服務(wù)年限。
2.2 控制系統(tǒng)方面
國產(chǎn)液壓支架控制系統(tǒng)的研發(fā)處于落后狀態(tài),嚴重制約了支架的移設(shè)速度的提高和綜采經(jīng)濟效益的發(fā)揮。世界上幾個主要產(chǎn)煤大國始終把支架控制系統(tǒng)作為提高綜采經(jīng)濟效益的重要手段, 20世紀60年代采用手動直控操作系統(tǒng);70年代采用先導(dǎo)控制系統(tǒng),隨之英國首先提出研制電液控制系統(tǒng), 80年代趨于成熟; 90年代道梯公司研制出全工作面電液控制系統(tǒng),緊隨其后威斯特伐利亞- 貝瑞特公司研制出更為先進的P- M3、P-M4電液控制系統(tǒng)。現(xiàn)美國、德國、英國、澳大利亞等國家基本上全是可編程電液控制,而我國仍多采用手動控制系統(tǒng)。
2.3 液壓元件方面
液壓元件的研發(fā)速度遠遠滯后于液壓支架發(fā)展的需要。液壓支架的可靠性主要依賴于液壓元件的可靠性,液壓支架在煤礦生產(chǎn)中應(yīng)用是否成功,關(guān)鍵在于液壓元件的技術(shù)性能是否達到要求。國外目前多采用大流量安全閥、液控單向閥、截止閥、初撐力保持閥及立柱快速回液閥。對液壓元件的結(jié)構(gòu)形式、幾何尺寸、材料選擇、熱處理方法和表面處理等各方面進行了深入的研究與開發(fā)。研制出一批密封性能好、靈敏度高、進排液能力大、抗沖擊載荷強的各類液壓元件,以適應(yīng)液壓支架工作性能的要求。而我國對此類液壓元件研發(fā)較為滯后,目前仍沿用上個世紀80年代的產(chǎn)品,沒有形成液壓元件通用化、系列化、標準化。
3 液壓支架發(fā)展前景展望
鑒于科學(xué)技術(shù)的高速發(fā)展,新技術(shù)、新工藝、新方法、新材料的不斷應(yīng)用及計算機技術(shù)的空前擴展,液壓支架的未來發(fā)展具有十分誘人的前景。
3.1 設(shè)計理念的更新,液壓支架發(fā)展的一場革命
在液壓支架設(shè)計中必須考慮環(huán)境的屬性。由于液壓支架的工作條件惡劣,人、機環(huán)境的相互關(guān)系問題顯得更加重要。綠色設(shè)計是將材料選擇、產(chǎn)品結(jié)構(gòu)、工藝方法、外觀造型和色彩搭配按照一定規(guī)律,采取藝術(shù)的方法加以巧妙融合,充分體現(xiàn)人機環(huán)境系統(tǒng)的和諧統(tǒng)一。笨重的液壓支架形象將被安全、可靠、易維修、低耗能、高效率、造型美觀所取代。
這種綠色設(shè)計,它不僅可慮環(huán)境和資源既要滿足經(jīng)濟發(fā)展需要,又要滿足人類生存發(fā)展需要,是人類可持續(xù)發(fā)展戰(zhàn)略在支架設(shè)計中的體現(xiàn)。如:液壓支架在設(shè)計過程中采用多目標模糊化設(shè)計,要求支撐力大,移架速度快,重量輕,用材少等,每個目標確定一個函數(shù),即得多個設(shè)計目標函數(shù),然后組合優(yōu)化,確定最佳方案。
3.2 采取純水液壓技術(shù),液壓支架將成為綠色機械
純水液壓技術(shù)是液壓領(lǐng)域的發(fā)展前沿。它不僅有良好的抗燃性、散熱性、而且價格也便宜,無污染,長久以來液壓支架在地表層下工作,由于使用工作介質(zhì)是乳化液,并有許多添加劑(乳化劑、防銹劑、防霉劑、偶合劑等) ,對地表以下微環(huán)境污染十分嚴重,所以,液壓支架使用純水液壓技術(shù),對降低煤礦的生產(chǎn)成本,保護環(huán)境是有益的,并可大大改善礦井的工作和安全條件。隨著社會不斷進步,人們對依賴生存的環(huán)境有了更高的要求,希望有一個安全、環(huán)保、高度文明的綠色環(huán)境。時代的要求呼喚著水壓傳動(起源于1605年發(fā)現(xiàn)帕斯卡定律)這一古老又嶄新的技術(shù)復(fù)出,并受到世界的關(guān)注。目前,西方國家集中力量研究該項技術(shù),并取得突破性進展。如:潤滑磨損問題,合理選用摩擦副材料,有工程塑料、結(jié)構(gòu)陶瓷、高分子材料、防銹防腐鍍層等。結(jié)構(gòu)陶瓷具有耐磨性,抗氣蝕性能好,良好的化學(xué)穩(wěn)定性,較低的磨擦系數(shù)等特征,備受青睞。在液壓元件中用結(jié)構(gòu)陶瓷代替部分金屬材料,大大的改善了其性能?？傊?新材料的成功研制與應(yīng)用,精密加工技術(shù)的不斷進步,以及各種新結(jié)構(gòu)液壓元件的制成,都將成為液壓支架采用純水液壓技術(shù)進入嚴格的無污染領(lǐng)域,提供十分誘人的應(yīng)用發(fā)展前景。
3.3 高科技的應(yīng)用,液壓支架趨于智能化
先進的科學(xué)技術(shù)應(yīng)用是將各種技術(shù)相互滲透,相互結(jié)合的基礎(chǔ)上相互輔助,相互促進和提高,充分利用各種相關(guān)技術(shù)的優(yōu)勢,揚長避短,使組合后的整體功能大于組成整體的各個部分功能之和的綜合性交叉學(xué)科。多種技術(shù)向“機械母體- 液壓支架”不斷滲透,包括機、電、液、光、磁等技術(shù)的伺服系統(tǒng)。具體說,是以液壓支架輸出的力、速度為目的,構(gòu)成了從輸出到輸入的閉環(huán)系統(tǒng),是涉及傳感技術(shù)、計算機控制技術(shù)、信號處理技術(shù)、機械傳動技術(shù)、液壓傳動技術(shù)等。由于快速運算速度,強大的記憶功能和靈敏的邏輯判斷功能,從而實現(xiàn)了人機對話,使之操作維護方便,整機功能強。液壓支架應(yīng)用功能不斷擴大,對礦井煤層地質(zhì)條件適應(yīng)性不斷增強,生產(chǎn)效益對設(shè)備的依賴性程度愈來愈大,工作可靠性更加重要。故障診斷技術(shù)(包括信號檢測,故障判斷,故障檢測,故障分析等內(nèi)容)將隨著高科技的發(fā)展理論(如小波技術(shù)、神經(jīng)網(wǎng)絡(luò),人工智能等)進入液壓支架的早期診斷,預(yù)防和減少事故的發(fā)生、維修的盲目性和維修時間,延長支架服務(wù)年限,提高生產(chǎn)效率。
4 結(jié)束語
綜上所述,液壓支架目前發(fā)展主要趨勢是:二柱掩護式架型,提高液壓支架強度、設(shè)計系數(shù)、移架速度,改進個別部件的結(jié)構(gòu)(整體頂梁、寬中心距等) ,液壓閥件系列化、標準化、通用化,高工作阻力,高可靠性,用微電子技術(shù)實現(xiàn)機電液一體化的數(shù)字采集、工況監(jiān)測、故障診斷和自動控制。
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