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摘 要 G400/900-WD 型采煤机是一种多电机驱动,横向布置的交流电牵引采煤 机。该机功率大,多电机横向布置,整机结构紧凑,采用交流变频调速系 统,变频调速采用机载式。截割电机、牵引电机等主要元部件均可从采空 区抽出,容易更换,方便维修。 牵引电机输出的转矩经三级圆柱齿轮和二级行星齿轮减速器减速后, 由行星架输出,通过驱动轮与行走轮相啮合,再由行走轮与工作面刮板输 送机上的齿轨啮合使采煤机来回行走,同时制动轴输出轴通过键与制动器 相连,实现电牵引部的制动。 左右牵引部,中间电控箱的联结螺柱,定位销,摇臂与左右电牵引部 铰接销轴四组,这些装置将采煤机各大部件联接成一个整体,起到紧固及 连接的作用。牵引部与行走部做成一体,使机身整体尺寸紧凑,缩小了机 身宽度。 G400/900-WD 型采煤机,操作方便,可靠性高,事故率低,开机效率高, 可满足高产高效工作面的需要。 关键词:采煤机;牵引部;行走部;行星齿轮 ABSTRACT The G400/900-WD coal mining machine is more than one kind of motor- driven, crosswise arrangement alternating current hauling coal mining machine. This machine power is big, the multi-electrical machinery crosswise arrangement, the complete machine structure is compact, uses the exchange frequency conversion velocity modulation system, the frequency conversion velocity modulation uses aircraft-borne -like. Cuts the electrical machinery, the pulling motor and so on main part to be possible to extract from the worked-out section, easy to replace, facilitates the service. The pulling motor outputs torque decelerates after the third-level cylindrical gears and the second-level planet gear reduction gear, by the planet carrier outputs, with walks lining on the feet and palms of buddha meshing through the driving gear, by walks again round and on working surface scraper conveyers rack rail meshing causes the coal mining machine back and forth to walk, simultaneously the brake spindle output shaft is connected through the key and the brake, realizes the electricity hauling department brake. About the hauling department, the middle electrically controlled boxs joint stud, the positioning pin, the rocking shaft sells the axis four groups with about electricity hauling department hinge, these installments join coal mining machine various major assemblies a whole, plays the fastening and the connection role. The hauling department with walks to make a body, caused the fuselage overall size to be compact, reduced the fuselage width. The G400/900-WD coal mining machine, the ease of operation, the reliability is high, the accident rate is low, the starting efficiency is high, may satisfy the high production highly effective working surface the need. Key word: The coal mining machine; the hauling department; walks; Planet gear 目 录 1 概述 .1 1.1 采煤机的发展概况 .1 1.2 国际上电牵引采煤机的技术发展状况 .1 1.3 国内电牵引采煤机的发展状况 .3 1.3.1. 20 世纪 70 年代是我国综合机械化采煤起步阶段 .3 1.3.2 .20 世纪 80 年代是我国采煤机发展的兴旺时期 .4 1.3.3 .20 世纪 90 年代至今是我国电牵引采煤机发展的时代 .5 1.4 采煤机的发展趋势 .7 1.5 采煤机类型 .7 1.6 采煤机的组成 .10 1.7 电牵引采煤机的优点 .12 2 牵引部的设计 .14 2.1 牵引机构传动系统 .14 2.1.1 主要技术参数 .14 2.1.2 电动机的选择 .14 2.1.3 传动比的分配 .15 2.2 牵引部传动计算 .17 2.2.1 各级传动转速、功率、转矩 .17 2.3 牵引部齿轮设计计算 .18 2.3.1 齿轮 1 和惰轮 2 的设计及强度效核 .18 2.3.2 齿轮 3 和惰轮 4 的设计及强度效核 .24 2.3.3 齿轮 5 和惰轮 6 的设计及强度效核 .30 2.4 牵引部行星机构的设计计算 .35 2.4.1 行星齿轮的计算 .37 2.4.2 行星轮啮合要素验算 .49 3 轴的设计及校核 .53 3.1 确定轴的最小直径 .53 3.2 轴的校核 .56 3.3 花键的强度校核 .63 3.4 轴承的校核 .65 4 采煤机的使用和维护 .67 4.1 采煤机的维护 .67 4.2 采煤机轴承的维护及漏油的防治 .69 4.3 煤矿机械传动齿轮失效的改进途径 .71 5 机械密封 .78 参考文献 .82 英文原文 .83 中文译文 .91 致谢 .98 第15页中国矿业大学2008届毕业设计英文原文Switched Reluctance Motors Drive for theElectrical Traction in ShearerH. ChenCollege of Information and Electrical EngineeringChina University of Mining & Technology, Xuzhou 221008, Chinachenhaocumttom.comAbstractThe paper presented the double Switched Reluctance motors parallel drive system for the electrical traction in shearer. The system components, such as the Switched Reluctance motor, the main circuit of the power converter and the controller, were described. The control strategies of the closed-loop rotor speed control with PI algorithm and balancing the distribution of the