露天煤矿大型挖掘装备高能效运行基础研究

Power shovel and hydraulic shovel are the most important equipment in surface coal mining. The common characteristics of them include large weight, high installation power, working around the clock, and huge energy consumption. State of the art technology and our previous research suggest that the major source of the energy waste in power shovel is the motor braking process during the swing of the upper part and descending of the hoisting part. While for hydraulic shovel, the energy efficiency is even lower. Throttling loss, potential energy loss during boom descending, kinetic energy loss during swing braking, and energy consumed by cooling system are the main energy waste sources. In order to reduce the energy waste, efficiently recovering and reusing the wasted kinetic and potential energy is key. But limited by existing technology, there still has no solution for recovering and reusing the wasted energy within the very short operating period of the machine. To overcome this problem, this project proposes four new solutions to reduce the energy consumption during power transferring: 1) passive and active driving principle of hoisting paper and swing part of power shovel; 2) integrated balance and active control principle of hydraulic- pneumatic storing of potential energy for hydraulic shovel; 3) passive and active hybrid driving principle of heavy swing part using hydraulic motor unit; 4) hydraulic oil cooling based on cooperation of regenerative power generating and active air cooling. By investigating the scientific problems and exploring the new principles of efficient open-air coal mining, the project will provide novel and advanced principles and approaches for efficiency improvements of power shovel and hydraulic shovel.

电铲和液压铲是露天煤矿开采最重要的挖掘装备，特征是质量大、装机功率大、长期连续运行、能耗巨大。研究表明，电铲的能量损失主要产生在上车回转制动和提升机构下放的电机制动过程；液压铲存在节流损失、动臂下放势能损失、回转制动动能损失和冷却系统附加损失，能效更低。显然，要降低这两种装备的能耗，关键是高效回收利用损失掉的动势能，但由于作业中，大功率驱动能量在动力源与执行器之间高频次、快速转换和传递，需要有高能效实时调控能量快速变化的方法。因此，围绕这两种装备运行中能量传递、转换与作用规律的科学问题，结合具体装备耗能特点，提出电铲提升机构与上车回转液-电混合主被动复合驱动，液压铲举升装置重力负载液-气储能平衡与低压损主驱动一体化控制、上车回转体多液压马达主被动复合驱动、热油液再生发电与主动送风协同冷却，4个能量快速变化实时调控的创新解决方案开展研究，探索露天煤矿挖掘装备高能效运行的新原理和新方法。

电铲和液压铲是露天矿山开采关键装备，机重大、装机功率大、长期连续运行、能耗巨大。研究表明，电铲能耗主要产生在上车回转和提升机构下放的电机制动过程；液压铲存在大的节流损失、动势能损失和冷却系统附加损失，能效更低。显然要降低这两种装备能耗，关键是高效回收利用损失掉的动势能，但由于作业中，大功率驱动能量在动力源与执行器之间高频次、快速转换和传递，需要有高能效实时调控能量快速变化的方法。因此，围绕这两种装备运行中能量传递、转换与作用规律的科学问题，提出了4个能量快速变化实时调控的创新解决方案开展研究。.提出的液-气储能平衡重载直线机构驱动原理，降低直线机构运行能耗达70%，装机功率降低60%，可节约整机燃油26%；主被动复合大惯性回转体驱动原理，降低回转体运行能耗46%以上；与现有技术相比，新原理具有传递链短、能量转换效率高、可大幅降低系统装机功率等优势。提出的基于元件试验和真实物理结构的数字样机设计方法，突破了液压挖掘机整机机、电、液、热、控制系统及载荷的实时信息交换和协同计算瓶颈，建立了系列化挖掘机数字样机平台，指导新机型设计并预测可能存在问题。基于此平台，成功研发出国内首台机重260 t和390 t的超大型液压铲。研究成果为我国自主研发高能效、低排放大型矿山挖掘装备提供了新原理和新方法。.在IEEE Transactions on Industrial Electronics、 Energy Conversion and Management、机械工程学报中英版等行业顶级期刊和学术会议发表论文68 篇，其中SCI索引期刊25篇（SCI 1区 Top期刊论文12篇），EI索引期刊21篇。项目核心内容凝练的科学难题大型移动液压装备高效节能运行机制，入选教育部征集的《10000个科学难题制造科学卷》。获山西省科技进步二等奖1项，“上银优秀机械博士学位论文奖”银奖1项、“中国煤炭学会青年科学技术奖优秀博士学位论文”1项，山西省优秀博士学位论文2篇、优秀硕士论文2篇。研究成果正转化应用。