CN117128018A - A miniature four-column hydraulic support system for physical testing - Google Patents
A miniature four-column hydraulic support system for physical testing Download PDFInfo
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- 238000013031 physical testing Methods 0.000 title claims description 25
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- 239000003921 oil Substances 0.000 claims description 177
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
- E21D23/04—Structural features of the supporting construction, e.g. linking members between adjacent frames or sets of props; Means for counteracting lateral sliding on inclined floor
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
- E21D23/16—Hydraulic or pneumatic features, e.g. circuits, arrangement or adaptation of valves, setting or retracting devices
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D23/00—Mine roof supports for step- by- step movement, e.g. in combination with provisions for shifting of conveyors, mining machines, or guides therefor
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Abstract
Description
技术领域Technical field
本发明涉及一种用于物理试验的微型四柱式液压支架系统，属于物理试验技术领域。The invention relates to a miniature four-column hydraulic support system for physical testing, belonging to the technical field of physical testing.
背景技术Background technique
物理试验由于其直观、高效、可控等优点，是反映支架及其围岩受力状态的最可靠的方法，良好的微型液压支架系统对支架围岩研究方面具有重要的作用。现有物理试验中，关于支架围岩控制方面，对支架的研究方法实现了从无到有，从单一替代结构到实体支架支护的转变，在此方面获得丰富的研究成果。但现有的支架及控制系统仍然过于简化，不够完善，与工程中实际支架的运动以及受力方式仍有差距。所以在物理试验中，一款体积小、性能优、操作简单方便的实体支架的技术创新至关重要，有利于对工作面整个支架围岩系统的分析。研究结果可为支架与围岩耦合相关物理试验单一变量或多变量分析提供帮助。其与围岩耦合相关试验数据对现场应用具有重要的参考价值。Due to its advantages of being intuitive, efficient, and controllable, physical testing is the most reliable method to reflect the stress state of the support and its surrounding rock. A good micro-hydraulic support system plays an important role in the study of the surrounding rock of the support. In the existing physical tests, regarding the control of the surrounding rock of the bracket, the research method of the bracket has realized the transformation from scratch, from a single alternative structure to the solid bracket support, and has obtained rich research results in this aspect. However, the existing brackets and control systems are still too simplified and not perfect enough, and there is still a gap between the movement and force-bearing methods of the actual brackets in the project. Therefore, in physical tests, the technological innovation of a solid support with small size, excellent performance, simple and convenient operation is crucial, which is conducive to the analysis of the entire support surrounding rock system of the working surface. The research results can provide help for single-variable or multi-variable analysis of physical experiments related to the coupling between the bracket and surrounding rock. The experimental data related to its coupling with the surrounding rock have important reference value for field applications.
发明内容Contents of the invention
本发明旨在提供一种用于物理试验的微型四柱式液压支架系统，以解决现有支架及控制系统过于简化、不够完善、与工程中实际支架的运动以及受力方式仍有差距的问题。The present invention aims to provide a miniature four-column hydraulic support system for physical testing to solve the problem that the existing support and control system are too simplified and incomplete, and there is still a gap between the movement and force-bearing mode of the actual support in the project.
本发明基于支架工作原理并结合相似理论、支架围岩耦合相互作用关系，研制了可用于物理试验的微型四柱式放顶煤液压支架的结构及其测控系统。Based on the working principle of the support, combined with the similarity theory and the coupling interaction relationship of the surrounding rock of the support, the present invention develops the structure and measurement and control system of a miniature four-column hydraulic support for top coal caving that can be used for physical testing.
本发明提供了一种用于物理试验的微型四柱式液压支架系统，包括支架骨架、液压控制系统、监测系统三部分；The invention provides a miniature four-column hydraulic support system for physical testing, which includes three parts: a support frame, a hydraulic control system, and a monitoring system;
所述支架骨架包括支架顶梁 、掩护梁、前、后连杆、底座、护帮板、护帮千斤顶、立柱；所述液压控制系统包括动力元件、执行元件、控制元件、辅助元件，所述动力元件为油泵，执行元件为液压缸，控制元件包括可用于远程无线控制的发射机与接收机以及各种液压阀：安全阀、溢流阀、单向阀、换向阀、球阀，辅助元件包括油箱、滤油器、冷却器、油管及管接头、密封圈、快换接头、测压接头、压力表、油位计；所述监测系统包括铰接式直线位移传感器、压力变送器、记录仪；The bracket frame includes a bracket top beam, a cover beam, front and rear connecting rods, a base, a guard plate, a guard jack, and a column; the hydraulic control system includes a power component, an actuator, a control component, and an auxiliary component. The power component is an oil pump, the actuator is a hydraulic cylinder, and the control components include transmitters and receivers that can be used for remote wireless control and various hydraulic valves: safety valves, relief valves, one-way valves, reversing valves, ball valves, and auxiliary components It includes an oil tank, an oil filter, a cooler, oil pipes and pipe joints, sealing rings, quick-change joints, pressure measuring joints, pressure gauges, and oil level gauges; the monitoring system includes an articulated linear displacement sensor, a pressure transmitter, and a recorder. instrument;
液压控制系统中的油管分别与护帮千斤顶、立柱连接，液压控制系统通过油泵提供动力，驱动立柱与护帮千斤顶中的液压缸运动带动支架骨架进行运动，立柱和护帮千斤顶与支架顶梁与底座通过销轴连接，监测系统中的压力变送器与液压控制系统中的油路油管相连，监测油压变化；监测系统中的铰接式直线位移传感器与前立柱同销轴连接，监测支架骨架顶梁位移。The oil pipes in the hydraulic control system are connected to the support jack and the column respectively. The hydraulic control system provides power through the oil pump to drive the movement of the hydraulic cylinder in the column and the support jack to drive the support frame to move. The column and the support jack are in contact with the support top beam. The base is connected through a pin, and the pressure transmitter in the monitoring system is connected to the oil pipe in the hydraulic control system to monitor oil pressure changes; the articulated linear displacement sensor in the monitoring system is connected to the front column with the same pin to monitor the frame of the bracket. Top beam displacement.
