Russia and Bulgaria discussed the potential for expanding cooperation. Roadheaders Advantages of radio monitoring equipment

The results of industrial research on the reliability of mining combines of selective action

A.S. Nosenko, A.A. Domnitsky, I.A.Nosenko

Shakhty Institute (branch) YRSPU (NPI) named after M.I. Platova

Abstract: The paper presents the results of industrial research on the reliability of KP21 mining shearers, manufactured by OJSC Kopeysk Machine-Building Plant in the conditions of the Almaznaya mine of the Gukovugol Management Company when carrying out preparatory workings with a cross section of up to 16 m2 with a strength of the enclosing rocks up to 7 units. on the scale of prof. M.M. Protodyakonov. Using the mathematical apparatus, the mathematical expectation, variance, standard deviation, coefficient of variation, etc. are established.

Key words: mining shearer of selective action, reliability, operating time to failure.

The roadheading machine of selective KP21 (Fig. 1) of domestic production is used for high-speed mining workings with a cross section of up to 30 m, for rocks with a strength of 7-10 units. on the scale of Professor M.M. Protodyakonov. It is used, in particular, in the construction of transport tunnels. The difference between the model under consideration and the previously known ones is the use of a hydraulic drive, which is very important.

In the Eastern Donbass region, the KP21 roadheader was used for the first time by the Gukovugol company when carrying out haulage drift No. 109, 1200 meters long at the Almaznaya mine.

Based on the “Methodology for organizing the collection and analysis of information on the performance of mining equipment in the Russian Donbass” by the Shakhty Institute (branch) of the YRSPU (NPI) named after M.I. Platov, together with OJSC "KMZ", industrial research was carried out to obtain information about its operation.

The observations were carried out for 20 months. During the reporting period, 2

workings with a length of 2200 meters (30 thousand meters) and 1200 meters (17450 m). The penetration rate was 252 m / month. In general, 100 failures were revealed for the combine.

Figure: 1. - Roadheader KP21

The most serious ones include: loosening of the heads of the bolts for fastening the flanges of the crown brakes, failure of the bearings of the gearboxes of the scraper arms and the working body, fracture of the conveyor star, wear of the sheets of the rotating part of the conveyor.

During the operation of the harvester, undercutting of roof rocks with a strength of up to 12 units took place, which affected the resource of the harvester. The distribution of the number of failures over the period of operation of the combine is shown in the diagram (Fig. 2).

As a result of the analysis of the data obtained, the operating time to failure was determined, as well as a list of parts and assemblies that affect the reliability of the harvester (table No. 1).

The research results formed the basis for further improvement of the mining machine of this standard size. Reinforced cutter brakes. A new design of the raking part has been developed, in which the raking arms are replaced by grooved discs. The arrangement of the gearboxes of the undercarriage has been changed. Variants of using the combine with a bunker reloader are considered.

Figure: 2. - Distribution of the number of combine failures by parts

Table No. 1 Indicators of reliability of the combine KP21 head. No. 20

Assembly Failed Quantity Operating time up to

unit node of failures 3 failures, m

Working body Gearbox: bearing No. 2 14000

Brake clutches 4 7500

Electric motor 3 9000

Loading Gearbox:

body bearing No. 7612, 8 6000

pinion shaft No. 0202087,

bevel wheel 2 27500

№ 0202009 2 24000

Backstage bearing 1 29000

Conveyor Reducer:

bearing No. 7610 3 9000

Star 2PNB2.13.86.220-01 2 20000

Scraper chain 2 19000

Stav sheets 6 12000

Undercarriage Track chain 3 19000

Hydraulic drive Telescope jack 6 19000

High pressure hose 9 21000

Metal tubes 5 12000

Hydraulic motor 1 27000

The obtained statistical parameters are used to calculate the random values \u200b\u200bof operating time to failure. The working conditions of the combines are shown in Table 2.

Table No. 2

Working conditions of combines KP21

№ p / p Serial number № Production Observation period, months. Sizes of working in rough / in 2 light, m \u200b\u200bRock hardness, units

1 KP-21 Head. No. 20 Conveyor drift No. 109 7 15.9 / 13.5 2 - 5/7

2 KP-21 Head. No. 34 Conveyor drift No. 113 20 16.0 / 15.2 2 - 5/7

Failures corresponding to individual units of each of the investigated combine are shown in Figure 3.

As can be seen from the diagrams above, a significant volume of failures belongs to the loader and is 40%. The weakest elements in terms of reliability are the chain pins (80%) and the drive sprocket (90%). The weak point of the loading body is the gearbox (85%). In the chassis, the main failures are tracks (90%). The working body has an unfinished hydraulic jack and a telescope boom brake (70%).

The statistical analysis of the results of observations of the performance of KP21 combines was made in accordance with the recommendations.

