超大采高综采工作面乳化液泵站系统

Emulsion pump station system for super high fully mechanized working face

为了满足8.8 m超大采高综采工作面乳化液用液需求,针对现有乳化液泵站系统存在单台泵站流量低、传动系统可靠性不高、吸排液阀寿命短、系统响应速度慢等问题,设计了超大采高综采工作面乳化液泵站系统,单台乳化液泵站流量达1200 L/min,额定工作压力达37.5 MPa。重点介绍了滑块与连杆球形铰接运动副、四点支撑曲轴设计、超大流量吸排液阀、泵站均衡控制、系统实时快速响应等泵站系统设计的关键技术。针对现有乳化液泵结构中滑块与连杆的连接采用圆柱销的形式,存在不能自动调心、无法消除侧向力的影响、滑块容易磨损等问题,提出了全新的球形铰接形式,连杆可以在水平方向有一定的摆动,消除了传统形式的侧向力的影响;独特的多点润滑孔道设计,使得球头与铰座之间形成稳定的润滑油膜,使用寿命更长。采用4个圆柱滚子轴承支撑曲轴,稳定性强,有效降低了曲轴的挠度,曲轴的受力更加均衡,解决了轴颈圆角应力突变的难题。从结构、材料、工艺上改善了吸排液阀性能,延长了吸排液阀寿命。泵站采用均衡控制策略,保证了每台泵的运行时间基本相等,保持泵的运行寿命均衡。泵站系统采用实时快速响应技术,提高了系统的响应速度,可实时响应设备对流量、压力的需求,保证动作的及时性及准确性。实际应用结果表明,该系统结构合理、性能可靠、维修方便,满足了8.8 m超大采高综采工作面对供液系统的要求,促进了煤矿的高产高效和安全生产。

In order to meet the emulsion demand of 8.8 m super high fully mechanized working face,and solve the problems of the existing emulsion pump station system,such as low flow rate of single pump station,insufficient reliability of transmission system,short life of suction and discharge valve and slow system response,the emulsion pump station system for super high fully mechanized working face is designed.The flow rate of a single emulsion pump station reaches 1,200 L/min and the rated working pressure reaches 37.5 MPa.The key technologies of pump station system design such as slider and connecting rod spherical articulated kinematic pair,four-point support crankshaft design,super flow suction and discharge valves,pump station equalization control and real-time rapid system response are discussed.In the existing emulsion pump structure,the slider is connected to the connecting rod in the form of a cylindrical pin,which cannot adjust the center automatically,cannot eliminate the influence of lateral forces,and make the slider easily worn.In order to solve the above problems,a new form of spherical articulation is proposed,in which the connecting rod can swing to a certain extent in the horizontal direction,eliminating the influence of lateral forces in the traditional form.The unique multiple point lubrication channel design makes a stable lubricating oil film to be formed between the ball head and the hinge seat,and makes the service life longer.Four cylindrical roller bearings are used to support the crankshaft,which has strong stability and reduces the deflection of the crankshaft effectively.The stress on the crankshaft is more balanced,which solves the problem of sudden stress changes in the journal fillet.The performance of the suction and discharge liquid valve has been improved in terms of the structure,material and process,and the life of the suction and discharge liquid valve has been increased.The pump station adopts a pump station equalization control strategy to ensure that the running time of each pump is basically the same and the life of the pumps is balanced.The pump station system adopts real-time rapid response technology,which improves the response speed of the system and responds to the equipment's demand for flow and pressure in real time,ensuring the timeliness and accuracy of the action.The practical application results show that the system has reasonable structure,reliable performance and easy maintenance,which meets the requirements of the fluid supply system in the 8.8 m super high fully mechanized working face and improves the high production efficiency and safe production of coal mines.