其中：in:
所述顶梁与所述底座上下相对设置，并通过立柱支撑并连接；The top beam and the base are arranged oppositely up and down, and are supported and connected by upright columns;
所述掩护梁上部与顶梁尾部铰接，下部与前、后连杆相连；所述前、后连杆上下分别与掩护梁和底座铰接，共同形成正四连杆机构，实现所述支架的运动趋势，使支架在运动过程中支架前端按照直线轨迹运行；The upper part of the shielding beam is hinged to the tail of the top beam, and the lower part is connected to the front and rear connecting rods; the upper and lower parts of the front and rear connecting rods are hinged to the shielding beam and the base respectively, forming a positive four-bar linkage mechanism to realize the movement trend of the bracket. , so that the front end of the bracket runs along a straight trajectory during the movement;
进一步地，所述立柱的两端分别与顶梁、底座通过销轴连接，所述立柱分前后两排，每排设两根立柱，所述立柱对称分布；Further, the two ends of the upright column are respectively connected to the top beam and the base through pins. The upright columns are divided into two rows, front and rear, with two upright columns in each row, and the upright columns are symmetrically distributed;
所述护帮板和护帮千斤顶铰接，所述护帮千斤顶的另一端与顶梁铰接，护帮板以顶梁的铰接轴心做旋转运动。所述顶梁与底座上设有用于销钉连接的销孔，且有多组销孔，通过在不同销孔固定销能提供不同的立柱支撑角度；前立柱朝向底座的前端呈倾斜设置，倾斜后的立柱与竖直方向的夹角为8°~10°。The guard plate is hinged to the guard jack, and the other end of the guard jack is hinged to the top beam, and the guard plate rotates around the hinge axis of the top beam. The top beam and the base are provided with pin holes for pin connection, and there are multiple sets of pin holes. By fixing pins in different pin holes, different column support angles can be provided; the front column is tilted toward the front end of the base, and the rear column is tilted. The angle between the vertical column and the vertical direction is 8°~10°.
所述立柱与所述护帮千斤顶的液压缸上腔连接补油路与回油路，下腔连接供油路与泄压油路；The upright column and the upper chamber of the hydraulic cylinder of the guard jack are connected to the oil supply path and the oil return path, and the lower chamber is connected to the oil supply path and the pressure relief oil path;
所述支架通过所述液压系统控制实现初撑、增阻、恒阻、卸压四个工作阶段；所述支架前端梁运动曲线符合双纽线特征，运动轨迹变化范围为0.46mm左右，小于理论上的最优值。The bracket realizes four working stages of initial support, resistance increase, constant resistance and pressure relief through the control of the hydraulic system; the movement curve of the front end beam of the bracket conforms to the characteristics of the lemniscate, and the range of movement trajectory change is about 0.46mm, which is smaller than the theoretical the optimal value on.
所述液压系统对所述液压系统必要的动力元件、控制元件、辅助元件如油泵、溢流阀、安全阀、管接头阀块、换向阀均进行了相应的非标设计改造，The hydraulic system has undergone corresponding non-standard design modifications for the necessary power components, control components, and auxiliary components of the hydraulic system such as oil pumps, relief valves, safety valves, pipe joint valve blocks, and reversing valves.
液压系统的动力元件采用无刷定量油泵（由无刷马达和油泵组成），通过2S或者3S锂电池供电，使用35A及以上无刷电调驱动；The power component of the hydraulic system uses a brushless quantitative oil pump (composed of a brushless motor and an oil pump), which is powered by a 2S or 3S lithium battery and driven by a 35A or above brushless ESC;
控制元件中的换向阀为三位四通阀，与接收机相连，换向阀的换位功能由伺服电机的运转来实现，发射机可通过无线传输对伺服电机进行控制。换向阀的开口大小、角度，电机的运转速度均可由发射机进行设置，并可进行远程操控；伺服电机的转动角度可调节，其角度大小可控制通过换向阀的流量，起到了节流阀的作用，可改变液压支架的起降速度。The reversing valve in the control component is a three-position four-way valve, which is connected to the receiver. The reversing valve's position-changing function is realized by the operation of the servo motor. The transmitter can control the servo motor through wireless transmission. The opening size and angle of the reversing valve and the operating speed of the motor can be set by the transmitter and can be controlled remotely; the rotation angle of the servo motor can be adjusted, and its angle size can control the flow through the reversing valve, which plays a role in throttling The function of the valve can change the lifting speed of the hydraulic support.
溢流阀与安全阀为设计定制的RC模型调压阀，通过在油泵出口接溢流阀，保护电机和油泵，试验过程中，通过观测压力表，施加初撑力至理论值，然后将换向阀调至中位锁油。随后由液压缸与换向阀后的安全阀形成的锁油路可实现支架的恒阻支撑。The relief valve and safety valve are customized RC model pressure regulating valves. The relief valve is connected to the oil pump outlet to protect the motor and oil pump. During the test, the initial support force is applied to the theoretical value by observing the pressure gauge, and then the replacement Adjust the valve to the neutral position to lock the oil. Subsequently, the locking oil path formed by the hydraulic cylinder and the safety valve behind the reversing valve can realize the constant resistance support of the bracket.
此外，单向阀、管接头阀块、滤油器等元件也均为设计定制的符合试验要求的功能和尺寸。In addition, components such as check valves, pipe joint valve blocks, and oil filters are also designed and customized with functions and sizes that meet the test requirements.