Based on the obtained experimental data, a statistical series of random variables (RV) was formed from 83 realizations X of the operating time to failure, with Xtp \u003d 23.0 r.m., Xmax \u003d 177.4 r.m. In this case, A1 \u003d 10; k \u003d 18.

For each interval, the following are calculated: n is the number of values \u200b\u200bof the random

values \u200b\u200bthat fall into the interval: u / n - frequency, ^ - - accumulated

frequency, p / pL1 - empirical probability density, p.m-1.

Figure: 3. - Distribution of failures by parts of KP-21 roadheaders. a) - combine KP-21 No. 20; b) - combine KP-21 No. 34; 1 - executive body, 2 - raking part, 3 - conveyor, 4 - fastener, 5 - undercarriage.

As a result, the calculated values \u200b\u200bof the statistical standard deviation of the SW: cx "\u003d 32.2 r.m. and the coefficient of variation y / \u003d 0.79.

Figure 4 shows a diagram of the SW distribution density. In the case when the form of the theoretical distribution function is not known,

the diagram serves as the basis for determining the theoretical distribution function.

Figure: 4. - Histogram of exponential distribution

/ (X) \u003d 0.025 e "" CB operating time to failure

As a result of processing the results obtained, it was found that the random values \u200b\u200bof the operating time to failure X of roadheaders obey an exponential distribution law.

The probability density of a random variable subject to an exponential distribution law is described by the expression:

Taking the value mx \u003d 41 r.m. as the mathematical expectation, we obtain / (X) \u003d 0.025 e -0 "025X.

As a result of the studies and calculations, a leveling distribution curve was built (Figure 6), which is a graph of the theoretical function f (X).

To establish the correspondence of the hypothesis put forward to statistical materials, K. Pearson's criterion of agreement x was used, the value of which is calculated by the formula:

where k is the number of intervals C, ni is the number of RV values \u200b\u200bin the i-th interval, n is the total number of obtained RV values, pi is the theoretical probability of RV falling into the i-th interval.

Figure: 5. - The graph of the theoretical function f (X) \u003d 0.0244-e - "

The probability p \u003d 0.01 obtained as a result of calculations is sufficient (p<0,1). Таким образом, считаем, что экспериментальные данные удовлетворяют принятому закону распределения СВ.

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This modification of the SEU system was developed for the KP series selective roadheaders manufactured by Kopeysk Machine Building Plant JSC.

The SEU M2D system is the result of invested effort and vast experience in operating systems of previous generations.

At the moment, the system is serially equipped at the plant of JSC "KMZ"

Roadheader KP21-14
Roadheader KP150
Roadheader KP220

The complete set of control equipment includes all the necessary subsystems, control units, control panels and actuators to ensure control of power electrohydraulics, power supply and protection of various units and elements of the mining machine.

During the development, considerable emphasis was placed not only on the safety of the machine, but also on the safety of the operating personnel and ensuring comfortable handling.

As a result, the efficiency of tunneling operations increases, including due to equipment downtime during unplanned repairs.

The electrohydraulic control system of the SEU "M2D" provides the following functions, which will be described in more detail below.

Remote radio control of the harvester
Combine control from the console located at the driver's workplace
Diagnostics of the presence of faults in individual elements of the system
Microprocessor protection and control of electric motors of the combine
A set of sensors for monitoring a wide range of parameters of the combine operation
A system for transmitting data to the surface, visualizing and generating analytical reports at the workplace of the mining dispatcher and computers of the management team
Pre-start warning and audible alarm
Other

1. Control panel PU2 SEU2.10.00.000-01

The PU2 control panel is a microcontroller with a 7-inch full-graphic display, a reliable keyboard with an opto-isolated contact and non-volatile memory. PU2 is installed in a specialized cassette, which reliably protects it from mechanical damage, simplifies and increases the reliability of installation.

PU2 in the M2RD system performs the following functions:

control of individual executive devices of the combine from the driver's workplace;
displaying the parameters of the system and outputting operational information to the display;
control and transmission of information about the state of the EMS system;
diagnostics of faults in individual elements of the system;
event log entry, incl. in black box mode

2. A set of radio remote control equipment for the KADRUK combine

The KADRUK equipment provides remote radio control of the combine in the line of sight. The body of the radio control panel RPDU AUK75D.70.200.000 is made of durable fiberglass. The combination of joysticks and a push-button keyboard provide convenient and intuitive control of the combine's executive devices.

The RPDU battery is charged directly in the mine without lifting "to the surface" when the RPDU is connected with a cable jumper to the PU2. At the same time, the RPDU continues to function as a wired remote control.

Also, to increase the safety of mining operations, the RPDU is equipped with an automatic general emergency stop in case of a fall.

3. A set of equipment for installation in the Control Station

The kit includes auxiliary equipment of the system that switches and controls individual functional units, collects information from various sensors, controls the power supply of electrohydraulic valves, power supply of the system, and Drive monitors MP1.