loads with fuzzy logic algorithm were given. The tests results were also presented. It is shown that the relative deviation of the average DC supplied current of the power converter in the Switched Reluctance motor 1 and in the Switched Reluctance motor 2 is within 10% Keywords- switched reluctance; motor control; shearer; coal mine; electrical drive I. INTRODUCTIONThe underground surroundings of the coal mines are very execrable. One side, it is the moist, high dust and inflammable surroundings. On the other side, the space of roadway is limited since it is necessary to save the investment of exploiting coal mines so that it is difficult to maintain the equipments. In the modern coal mines, the automatization equipments could be used widely. The faults of the automatization equipments could affect the production and the benefit of the coal mines. The shearer is the mining equipment that coal could be cut from the coal wall. The traditional shearer was driven by the hydrostatic transmission system. The fault ratio of the hydrostatic transmission system is high since the fluid in hydrostatic transmission system could be polluted easily. The faults of the hydrostatic transmission system could affect the production and the benefit of the coal mines directly. The fault ratio of the motor drive system is lower than that of the hydrostatic transmission system, but it is difficult to cool the motor drive system in coal mines since the motor drive system should be installed within the flameproof enclosure for safety protection. The motor drive system is also one of the pivotal parts in the automatization equipments. The development of the novel types of the motor drive system had been attached importance to by the coal mines. The Switched Reluctance motor drive could become the main equipments for adjustable speed electrical drive system in coal mines 1, because it has the high operational reliability and the fault tolerant ability 2. The Switched Reluctance motor drive made up of the double-salient pole Switched Reluctance motor, the unipolar power converter and the controller is firm in the motor and in the power converter. There is no brush structure in the motor and no fault of ambipolar power converter in the power converter 34. The Switched Reluctance motor drive could be operated at the condition of lacked phases fault depended on the independence of each phase in the motor and the power converter 5. There is no winding in the rotor so that there is no copper loss in the loss and there is only little iron loss in the rotor. It is easy to cool the motor since it is not necessary to cool the rotor. The shearer driven by the Switched Reluctance motor drive had been developed. The paper presented the developed prototype. II. SYSTEM COMPONENTSThe developed Switched Reluctance motors drive for the electrical traction in shearer is a type of the double Switched Reluctance motors parallel drive system. The system is made up of two Switched Reluctance motors, a control box installed the power converter and the controller. The adopted two Switched Reluctance motors are all three-phase 12/8 structure Switched Reluctance motor, which were shown in Figure 1. The two Switched Reluctance motors were packing by the explosion-proof enclosure, respectively. The rated output power of one motor is 40 KW at the rotor speed 1155 r/min, and the adjustable speed range is from 100 r/min to 1500r/min. Figure 1.Photograph of the two three-phase 12/8 structure Switched Reluctance motorThe power converter consists of two three-phase asymmetric bridge power converter in parallel. The IGBTs were used as the main