千万吨级矿井智能化综采成套装备及关键技术

Complete sets of equipment and key technologies for intelligent fully-mechanized mining of ten-million tonnage level mine

针对国内厚3~4 m煤层生产效率低、采煤机割煤速度慢、液压支架自移跟机可靠性差等问题,根据转龙湾煤矿Ⅱ-3号煤层233采区煤层赋存情况,为了实现转龙湾煤矿一矿一井一面的千万吨级智能化矿井建设目标,开展了3~4 m厚煤层液压支架、采煤机、刮板输送机等成套装备一体化设计,确定了成套装备的技术参数和关键结构,研制了高可靠性、智能化成套装备,突破了基于惯性导航系统的综采工作面直线度精确检测技术、采煤机记忆截割智能控制技术、基于煤流负荷模型的刮板输送机智能调速技术、工作面端头联合支护技术等关键技术,实现了采煤机自主定位、记忆截割,液压支架自动跟机移架、推移刮板输送机和自动矫直,刮板输送机智能柔性变频调速,2巷超前液压支架协同推进,设备列车的自动控制和快速自移。结果表明,上述关键技术保障了综采装备的成套协同作业和连续回采,工作面具备了年产1000万t的水平,大幅减少了采煤工作面的操作工人数量,实现了远程监控和少人值守常态化模式的智能化采煤作业,自2015年10月在转龙湾煤矿23303工作面进行工程示范应用,效果显著,每班可减少操作工人5人,最高日产达到3.78万t,最高月产90.13万t,建立了3~4 m厚煤层年产千万吨的配套模式,可为类似煤层赋存条件高产高效生产提供经验。

Aiming at the problems of low production efficiency of the 3~4 m coal seams,slow shearer cutting speed,poor reliability of hydraulic support self-moving advancement,based on coal seam occurrence in No.233 mining area of No.2-3 coal seam in Zhuanlongwan Coal Mine,in order to achieve the goal of ten-million tonnage level intelligent mine construction in one well of one mine in Zhuanlongwan coal mine,an integrated design of complete equipment was developed and the technical parameters and key structures of fully mechanized mining equipment were determined.Several key technologies were developed such as the accurate detection of straightness of mining face based on the full-scale mining face straightness accurate detection technology,shearer memory cutting intelligent control technology,intelligent speed regulation technology of scraper conveyor based on coal flow load model,and joint support technology at the end of the working face,etc.Thus,the machine independently locates and cuts with memory,the hydraulic support automatically moves,pushes and straightens with the machine,the scraper conveyor intelligently and flexibly converses frequency and regulates speed,the two-lane advanced hydraulic support cooperates to advance,and the equipment train automatically controls and quickly moves.The results show that the above-mentioned key technologies ensure the complete set of coordinated operation and continuous recovery of the comprehensive mining equipment.The working face achieves an annual output of 10 million tons,which greatly reduces the number of operating workers at the coal mining face,and realizes intelligent and remote monitoring and less-attended intelligent coal mining normalization mode.Since October 2015,the project has been demonstrated and applied at Zhuanlongwan Coal Mine’s No.23303 working face,which received remarkable effect.The number of operating workers can be reduced by 5 per shift.The maximum daily output reaches 37800 tons,and the maximum monthly output reaches 901300 tons,a supporting model with an annual output of 10 million tons in 3 m to 4 m thick coal seam has been established,providing experience for high-yield and efficient production with similar coal seam conditions.