采煤机摇臂传动系统寿命预测与优化分析

Life prediction and optimization analysis of shearer rocker arm’s transmission system

轴承和齿轮寿命是影响采煤机摇臂传动系统可靠性的关键,以MG500/1180型采煤机为对象,采用虚拟仿真分析方法研究其传动系统寿命问题。综合考虑了驱动电机的机械特性、轴承挡边间隙和摩擦、齿轮啮合侧隙及润滑油黏度等因素,运用RomaxDesign建立了包含轴、轴承、齿轮的摇臂传动系统虚拟仿真模型,以试验测得滚筒载荷为外部激励,对传动系统各零件的强度和寿命进行了分析研究,确定了影响传动系统寿命的轴承和齿轮,采用等寿命优化方法对轴承进行选型优化,采用微观几何优化方法对寿命最短齿轮进行修形,结果表明:优化后各轴承寿命基本稳定在采煤机一个检修周期内,其中最短轴承寿命由1.5×104h增至3.97×104h;齿轮最大接触应力由1045.77MPa减至1000.50MPa,寿命由1.003×105h增至7.378×105h,提高了传动系统可靠性。

The service life of bearing and gear is the key to affecting the reliability of shearer rocker’s transmission system.Taking the MG500 / 1180 shearer as the example,an analysis on the service life of transmission system is conducted by means of virtual simulation.With such factors as the driving motor’s mechanical characteristics,bearing rib clearance and friction,gear meshing clearance,lubricating oil viscosity,and so on taken into consideration,the virtual simulation model of transmission system including shafts,bearings and gears is set up with the aid of Romax Design.With the experimentally-measured drum load as the external crack drive,a study is made on the strength and service life of transmission system’s components.The bearing and gear which affect the service life of transmission system are obtained.The method of equal life optimization is adopted for the bearing optimization,and the micro-geometric optimization method is adopted for the modification of the gear with the shortest service life.The results show that based on the optimization,the bearing’s service life remains at a stable level during the maintenance cycle,with the minimum level increasing from 1.50×104 h to 3.97×104 h.For the gear,its maximum contact stress reduces from 1 045.77 MPa to 1 000.50 MPa,and its service life increases from 1.003×105 h to 7.378×105 h.Thus,the reliability of transmission system is improved.