switches. Three-phase 380V AC power source was rectificated and supplied to the power converter. The main circuit of the power converter was shown in Figure 2Figure 2. Main circuit of the power converter. In the controller, there were the rotor position detection circuit, the commutation circuit, the current and voltage protection circuit, the main switches gate driver circuit and the digital controller for rotor speed closed-loop and balancing the distribution of the loads. III. CONTROL STRATEGYThe two Switched Reluctance motor could all drive the shearer by the transmission outfit in the same traction guide way so that the rotor speed of the two Switched Reluctance motors could be synchronized. The closed-loop rotor speed control of the double Switched Reluctance motors parallel drive system could be implemented by PI algorithm. In the Switched Reluctance motor 1, the triggered signals of the main switches in the power converter are modulated by PWM signal, the comparison of the given rotor speed and the practical rotor speed are made and the duty ratio of PWM signal are regulated as follows, where, is the given rotor speed, is the practical rotor speed, is the difference of the rotor speed, is the increment of the duty ratio of PWM signal of the Switched Reluctance motor 1 at k time, is the integral coefficient, is the proportion coefficient, ek is the difference of the rotor speed at k time, ek-1 is the difference of the rotor speed at k-1 time, D1(k) is the duty ratio of PWM signal of the Switched Reluctance motor 1 at k time, and D1(k-1) is the duty ratio of PWM signal of the Switched Reluctance motor 1 at k-1 time. The output power of the Switched Reluctance motor drive system is approximately in proportion to the average DC supplied current of the power converter as follows, where, P2 is the output power of the Switched Reluctance motor drive system, Iin is the average DC supplied current of the power converter. In the Switched Reluctance motor 2, the triggered signals of the main switches in the power converter are also modulated by PWM signal. The balancing the distribution of the loads between the two Switched Reluctance motors could be implemented by fuzzy logic algorithm. In the fuzzy logic regulator, there are two input control parameters, one is the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors, and the other is the variation of the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors. The output control parameter is the increment of the duty ratio of the PWM signal of the Switched Reluctance motor 2. The block diagram of the double Switched Reluctance motors parallel drive system for the electrical traction in shearer was shown in Figure 3. Figure 3. Block diagram of the double Switched Reluctance motors parallel drive system for the electrical traction in shearerThe deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors at the moment of ti is where, Iin1 is the practical average DC supplied current of the power converter in the Switched Reluctance motor 1 at the moment of ti, Iin2 is the practical average DC supplied current of the power converter in the Switched Reluctance motor 2 at the moment of ti. The variation of the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors at the moment of ti is where, ei-1 is the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors at the moment of ti-1. The duty ratio of the PWM signal of the Switched Reluctance motor 2 at the moment of ti is where, D2(i) is the increment of the duty ratio of the PWM signal of the Switched Reluctance motor 2 at the moment of ti and D2(i-1) is the duty ratio of the PWM signal of the Switched