MG400/951-WD型采煤机螺旋滚筒可靠性灵敏度优化设计

Reliability and sensitivity optimal design of MG400/951-WD shearer’s spiral drum

为提高含夹矸煤层赋存条件下采煤机螺旋滚筒的可靠性,以“MG400/951-WD”采煤机为研究对象,对含夹矸煤层的试样进行物理力学参数测试。基于破煤理论,模拟得到含夹矸煤层赋存条件下螺旋滚筒的冲击载荷。结合刚柔耦合虚拟样机技术建立以螺旋滚筒为模态中性文件的采煤机刚柔耦合虚拟样机模型,得到螺旋滚筒的应力分布规律和振动特性。对采煤机刚柔耦合模型进行受迫振动分析,得到系统模态频率。在可靠性干涉理论和共振失效准则分析的基础上,利用神经网络,讨论相关失效理论的采煤机螺旋滚筒可靠性灵敏度优化设计问题。分析牵引速度v_(q)、螺旋滚筒直径D、螺旋升角a、螺旋滚筒宽度B和截线距t对螺旋滚筒应力可靠性、振动频率可靠性和振幅可靠性的影响。构建螺旋滚筒多目标优化设计状态函数,利用结构进化优化算法,得到螺旋滚筒设计变量的最优解。结果表明:优化后螺旋滚筒最大应力为770.0351 MPa,较优化前降低11.42%;优化后的螺旋滚筒固有频率得到提升;优化后螺旋滚筒振幅为0.3616 mm,较优化前降低20.12%,动力学指标得到改善,螺旋滚筒设计变量对其可靠性的影响程度降低;优化后螺旋滚筒可靠度由0.8324提高至0.9885。将刚柔耦合虚拟样机技术与基于相关失效模式的可靠性灵敏度设计理论和结构进化算法相结合,为设计含夹矸煤层赋存条件下的高可靠性采煤机螺旋滚筒提供更快速、可靠的技术手段。

In order to improve the reliability of shearer spiral drum in coal seam with gangue,taking the MG400/951-WD shearer model as the research object,the physical and mechanical parameters of coal seam samples with gangue were tested.Based on the coal breaking theory,the impact load of the spiral drum in a coal seam with gangue was simulated.Combined with rigid-flexible coupling virtual prototype technology,a rigid-flexible coupling virtual prototype model of a shearer with a spiral drum as the modal neutral file was established,and the stress distribution and vibration characteristics of the screw drum were obtained.The system modal frequency was obtained by forced vibration analysis of the shearer rigid-flexible coupling model.Based on reliability interference and resonance failure criterion,the reliability and sensitivity optimal design of shearer spiral drum under relevant failure theory was investigated using neural network.The effects of traction speed v_(q),drum diameter D,drum angle a,drum width B and tangent distance t on stress reliability,vibration frequency reliability and amplitude reliability of the drum were analyzed.Multi-objective optimization design state function of the spiral drum was constructed,and the optimal solution of the design variables of the spiral drum was obtained by the structural evolution optimization algorithm.The results show that the maximum stress of the spiral drum after optimization is 770.0351 MPa,which decreases by 11.42%.The natural frequency of the spiral drum is improved after optimization,and the amplitude of the drum is 0.3616 mm,which decreases by 20.12%.The dynamic index is improved,and the influence degree of the design variable of the drum on its reliability is reduced.The reliability of spiral drum is increased from 0.8324 to 0.9885.Rigid-flexible coupling virtual prototype technology is combined with the reliability and sensitivity design theory,structural evolution algorithm,and relevant failure modes,which provides a more rapid and reliable technical means for the design of high-reliability shearer spiral drum under the condition of coal seam with gangue.