本发明所述液压系统通过设计的油路与非标设计改造的重要元件，可完全满足实现液压支架的初撑、增阻、恒阻、卸压四个工作阶段，满足试验近似真实地还原现场的需求。The hydraulic system of the present invention can fully meet the four working stages of initial support, increasing resistance, constant resistance, and pressure relief of the hydraulic support through the designed oil circuit and non-standard designed and modified important components, and can satisfy the test to approximate and truly restore the scene. needs.
液压系统的连接关系及控制过程如下：液压油通过过滤器和油泵后分为两路，一路接直动式溢流阀，一路与换向阀进油口接通；换向阀为三位四通型，常态位时液压进油口与回油口相通，连接负载的油口封闭。电机运转速率，换向阀的控制均由发射机完成；The connection relationship and control process of the hydraulic system are as follows: after the hydraulic oil passes through the filter and oil pump, it is divided into two channels, one is connected to the direct-acting relief valve, and the other is connected to the oil inlet of the reversing valve; the reversing valve is a three-position four-position valve. Through type, in the normal position, the hydraulic oil inlet and oil return port are connected, and the oil port connecting the load is closed. The control of motor operating speed and reversing valve is completed by the transmitter;
供油路采用两路并联法，一路接球阀，一路接单向阀。其中油路经过球阀后直接与支架立柱油缸进油口相接。另一路通过单向阀后分流为两路，一路接压力变送器，压力变送器与记录仪相连，实时传输油压大小；一路接弹簧式安全阀；支架初撑力可由油泵之后的直动式溢流阀调节。初撑力设定值为比实际值大0.1MPa，用来弥补液压冲击现象造成的压力损失。弹簧式安全阀的调定值比实际值高10%~20%；The oil supply line adopts two-way parallel connection method, one is connected to the ball valve and the other is connected to the one-way valve. The oil circuit passes through the ball valve and is directly connected to the oil inlet of the bracket column oil cylinder. The other channel is divided into two channels after passing through the one-way valve. One channel is connected to the pressure transmitter. The pressure transmitter is connected to the recorder to transmit the oil pressure in real time. The other channel is connected to the spring-type safety valve. The initial support force of the bracket can be determined by the pressure directly after the oil pump. Adjustable relief valve. The initial support force setting value is 0.1MPa greater than the actual value to compensate for the pressure loss caused by hydraulic shock. The setting value of the spring-type safety valve is 10% to 20% higher than the actual value;
回油路直接与支架油缸回油口相连。换向阀回油口与油箱相连。在液压油缸的上腔中并联有补充油路，在支架压力超过额定工作阻力后立柱下缩让压后补充液压缸上腔油压。防止因为液压缸进入空气影响支架运动的稳定性与承载特性；The oil return line is directly connected to the oil return port of the bracket oil cylinder. The oil return port of the reversing valve is connected to the oil tank. There is a supplementary oil circuit in parallel with the upper chamber of the hydraulic cylinder. After the support pressure exceeds the rated working resistance, the column is retracted to replenish the oil pressure in the upper chamber of the hydraulic cylinder. Prevent air from entering the hydraulic cylinder from affecting the stability and load-bearing characteristics of the bracket movement;
整个油路中多路油路并联的情况下，采用管接头阀块进行并联油路；When multiple oil circuits are connected in parallel in the entire oil circuit, a pipe joint valve block is used to connect the oil circuits in parallel;
护帮板千斤顶的液压油路与主立柱一致。The hydraulic oil circuit of the guard plate jack is consistent with the main column.
所述铰接式直线位移传感器与支架同排立柱平行安装在同排两个立柱中间位置，位移传感器上端在顶梁柱窝中铰接安装，下端在底座柱窝中铰接安装，前后排各一个，与记录仪相连，传输位移数据；压力传感器在油路中设置，传输油压大小，通过油压计算支架受力情况。The articulated linear displacement sensor is installed parallel to the columns in the same row of the bracket at the middle position of the two columns in the same row. The upper end of the displacement sensor is hingedly installed in the top beam column socket, and the lower end is hingedly installed in the base column socket. One in the front and rear rows, and the recorder Connected to transmit displacement data; a pressure sensor is set in the oil circuit to transmit the oil pressure and calculate the stress of the bracket through the oil pressure.
进一步地，所述立柱的液压油缸有上、下两个油腔，其中油缸上腔并联补油路与回油路，下腔连接供油路与泄压油路。立柱液压缸上部通过销钉与顶梁铰接，立柱液压缸下部通过销钉与底座铰接。Further, the hydraulic cylinder of the column has two oil chambers, upper and lower. The upper chamber of the oil cylinder is connected in parallel with the oil supply path and the oil return path, and the lower chamber is connected with the oil supply path and the pressure relief oil path. The upper part of the column hydraulic cylinder is hinged with the top beam through pins, and the lower part of the column hydraulic cylinder is hinged with the base through pins.
进一步地，支架附近的油管在进行相似模拟试验时可能会损坏，因此靠近支架的油管外装有油管弹簧套，防止试验材料对油管造成损坏；液压油路中各个接头采用橡胶密封圈或组合垫片密封。Furthermore, the oil pipes near the bracket may be damaged during similar simulation tests, so the oil pipes close to the bracket are equipped with oil pipe spring sleeves to prevent the test materials from causing damage to the oil pipes; rubber seals or combined gaskets are used for each joint in the hydraulic oil line. seal.
进一步地，所述掩护梁与前、后连杆，底座通过销钉铰接，形成正四连杆机构，保持支架的稳定性，保证支架的纵向和横向稳定性，承受和传递外载，保证支架的整体刚度。Further, the shielding beam, the front and rear connecting rods, and the base are hinged through pins to form a positive four-bar linkage mechanism, which maintains the stability of the bracket, ensures the longitudinal and lateral stability of the bracket, withstands and transmits external loads, and ensures the integrity of the bracket. Stiffness.