Reluctance motor 2 at the moment of ti-1. The fuzzy logic algorithm could be expressed as follows, where, E is the fuzzy set of the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors, EC is the fuzzy set of the variation of the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors, and U is the fuzzy set of the increment of the duty ratio of the PWM signal of the Switched Reluctance motor 2. The continuous deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors could be changed into the discrete amount at the interval -5, +5, based on the equations as follows, The continuous variation of the deviation of the average DC supplied current of the power converter between the two Switched Reluctance motors could also be changed into the discrete amount at the interval -5, +5, based on the equations as follows, The discrete increment of the duty ratio of PWM signal of the Switched Reluctance motor 2 at the interval -5, +5 could be changed into the continuous amount at the interval -1.0%, +1.0%, based on the equations as follows, There is a decision forms of the fuzzy logic algorithm based on the above principles, which was stored in the programme storage cell of the controller. While the difference of the distribution of the loads between the two Switched Reluctance motors could be got, the duty ratio of PWM signal of the Switched Reluctance motor 2 will be regulated based on the decision forms of the fuzzy logic algorithm and the distribution of the loads between the two Switched Reluctance motors could be balanced. IV. TESTED RESULTSThe developed double Switched Reluctance motors parallel drive system prototype had been tested experimentally. Table I gives the tests results, where is the relative deviation of the average DC supplied current of the power converter in the Switched Reluctance motor 1, is the relative deviation of the average DC2 supplied current of the power converter in the Switched Reluctance motor 2, and, TABLE I.TESTS RESULTS OF PROTOTYPEIt is shown that the relative deviation of the average DC supplied current of the power converter in the Switched Reluctance motor 1 and in the Switched Reluctance motor 2 is within 10% . V. CONCLUSIONThe paper presented the double Switched Reluctance motors parallel drive system for the electrical traction in shearer. The novel type of the shearer in coal mines driven by the Switched Reluctance motors drive system contributes to reduce the fault ratio of the shearer, enhance the operational reliability of the shearer and increase the benefit of the coal mines directly. The drive type of the double Switched Reluctance motors parallel drive system could also contribute to enhance the operational reliability compared with the drive type of the single Switched Reluctance motor drive system. REFERENCES 1 H. Chen, G. Xie, “A Switched Reluctance Motor Drive System for Storage Battery Electric Vehicle in Coal Mine,” Proceedings of the 5th IFAC Symposium on Low Cost Automation, pp.95-99, Sept. 1998. 2 H. Chen, X. Meng, F. Xiao, T. Su, G. Xie, “Fault tolerant control for switched reluctance motor drive,” Proceedings of the 28 Annual Conference of the IEEE Industrial Electronics Society, pp.1050-1054, Nov. 2002. 3 R. M. Davis, W. F. Ray, R. J. Blake, “Inverter drive for switched reluctance motor:circuit and component ratings,” IEE Proc. B, vol.128, no.3, pp. 126-136, Sept. 1981. 4 D. Liu, et al., Switched Reluctance Motor Drive. Beijing: Mechanical Industry Press, 1994. 5 H. Chen, J. Jiang, C. Zhang, G. Xie, “Analysis of the four-phase switched reluctance motor drive under the lacking one phase fault condition,” Proceedings of IEEE 5th Asia-Pacific Conference on Circuit and Systems, pp.304-308, Dec. 2000. 