迈步行走主动激振式掘支一体机截割载荷特性及其优化控制研究

The background of this research is based on the safe, efficient and intelligent driving operation of a stepping-type active vibration excitation drivage-support integrative machine which concurrently operates with multiple cutting heads. Combining experiment research, numerical simulation and theoretical analysis, the mechanical characteristics of elastic, plastic and fracture processes in coal rock breaking by cutting heads are to be investigated, and the influence of vibration characteristic of cutting picks on that mechanical characteristics is to be studied. The inter-coupling relationship of three characteristics including cutting load of cutting heads, vibration and active excitation of the machine is to be analyzed. The non-linear stochastic coupling dynamics model for the system of the drivage-support integrative machine and the surrounding rocks is to be constructed. By numerical simulation and experimental study, the dynamic response of the system is to be analyzed and the influential mechanism on the dynamic cutting load by the coupling effect of multiple factors (machine body vibration, etc.) is to be revealed. The coupling dynamic response model of the dynamic support for roof and floor of tunnels is to be constructed, dynamic support constraint for roof and floor of tunnels is to be studied. Taking advancing velocity, active excitation frequency and amplitude of cutting heads as control variables, aiming at the optimization of cutting efficiency and energy consumption, regarding the non-linear stochastic coupling dynamics model for the system of the drivage-support integrative machine and the surrounding rocks as resolver, considering the roof and floor supporting condition as constraints and binging in rapid non-dominated sorting genetic algorithm, this research is devoted to construct self-adaptive dynamic optimization methodology for the control of cutting load under the concurrent operation effect of multiple cutting heads. The accomplishment of this research can realize the autonomous control of operating process for the drivage-support integrative machine and provide theoretical support for the development of multifunctional drivage-support integrative machine with high efficiency.

以研究一种迈步行走主动激振式多截割头并行作业掘支一体机满足安全高效智能化掘进作业的工程需求为背景，通过理论、实验、数值模拟相结合，研究截齿破岩的弹性、塑性、断裂过程的力学特征，以及截齿振动特性对其影响机理；研究截割头截割载荷、机身振动、主动激振特征的相互耦合关系，构造围岩-掘支一体机系统非线性随机耦合动力学模型，采用数值模拟和实验研究，分析系统的动力响应，揭示机身振动等多因素耦合作用下截割动载荷的影响机制；建立顶底板动态支护耦合动力响应模型，研究顶底板的动态支护约束，将截割头推进速度、主动激振频率和振幅作为控制变量，以截割效率和能耗为优化目标，以围岩-掘支一体系统的非线性随机耦合动力学模型为解析器，以顶底板支护条件为约束，引入快速非支配排序遗传算法，建立多截割头并行作用下截割载荷的自适应动态优化控制方法，实现掘支一体机作业过程的自主控制，为研制多功能高效掘支一体机提供理论支撑。

掘支一体机是旨在解决煤矿井下采掘失衡问题，提高煤炭生产效率的新一代巷道掘进装备。但该设备在作业过程中，仍存在截割控制精度低、激振器激振特征对破岩效果的作用规律不明，支护装置与围岩耦合作用机理不清，截割载荷控制方法不详等问题。为此，本课题采用理论、实验、数值仿真相结合的综合研究方法，针对掘支一体机截割载荷特性、围岩-掘支一体机系统动力学特性、顶底板动态支护约束、截割载荷自适应优化控制等关键科学问题，开展了深入的研究与探索，取得了如下创新性成果：.(1)掌握了井下综掘巷道围岩变形特征和主要破坏规律，探明了不同外激励对截割部受迫振动的响应规律，建立了含机身振动特征和主动激振特征的截割载荷模型及截齿破岩数学模型，得出了系统最优激振频率和激振振幅，阐明了运动参数变化对截割载荷、载荷波动系数及截割比能耗的影响。.(2)依据顶板支护要求，构建了围岩-掘支一体机系统非线性随机耦合动力学模型，研究了多截割头并行作业下支护装置与顶底板动力耦合作用关系，得到了掘支一体机支护顶板的动态约束条件。.(3)提出了一种巷道断面定形截割控制技术，探明了不同油缸位移传感器误差等级对截割头在巷道空间内定位偏差精度的影响规律，阐明了截割头对巷道外轮廓的创成机理，掌握了截割头结构参数、运动参数对截割表面形貌特征的影响规律。.(4)提出了基于液压转阀的主动激振辅助截割破岩理论，设计了液压激振系统，分析了激振缸腔压力、激振振幅、速度、加速度变化规律，基于EDEM离散元软件仿真模拟了传统截割与主动激振截割工况，研究了不同激振方式下截落煤岩颗粒数量、颗粒截落速度、颗粒空间散落位置分布规律；数值模拟和分析了多组不同控制变量组合下的截割载荷的动态自适应优化控制效果；.(5)提出了基于模糊PID的截割载荷自适应动态优化控制方法，设计了截割头空间运动轨迹模糊控制器，研究了巷道断面定形定向截割控制技术，进行了截割头动态截割过程截割误差仿真分析。.直接相关成果在项目开展期间发表学术论文25篇，申请国家发明专利25项，实用新型专利40项，其中授权国家发明专利6项，实用新型专利14项；培养博士研究生8人，硕士研究生9人，参加国内外学术合作交流活动7人次；获辽宁省专利奖二等奖1项，省部级奖励3项，主持及参与省部级重点项目3项，获得人才称号5人次。