进一步地，微型液压支架四连杆结构的各部分尺寸：掩护梁长度为43.56mm，前连杆长度为43.04mm，后连杆长度为49.66mm，前、后连杆在掩护梁上的上铰点间距13.07mm，前连杆下铰点与底座底面的距离为24.94mm，后连杆下铰点与底座底面的距离为16mm。所述液压系统控制驱动液压杆使液压支架进行升降，支架的升降高度范围为56mm~86mm。Further, the dimensions of each part of the four-link structure of the miniature hydraulic support: the length of the shielding beam is 43.56mm, the length of the front link is 43.04mm, the length of the rear link is 49.66mm, and the front and rear links are hinged on the shielding beam. The distance between points is 13.07mm, the distance between the lower hinge point of the front link and the bottom surface of the base is 24.94mm, and the distance between the lower hinge point of the rear link and the bottom surface of the base is 16mm. The hydraulic system controls and drives the hydraulic rod to lift the hydraulic bracket, and the lifting height range of the bracket is 56mm~86mm.
本发明提供了上述用于物理试验的微型四柱式液压支架系统的使用方法，所述支架通过液压系统实现初撑、增阻、恒阻、卸压四个工作阶段；The invention provides a method of using the above-mentioned miniature four-column hydraulic support system for physical testing. The support realizes four working stages of initial support, resistance increase, constant resistance and pressure relief through the hydraulic system;
（1）初撑阶段，关闭球阀，打开电调，将换向阀调至供油路，支架升起后对顶板施加支承力，达到初撑力后将换向阀调至中位，并停止供油；在单向阀的作用下，各油腔可分别保持稳定带压状态，对顶板起到主动预支撑作用； (1) In the initial support stage, close the ball valve, turn on the electric regulator, and adjust the reversing valve to the oil supply line. After the bracket is raised, a supporting force is applied to the top plate. After reaching the initial supporting force, adjust the reversing valve to the neutral position and stop. Oil supply; under the action of the one-way valve, each oil chamber can maintain a stable pressurized state, playing an active pre-support role for the top plate;
（2）增阻阶段，随着顶板的下沉，支架受力逐渐变大；此过程由支架闭油路完成；(2) In the resistance increasing stage, as the roof sinks, the force on the bracket gradually increases; this process is completed by the bracket closing the oil circuit;
（3）恒阻阶段，当支架受力超过安全阀调定压力时，弹簧式安全阀自动打开卸压，支架立柱下缩，补油路给支架立柱液压缸上腔补液，在此过程中支架工作阻力基本不变；(3) In the constant resistance stage, when the force on the bracket exceeds the set pressure of the safety valve, the spring-type safety valve automatically opens to relieve the pressure, the bracket column shrinks, and the oil supply line replenishes the upper chamber of the bracket column hydraulic cylinder with fluid. During this process, the bracket The working resistance remains basically unchanged;
（4）支架降架时，打开球阀，将换向阀调至回油路，支架在立柱上腔油压的推动下缓慢下降，降到最低位置时停止供油。(4) When lowering the bracket, open the ball valve and adjust the reversing valve to the oil return line. The bracket will slowly drop driven by the oil pressure in the upper chamber of the column, and stop supplying oil when it reaches the lowest position.
本发明的有益效果：Beneficial effects of the present invention:
（1）本发明对物理试验有重要的作用，本发明提供的微型液压支架具有良好的初撑、增阻、恒阻和安全保护作用下的快速卸压性能；液压系统部分通过对液压油路及必要的动力元件、控制元件、辅助元件进行特殊设计，整套设备具有造价低廉、操作简单、响应速度快、压力损失小、试验结果精确、还原度高、直观性强等优点；(1) The present invention plays an important role in physical testing. The micro-hydraulic support provided by the present invention has good initial support, resistance increase, constant resistance and rapid pressure relief performance under safety protection; the hydraulic system part passes through the hydraulic oil circuit And the necessary power components, control components, and auxiliary components are specially designed. The entire set of equipment has the advantages of low cost, simple operation, fast response, small pressure loss, accurate test results, high degree of reduction, and strong intuitiveness;
（2）由于其初撑力与工作阻力参数可控性，可灵活应用于模拟不同真实工况下的支架，可根据试验需求控制变量，改变支架的初撑力与工作阻力，得到多组试验对比结果，更好地满足试验需求，给工程施工中的新技术，新工艺及以施工技术新方案的工业试验提供有价值的试验数据。(2) Due to the controllability of its initial support force and working resistance parameters, it can be flexibly used to simulate brackets under different real working conditions. Variables can be controlled according to test requirements, and the initial support force and working resistance of the bracket can be changed to obtain multiple sets of tests. The comparison results can better meet the test needs and provide valuable test data for industrial tests of new technologies, new processes and new construction technology solutions in engineering construction.
附图说明Description of the drawings
图1为本发明用于物理试验的微型液压支架的立体结构示意图；Figure 1 is a schematic three-dimensional structural diagram of a miniature hydraulic support used for physical testing according to the present invention;
图2为本发明用于物理试验的微型液压支架的三视图；Figure 2 is a three-dimensional view of the miniature hydraulic support used for physical testing according to the present invention;
图3为本发明用于物理试验的微型液压支架的主视图的A-A剖视图；Figure 3 is an A-A cross-sectional view of the front view of the miniature hydraulic support used for physical testing of the present invention;
图4为本发明用于物理试验的微型液压支架的主视图的B-B剖视图；Figure 4 is a B-B cross-sectional view of the front view of the miniature hydraulic support used for physical testing of the present invention;
图5为本发明用于物理试验的微型液压支架系统的液压系统结构图；Figure 5 is a hydraulic system structural diagram of the miniature hydraulic support system used for physical testing according to the present invention;
图中：1-支架顶梁、2-前连杆、3-掩护梁、4-后连杆、5-底座、6-柱窝、7-立柱、8-直线位移传感器、9-护帮板、10-护帮板千斤顶。In the picture: 1-bracket top beam, 2-front link, 3-cover beam, 4-rear link, 5-base, 6-column socket, 7-column, 8-linear displacement sensor, 9-guard plate , 10-Guard plate jack.