中文译文电牵引采煤机的开关磁阻电动机摘要:本章介绍了电牵引采煤机双重开关磁阻电动机的并联驱动系统。该系统由开关磁阻电动机,功率变换器电路和控制器组成。给出了由通过采用比例积分算法的调节转子速度的闭环回路和模糊逻辑算法实现的负荷的均衡分布组成的控制策略。介绍了实验结果。开关磁阻电动机1和开关磁阻电动机2的功率变换器的平均直流的相对误差为。关键词:开关磁阻;电动控制;采煤机;煤矿;电传动 .介绍 煤矿的地下环境是非常恶劣的。一方面由于它是潮湿的,高粉尘的,和易燃的环境。另一方面,为了节约开采成本,巷道空间是有限,以至于设备很难维护。自动化设备在现代化煤矿已经得到广泛应用。自动化设备的故障会直接影响到煤矿的产量和效益。采煤机是采煤的主要矿山设备。传统的滚筒采煤机是通过液压传动系统传动的。液压传动系统的故障率很高,因为液压传动系统的液体很容易受环境污染。液压传动系统的故障直接影响到煤矿的产量和效率。电传动系统比液压传动系统的故障率低。但是,矿井中电机传动系统的散热性差,是因为为了煤矿安全,电机传动系统被封装在防爆的外壳内。电机传动系统是自动化设备的重要组成部分。电机传动系统的小说类型的发展对煤矿很重要。开关磁阻电动机传动是煤矿调速传动系统的主要设备,由于它的高工作可靠性和高容错能力。由双极点开关磁阻电动机,单级功率变换器和控制器组成的开关磁阻电动机传动是电动机和功率变换器的核心。电动机没有毛刷,功率变换器没有双极功率变换器的故障。开关磁阻电动机传动可以在缺相的情况下运行,它是依靠电动机和功率变换器相位独立性来实现的。转子上没有绕组,以至于转子上没有铜损和很小的铁损。因为不需要冷却转子,所以很容易冷却电动机。由开关磁阻电动机传动的采煤机正在不断发展。本章介绍了发展的样机。系统组成电牵引采煤机的开关磁阻电动机传动是一个双重开关磁阻电动机并联传动系统。这个系统是由两个开关磁阻电动机,一个控制箱,这个控制箱是安装在功率变换器和控制器上。采用的开关磁阻电动机是三相12/8结构的开关磁阻电动机,如图一所示。双重开关磁阻电动机分别包装在防爆外壳内。电动机的额定功率是40KW,转速是1155r/min,调速范围是100r/min1500r/min。图一:三相12/8结构的开关磁阻电动机功率变换器是由两个三相不对称桥式变换器并列组成。IGBTs是电路的主要开关元件。经整流后三相交流380V电源提供给功率变换器。功率变换器的主要电路如图二所示。图二:功率变换器的主要电路控制器由转子位置检测电路,整流电路,电流和电压保护电路,主要开关的门极驱动电路和闭环调速数字控制器和负荷均衡分配组成。.控制方法采用同一个牵引方法,双重开关磁阻电动机通过传送设备用来驱动采煤机,来确保双重开关磁阻电动机的转子速度同步运行。并联驱动的双重开关磁阻电动机的闭环转子调速回路可以通过比例积分算法来实现。在开关磁阻电动机1中,功率变换器主要开关的触发信号是通过PWM信号调制的。比较给定的转子速度和实际的转子速度,PWM的占空比调节如下:其中,是给定的转子速度,是实际的转子速度,是转子速度的差。在k时刻内,开关磁阻电动机1PWM信号占空比的增量。 是积分系数, 比例系数,转子速度在K时间内的差。转子速度在K-1时间内的差, 在k时刻内,开关磁阻电动机1PWM信号占空比,在k-1时刻内,开关磁阻电动机1PWM信号占空比。开关磁阻电动机传动系统的输出功率和功率变换器的电流成正比,如下所示:其中,是开关磁阻电动机传动系统的输出功率,功率变换器的平均直流电流。在开关磁阻电动机2中,功率变换器主要开关的触发信号是通过PWM信号调制的。双重开关磁阻电动机之间的负荷均衡分布是通过模糊逻辑算法来实现的。在模糊逻辑调节器中有两个输入控制参数,一个是双重开关磁阻电动机之间的功率变换器的平均电流的偏差,另一个是双重开关磁阻电动机之间的功率变换器的平均直流电流的偏差的变化。输出控制参数是开关磁阻电动机2 PWM信号占空比的增量。电牵引采煤机双重开关磁阻电动机并列传动系统的方框图见图三所示。 图三: 电牵引采煤机并列传动系统的方框图功率变换器平均直流电流在双重开关磁阻电动机之间的偏差在时刻为:其中,在时刻,功率变换器在开关磁阻电动机1中实际平均直流电流,在时刻,功率变换器在开关磁阻电动机2中实际平均直流.双重开关磁阻电动机在时刻的功率变换器平均直流电流的偏差的变量为:其中, 是双重开关磁阻电动机在时刻的功率变换器平均电流的偏差。 开关磁阻电动机2在时的PWM信号的占空比为: 其中,在时刻的PWM信号占空比的增量,是开关磁阻电动机2在时刻的PWM信号的占空比。 模糊逻辑算法用以下来表示:其中,为模糊集合开关磁阻电动机间的功率变换器的平均直流电流的相对误差,为模糊集合开关磁阻电动机间的功率变换器的平均直流电流的相对误差的变量,为模糊集合中开关磁阻电动机2 PWM信号占空比的增量。开关磁阻电动机间的功率变换器的平均直流电流的相对误差在-,+区间内的连续偏差可以转变为分散偏差。公式如下:开关磁阻电动机间的功率变换器的平均直流电流的相对误差在区间内的连续变量可以转变为分散变量。公式如下:在区间-,+内,开关磁阻电动机的功率变换器信号的占空比的分散增量可以转变为在区间-.,+.内的连续增量,公式如下:根据上面的原理,这里是模糊逻辑算法的一个判定形式。模糊逻辑算法是存储在控制器的程序存储单元内。当检测到双重开关磁阻电动机负荷分配差异的时候,开关磁阻电动机中的占空比将被调节,这是根据模糊逻辑算法的判定形式,从而,双重开关磁阻电动机负荷分配将会达到平衡状态。.实验结果发展的双重开关磁阻电动机并联传动系统样机已经通过实验测量得到了。表一给出了测试结果,其中为开关磁阻电动机的功率变换器的平均直流电流的相对误差,为开关磁阻电动机的功率变换器的平均直流电流的相对误差,即:表一:样机的实验结果该表显示了开关磁阻电动机1和开关磁阻电动机2的功率变换器的平均直流的相对误差为结论本章介绍了电牵引采煤机双重开关磁阻电动机的并联驱动系统。开关磁阻电动机驱动系统驱动了矿井中的小型采煤机有助于减少采煤机的故障率,提高了采煤机的工作可靠性,直接增加了煤矿的效益。相对于单级开关磁阻电动机的驱动,双重开关磁阻电动机并联传动系统的驱动也有助于提高工作可靠性。REFERENCES 1 H. Chen, G. Xie, “A Switched Reluctance Motor Drive System for Storage Battery Electric Vehicle in Coal Mine,” Proceedings of the 5th IFAC Symposium on Low Cost Automation, pp.95-99, Sept. 1998. 2 H. Chen, X. Meng, F. Xiao, T. Su, G. Xie, “Fault tolerant control for switched reluctance motor drive,” Proceedings of the 28 Annual Conference of the IEEE Industrial Electronics Society, pp.1050-1054, Nov. 2002. 3 R. M. Davis, W. F. Ray, R. J. Blake, “Inverter drive for switched reluctance motor:circuit and component ratings,” IEE Proc. B, vol.128, no.3, pp. 126-136, Sept. 1981. 4 D. Liu, et al., Switched Reluctance Motor Drive. Beijing: Mechanical Industry Press, 1994. 5 H. Chen, J. Jiang, C. Zhang, G. Xie, “Analysis of the four-phase switched reluctance motor drive under the lacking one phase fault condition,” Proceedings of IEEE 5th Asia-Pacific Conference on Circuit and Systems, pp.304-308, Dec. 2000.
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