具体实施方式Detailed ways
下面通过实施例来进一步说明本发明，但不局限于以下实施例。The present invention is further described below through examples, but is not limited to the following examples.
实施例Example
如图1~5所示，一种用于物理试验的微型四柱式液压支架系统，包括支架骨架、液压控制系统、监测系统三部分；As shown in Figures 1 to 5, a miniature four-column hydraulic support system for physical testing includes three parts: a support frame, a hydraulic control system, and a monitoring system;
所述支架骨架包括支架顶梁1、掩护梁3、前连杆2、后连杆4、底座5、护帮板9、护帮板千斤顶10、立柱7；所述液压控制系统包括动力元件、执行元件、控制元件、辅助元件，所述动力元件为油泵，执行元件为液压缸，控制元件包括可用于远程无线控制的发射机与接收机、各种液压阀：安全阀、溢流阀、单向阀、换向阀、球阀；辅助元件包括油箱、滤油器、冷却器、油管及管接头、密封圈、快换接头、测压接头、压力表、油位计；所述监测系统包括铰接式直线位移传感器、压力变送器、记录仪；The bracket frame includes a bracket top beam 1, a cover beam 3, a front link 2, a rear link 4, a base 5, a guard plate 9, a guard plate jack 10, and a column 7; the hydraulic control system includes power components, Actuating elements, control elements, and auxiliary elements. The power element is an oil pump, and the actuating element is a hydraulic cylinder. The control elements include transmitters and receivers that can be used for remote wireless control, various hydraulic valves: safety valves, relief valves, single Directional valves, reversing valves, and ball valves; auxiliary components include oil tanks, oil filters, coolers, oil pipes and pipe joints, sealing rings, quick-change joints, pressure measuring joints, pressure gauges, and oil level gauges; the monitoring system includes hinges Type linear displacement sensor, pressure transmitter, recorder;
液压控制系统中的油管分别与护帮板千斤顶10、立柱7连接，通过立柱7与护帮板千斤顶10的运动控制支架骨架进行运动，液压控制系统通过油泵提供动力，驱动立柱与护帮板千斤顶中的液压缸运动，立柱和护帮板千斤顶与支架顶梁1与底座5通过销轴连接，监测系统中的压力变送器与液压控制系统中的油路油管相连，监测油压变化；监测系统中的铰接式直线位移传感器与前立柱7同销轴连接，监测支架骨架顶梁位移。The oil pipes in the hydraulic control system are connected to the guard plate jack 10 and the column 7 respectively, and the motion control bracket frame of the column 7 and the guard plate jack 10 moves. The hydraulic control system provides power through the oil pump to drive the column and the guard plate jack 10. The hydraulic cylinder in the system moves, the column and guard plate jacks are connected to the support beam 1 and the base 5 through pins. The pressure transmitter in the monitoring system is connected to the oil line and oil pipe in the hydraulic control system to monitor changes in oil pressure; monitoring The articulated linear displacement sensor in the system is connected with the front column 7 with a pin to monitor the displacement of the top beam of the support frame.
其中：所述支架顶梁1与所述底座5上下相对设置，并通过立柱7支撑并连接；Among them: the bracket top beam 1 and the base 5 are arranged oppositely up and down, and are supported and connected by the upright column 7;
所述掩护梁3上部与顶梁1尾部铰接，下部与前、后连杆相连；所述前、后连杆上下分别与掩护梁3和底座5铰接，共同形成正四连杆机构，实现所述支架的运动趋势，使支架在运动过程中支架顶梁1前端按照直线轨迹运行；The upper part of the shield beam 3 is hinged to the tail of the top beam 1, and the lower part is connected to the front and rear links; the upper and lower parts of the front and rear links are hinged to the shield beam 3 and the base 5 respectively, forming a positive four-bar linkage mechanism to achieve the above The movement trend of the bracket causes the front end of the bracket top beam 1 to run along a straight trajectory during the movement of the bracket;
进一步地，所述立柱7的两端分别与顶梁、底座通过销轴连接，所述立柱分前后两排，每排设两根立柱，所述立柱对称分布；Further, the two ends of the upright column 7 are respectively connected with the top beam and the base through pins. The upright columns are divided into two rows, front and rear, with two upright columns in each row, and the upright columns are symmetrically distributed;
所述护帮板9和护帮板千斤顶10铰接，所述护帮板千斤顶10的另一端与顶梁铰接，护帮板9以顶梁的铰接轴心做旋转运动。所述顶梁与底座上设有用于销钉连接的销孔，且有多组销孔，通过在不同销孔固定销能提供不同的立柱支撑角度；前立柱朝向底座的前端呈倾斜设置，倾斜后的立柱与竖直方向的夹角为8°。The guard plate 9 is hinged to the guard plate jack 10, and the other end of the guard plate jack 10 is hinged to the top beam. The guard plate 9 rotates around the hinge axis of the top beam. The top beam and the base are provided with pin holes for pin connection, and there are multiple sets of pin holes. By fixing pins in different pin holes, different column support angles can be provided; the front column is tilted toward the front end of the base, and the rear column is tilted. The angle between the vertical column and the vertical direction is 8°.
所述铰接式直线位移传感器与支架同排立柱平行安装在同排两个立柱中间位置，位移传感器上端在顶梁柱窝中铰接安装，下端在底座柱窝中铰接安装，前后排各一个，与记录仪相连，传输位移数据；压力传感器在油路中设置，传输油压大小，通过油压计算支架受力情况。The articulated linear displacement sensor is installed parallel to the columns in the same row of the bracket at the middle position of the two columns in the same row. The upper end of the displacement sensor is hingedly installed in the top beam column socket, and the lower end is hingedly installed in the base column socket. One in the front and rear rows, and the recorder Connected to transmit displacement data; a pressure sensor is set in the oil circuit to transmit the oil pressure and calculate the stress of the bracket through the oil pressure.
进一步地，所述立柱的液压油缸有上、下两个油腔，其中油缸上腔并联补油路与回油路，下腔连接供油路与泄压油路。立柱液压缸上部通过销钉与顶梁铰接，立柱液压缸下部通过销钉与底座铰接。Further, the hydraulic cylinder of the column has two oil chambers, upper and lower. The upper chamber of the oil cylinder is connected in parallel with the oil supply path and the oil return path, and the lower chamber is connected with the oil supply path and the pressure relief oil path. The upper part of the column hydraulic cylinder is hinged with the top beam through pins, and the lower part of the column hydraulic cylinder is hinged with the base through pins.
进一步地，靠近支架的油管（支架附近的油管在进行相似模拟试验时可能会损坏）外装有油管弹簧套，防止试验材料对油管造成损坏；液压油路中各个接头采用橡胶密封圈或组合垫片密封。Furthermore, the oil pipe close to the bracket (the oil pipe near the bracket may be damaged during similar simulation tests) is equipped with a oil pipe spring sleeve to prevent the test material from causing damage to the oil pipe; each joint in the hydraulic oil line uses a rubber sealing ring or a combination gasket seal.
进一步地，所述掩护梁与前、后连杆，底座通过销钉铰接，形成正四连杆机构，保持支架的稳定性，保证支架的纵向和横向稳定性，承受和传递外载，保证支架的整体刚度。Further, the shielding beam, the front and rear connecting rods, and the base are hinged through pins to form a positive four-bar linkage mechanism, which maintains the stability of the bracket, ensures the longitudinal and lateral stability of the bracket, withstands and transmits external loads, and ensures the integrity of the bracket. Stiffness.
所述液压系统对所述液压系统必要的动力元件、控制元件、辅助元件如油泵、溢流阀、安全阀、管接头阀块、换向阀均进行了相应的非标设计改造，The hydraulic system has undergone corresponding non-standard design modifications for the necessary power components, control components, and auxiliary components of the hydraulic system such as oil pumps, relief valves, safety valves, pipe joint valve blocks, and reversing valves.
液压系统的动力元件采用无刷定量油泵（由无刷马达和油泵组成），通过2S或者3S锂电池供电，使用35A及以上无刷电调驱动；The power component of the hydraulic system uses a brushless quantitative oil pump (composed of a brushless motor and an oil pump), which is powered by a 2S or 3S lithium battery and driven by a 35A or above brushless ESC;
控制元件中的换向阀为三位四通阀，与接收机相连，换向阀的换位功能由伺服电机的运转来实现，发射机可通过无线传输对伺服电机进行控制。换向阀的开口大小、角度、电机的运转速度均可由发射机进行设置，并可进行远程操控；伺服电机的转动角度可调节，其角度大小可控制通过换向阀的流量，起到了节流阀的作用，可改变液压支架的起降速度。The reversing valve in the control component is a three-position four-way valve, which is connected to the receiver. The reversing valve's position-changing function is realized by the operation of the servo motor. The transmitter can control the servo motor through wireless transmission. The opening size and angle of the reversing valve and the operating speed of the motor can be set by the transmitter and can be controlled remotely; the rotation angle of the servo motor can be adjusted, and its angle size can control the flow through the reversing valve, thus throttling The function of the valve can change the lifting speed of the hydraulic support.
溢流阀与安全阀为设计定制的RC模型调压阀，通过在油泵出口接溢流阀，保护电机和油泵，试验过程中，通过观测压力表，施加初撑力至理论值，然后将换向阀调至中位锁油。随后由液压缸与换向阀后的安全阀形成的锁油路可实现支架的恒阻支撑。The relief valve and safety valve are customized RC model pressure regulating valves. The relief valve is connected to the oil pump outlet to protect the motor and oil pump. During the test, the initial support force is applied to the theoretical value by observing the pressure gauge, and then the replacement Adjust the valve to the neutral position to lock the oil. Subsequently, the locking oil path formed by the hydraulic cylinder and the safety valve behind the reversing valve can realize the constant resistance support of the bracket.
此外，单向阀、管接头阀块、滤油器等元件也均为设计定制的符合试验要求的功能和尺寸。In addition, components such as check valves, pipe joint valve blocks, and oil filters are also designed and customized with functions and sizes that meet the test requirements.
本发明所述液压系统通过设计的油路与非标设计改造的重要元件，可完全满足实现液压支架的初撑、增阻、恒阻、卸压四个工作阶段，满足试验近似真实地还原现场的需求。The hydraulic system of the present invention can fully meet the four working stages of initial support, increasing resistance, constant resistance, and pressure relief of the hydraulic support through the designed oil circuit and non-standard designed and modified important components, and can satisfy the test to approximate and truly restore the scene. needs.
液压系统的连接关系及控制过程如下：液压油通过过滤器和油泵后分为两路，一路接直动式溢流阀，一路与换向阀进油口接通；换向阀为三位四通型，常态位时液压进油口与回油口相通，连接负载的油口封闭。电机运转速率，换向阀的控制均由发射机完成；The connection relationship and control process of the hydraulic system are as follows: after the hydraulic oil passes through the filter and oil pump, it is divided into two channels, one is connected to the direct-acting relief valve, and the other is connected to the oil inlet of the reversing valve; the reversing valve is a three-position four-position valve. Through type, in the normal position, the hydraulic oil inlet and oil return port are connected, and the oil port connecting the load is closed. The control of motor operating speed and reversing valve is completed by the transmitter;
供油路采用两路并联法，一路接球阀，一路接单向阀。其中油路经过球阀后直接与支架立柱7油缸进油口相接。另一路通过单向阀后分流为两路，一路接压力变送器，压力变送器与记录仪相连，实时传输油压大小；一路接弹簧式安全阀；支架初撑力可由油泵之后的直动式溢流阀调节。初撑力设定值为比实际值大0.1MPa，用来弥补液压冲击现象造成的压力损失。弹簧式安全阀的调定值比实际值高10%~20%；The oil supply line adopts two-way parallel connection method, one is connected to the ball valve and the other is connected to the one-way valve. The oil circuit passes through the ball valve and is directly connected to the oil inlet of the oil cylinder 7 of the bracket column. The other channel is divided into two channels after passing through the one-way valve. One channel is connected to the pressure transmitter. The pressure transmitter is connected to the recorder to transmit the oil pressure in real time. The other channel is connected to the spring-type safety valve. The initial support force of the bracket can be determined by the pressure directly after the oil pump. Adjustable relief valve. The initial support force setting value is 0.1MPa greater than the actual value to compensate for the pressure loss caused by hydraulic shock. The setting value of the spring-type safety valve is 10% to 20% higher than the actual value;
回油路直接与支架油缸回油口相连。换向阀回油口与油箱相连。在液压油缸的上腔中并联有补充油路，在支架压力超过额定工作阻力后立柱下缩让压后补充液压缸上腔油压。防止因为液压缸进入空气影响支架运动的稳定性与承载特性；The oil return line is directly connected to the oil return port of the bracket oil cylinder. The oil return port of the reversing valve is connected to the oil tank. There is a supplementary oil circuit in parallel with the upper chamber of the hydraulic cylinder. After the support pressure exceeds the rated working resistance, the column is retracted to replenish the oil pressure in the upper chamber of the hydraulic cylinder. Prevent air from entering the hydraulic cylinder from affecting the stability and load-bearing characteristics of the bracket movement;
整个油路中多路油路并联的情况下，采用管接头阀块进行并联油路；When multiple oil circuits are connected in parallel in the entire oil circuit, a pipe joint valve block is used to connect the oil circuits in parallel;
护帮板千斤顶的液压油路与主立柱一致。The hydraulic oil circuit of the guard plate jack is consistent with the main column.
所述立柱与所述护帮板千斤顶的液压缸上腔连接补油路与回油路，下腔连接供油路与泄压油路；The upper chamber of the hydraulic cylinder of the column and the guard plate jack is connected to the oil supply path and the oil return path, and the lower chamber is connected to the oil supply path and the pressure relief oil path;
所述支架通过所述液压系统控制实现初撑、增阻、恒阻、卸压四个工作阶段；所述支架前端梁运动曲线符合双纽线特征，运动轨迹变化范围为0.46mm左右，小于理论上的最优值。本发明所述的双纽线特征为：护帮板水平运动轨迹变化范围为 0.46mm左右。液压支架设计原则为，从最高高度降到最低位置时，护帮板水平运动轨迹变化应小于 70mm，最好在 30mm 以下，计算得出微型支架的护帮板水平运动轨迹变化应小于 1.4mm，最好在0.6mm 以下，支架运动仿真结果在最优值0.6mm以内。The bracket realizes four working stages of initial support, resistance increase, constant resistance and pressure relief through the control of the hydraulic system; the movement curve of the front end beam of the bracket conforms to the characteristics of the lemniscate, and the range of movement trajectory change is about 0.46mm, which is smaller than the theoretical the optimal value on. The characteristics of the lemniscate of the present invention are: the variation range of the horizontal movement trajectory of the guard panel is about 0.46mm. The design principle of the hydraulic support is that when it is lowered from the highest height to the lowest position, the change in the horizontal motion trajectory of the guard plate should be less than 70mm, preferably less than 30mm. It is calculated that the change in the horizontal movement trajectory of the mini bracket's guard plate should be less than 1.4mm. It is best to be below 0.6mm, and the bracket motion simulation results are within the optimal value of 0.6mm.
具体地，本实施例中，支架以ZF15000/27.5/42型放顶煤液压支架为原形，对其结构进行简化后的小型支架，与原型支架相比，省去了尾梁、 插板、推杆、伸缩梁结构，简化了立柱柱窝、前梁、侧护板和顶梁。几何相似比取CL=50，容重相似比Cλ=1.6，原型支架的初撑力为12778kN，额定工作阻力为15000kN，根据计算得到，模拟支架施加初撑力时的泵站压力约为0.57MPa，达到额定工作阻力后的泵站压力为0.67MPa；相似模拟支架顶梁长度L' 1=0.1063m，模拟液压缸内径为10mm，外径14mm，模拟支架共四个立柱。本发明以现实支架为原型简化的小型支架，用于物理试验，但不局限于一种现有支架，可以根据不同的现有支架修改液压系统参数满足试验要求。Specifically, in this embodiment, the bracket is based on the ZF15000/27.5/42 top coal caving hydraulic bracket, and its structure is simplified into a small bracket. Compared with the prototype bracket, the tail beam, inserting plate, and pusher are omitted. The pole and telescopic beam structure simplifies the column socket, front beam, side fenders and top beam. The geometric similarity ratio is C L =50, the volume-to-weight similarity ratio C λ =1.6, the initial supporting force of the prototype bracket is 12778kN, and the rated working resistance is 15000kN. According to calculations, the pumping station pressure when the simulated bracket exerts the initial supporting force is about 0.57 MPa, the pressure of the pump station after reaching the rated working resistance is 0.67MPa; the length of the top beam of the similar simulation support is L ' 1 =0.1063m, the inner diameter of the simulation hydraulic cylinder is 10mm, the outer diameter is 14mm, and the simulation support has a total of four columns. The present invention uses a realistic bracket as a prototype to simplify a small bracket for physical testing, but is not limited to one existing bracket. The hydraulic system parameters can be modified according to different existing brackets to meet test requirements.
进一步地，通过计算和几何作图法确定，微型液压支架四连杆结构的各部分尺寸：掩护梁长度为43.56mm，前连杆长度为43.04mm，后连杆长度为49.66mm，前、后连杆在掩护梁上的上铰点间距13.07mm，前连杆下铰点与底座底面的距离为24.94mm，后连杆下铰点与底座底面的距离为16mm。所述液压系统控制驱动液压杆使液压支架进行升降，支架的升降高度范围为56mm~86mm。Further, through calculation and geometric drawing methods, the dimensions of each part of the four-link structure of the micro hydraulic support are determined: the length of the cover beam is 43.56mm, the length of the front link is 43.04mm, the length of the rear link is 49.66mm, the length of the front and rear The distance between the upper hinge point of the connecting rod on the shield beam is 13.07mm, the distance between the lower hinge point of the front link and the bottom surface of the base is 24.94mm, and the distance between the lower hinge point of the rear link and the bottom surface of the base is 16mm. The hydraulic system controls and drives the hydraulic rod to lift the hydraulic bracket, and the lifting height range of the bracket is 56mm~86mm.
所述支架结构屈服强度检测中分别以 1 倍和 3 倍的理论应力（支架额定工作阻力时承受的最大压力）施加，进行强度分析。材料为标准 45 号钢，屈服应力为 530MPa。模拟结果中顶梁所受应力最大值为 130MPa，远小于可使其屈服的等效应力值，支架强度设计满足试验要求。In the yield strength test of the bracket structure, 1 times and 3 times the theoretical stress (the maximum pressure endured by the bracket at rated working resistance) were applied respectively for strength analysis. The material is standard No. 45 steel with a yield stress of 530MPa. In the simulation results, the maximum stress on the top beam is 130MPa, which is far less than the equivalent stress value that can make it yield. The strength design of the bracket meets the test requirements.
本发明提供了上述用于物理试验的微型四柱式液压支架系统的使用方法，所述支架通过液压系统实现初撑、增阻、恒阻、卸压四个工作阶段；The invention provides a method of using the above-mentioned miniature four-column hydraulic support system for physical testing. The support realizes four working stages of initial support, resistance increase, constant resistance and pressure relief through the hydraulic system;
（1）初撑阶段，关闭球阀，打开电调，将换向阀调至供油路，支架升起后对顶板施加支承力，达到初撑力后将换向阀调至中位，并停止供油；在单向阀的作用下，各油腔可分别保持稳定带压状态，对顶板起到主动预支撑作用； (1) In the initial support stage, close the ball valve, turn on the electric regulator, and adjust the reversing valve to the oil supply line. After the bracket is raised, a supporting force is applied to the top plate. After reaching the initial supporting force, adjust the reversing valve to the neutral position and stop. Oil supply; under the action of the one-way valve, each oil chamber can maintain a stable pressurized state, playing an active pre-support role for the top plate;
（2）增阻阶段，随着顶板的下沉，支架受力逐渐变大；此过程由支架闭油路完成；(2) In the resistance increasing stage, as the roof sinks, the force on the bracket gradually increases; this process is completed by the bracket closing the oil circuit;
（3）恒阻阶段，当支架受力超过安全阀调定压力时，弹簧式安全阀自动打开卸压，支架立柱下缩，补油路给支架上腔补液，在此过程中支架工作阻力基本不变；(3) In the constant resistance stage, when the force on the stent exceeds the set pressure of the safety valve, the spring-type safety valve automatically opens to relieve the pressure, the stent column shrinks, and the oil supply line replenishes the upper cavity of the stent. During this process, the working resistance of the stent is basically constant;
（4）支架降架时，打开球阀，将换向阀调至回油路，支架在立柱上腔油压的推动下缓慢下降，降到最低位置时停止供油。(4) When lowering the bracket, open the ball valve and adjust the reversing valve to the oil return line. The bracket will slowly drop driven by the oil pressure in the upper chamber of the column, and stop supplying oil when it reaches the lowest position.
本发明提供的微型液压支架各个零件的组装为间隙配合，销轴连接处孔径为正公差，各结构件相对位置应由固定槽、定位销等固定，防止结构件之间的摩擦力对支架运动影响较大，以保证支架能够稳定运行且受力均匀。The various parts of the micro hydraulic support provided by the present invention are assembled with clearance fit, the aperture of the pin shaft connection is a positive tolerance, and the relative position of each structural part should be fixed by fixed grooves, positioning pins, etc. to prevent the friction between the structural parts from affecting the movement of the support. The impact is large to ensure that the bracket can operate stably and receive uniform force.
以上实施例仅用以说明本发明专利而并非限制本发明专利所描述的技术方案；因此尽管本说明书参照上述的各个实施例对本发明专利已进行了详细的说明，但是本领域的技术人员应当理解，仍然可以对本发明专利进行修改或等同替换；而一切不脱离本发明专利的精神和范围的技术方案及其改进，其均应涵盖在本发明专利的权利要求范围中。The above embodiments are only used to illustrate the patent of the present invention and do not limit the technical solutions described in the patent of the present invention; therefore, although the present patent has been described in detail with reference to each of the above embodiments, those skilled in the art should understand that , the patent of the present invention can still be modified or equivalently substituted; and all technical solutions and improvements that do not deviate from the spirit and scope of the patent of the present invention shall be covered by the claims of the patent of the present invention.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN119860254A (en) * | 2025-02-25 | 2025-04-22 | 山东科技大学 | Electric bracket capable of steplessly regulating expansion ratio for coal mine |
| CN119860254B (en) * | 2025-02-25 | 2025-09-23 | 山东科技大学 | Electric bracket capable of steplessly regulating expansion ratio for coal mine |
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