MP1 drive monitor

The MP1 drive monitor is a microprocessor-based device for control, monitoring and protection of an electric motor. MP1 is equipped with a contactless current sensor and is connected to the central microcontroller (Control Panel PU2) via the digital CAN interface. The MP1 drive monitor has the ability to monitor the operability of the vacuum contactor control unit circuit for switching the afterburner current modes to the holding current, which is necessary for vacuum contactors with electromechanical control of modes.

Main functionality of the MP1 drive monitor:

control of the technological overload current of the electric motor with the formation of a "reverse-current-time" protective characteristic (the settings for overload, overload are set from the system menu, stored in the non-volatile memory of the control panel PU2);
shutdown of the electric motor in case of technological overload;
storing in the "Black box" in real time information about the achievement of the motor currents of the values \u200b\u200bof the overload settings and the values \u200b\u200bof the overload currents during the period of the protective characteristic;
control of the overturning (or "jamming") current of the electric motor with the formation of a protective characteristic and the shutdown of the electric motor in the event of "overturning" or "jamming";
inrush current control with saving in the memory of the “inrush current profile”. Determination of the completed start for various conditions of starting the electric motor and disconnecting the electric motor before the "failed" start;
short-circuit current monitoring at the outgoing connection (in the load) with shutdown of the electric motor in the event of a "short circuit";
monitoring of 3-phase voltage (660 / 1140V) in the load, monitoring of phase imbalance in the load. In the event of an "unacceptable phase imbalance" - signaling and shutdown of the electric motor;
monitoring the state of temperature sensors (thermal relays or posistors) built into the stator windings and (or) bearing assemblies of electric motors, with automatic monitoring of the closed state of the line to the temperature sensor and turning off the electric motor if the winding and bearings overheat;
measurement of the insulation resistance of the outgoing connection to the contactor (power cable and stator winding) before switching on the load (electric motor) with storing the measured insulation resistance value (30 kOhm ... .5 Mohm) in the module memory for automatic comparison with the value "from start to start" (forecast of resistance changes insulation for PPR);
protection against "frequent starts" in accordance with the restrictions imposed in the technical specifications for electric motors;
automatic calculation of the active power of the drive electric motor, taking into account the calculation and storage in the memory of the energy consumption kW * h (data transfer to the main control panel PU2 of the system of electrohydraulic control of the SEU). Accounting for the operating time of the drive ("engine hours", the number of starting cycles, including those with maximum load) with the fixation of these parameters in the non-volatile memory of the MP and the system of the SED;
monitoring the serviceability of the vacuum contactor with automatic checking of the time intervals for switching on (including in the "forcing" mode) and switching off according to the actual development of the auxiliary contacts and according to the signals of the current sensors (in all three phases);
identification of attempts to block the vacuum contactor "mechanically" with the preservation of this event in the ESP system;
identification of malfunctions of control units of vacuum contactors responsible for switching from the "Afterburner" mode to the "Hold" mode by measuring the currents of the forced mode and the holding mode (relevant for vacuum contactors that have mode control via a block contact, the so-called "electromechanical circuit switching ").

4. Set of electric hydraulic control of the combine

Designed for electro-hydraulic control of power hydraulics of roadheader mechanisms: executive body (moving, telescoping), feeder, combine travel, conveyor, supports, support lifter, loading.

In the SEU "M2D" System, the EGR SEU.14.00.000 Electrohydraulic distributor is used as a control electrohydraulic valve, which is a control electrohydraulic unit for 2 commands. The SEU "M2D", which is serially supplied to the roadheaders KP21-02, KP21-04, KP21-150, KP220, includes a set of 14 Electric hydraulic valves.

The EGR is controlled remotely using the PU2 Control Panel or another control device, incl. according to a given program and algorithm in automatic mode, or in manual mode, using the lever for moving the electromagnet spool.

5. Equipment for control of parameters of ACP and equipment for radio monitoring

It is a set of digital sensors for collecting data on the condition of the roadheader elements:

monitoring of pressure in hydraulic lines;
monitoring the position of the executive body;
monitoring the temperature of gearboxes, oil and other elements;
monitoring the oil level in the gearboxes and in the oil tank;
monitoring the concentration of methane and other gases;
other.

The system can use both "classic" wired sensors and radio monitoring equipment, which is a set of wireless sensors transmitting the measurement results via a radio channel to the reader installed on the combine (radio modem - stationary radio frequency unit URCHS-JN).

Advantages of radio monitoring equipment:

The ability to transmit data over a radio channel at a distance of up to 30m;
No external power supply, battery support;
The absence of cables and connectors, which allows placing the components of the equipment in hard-to-reach places, protects against a break in the communication line and increases noise immunity;
Full diagnostic control, which excludes "sensor imitation";
High resistance to overloads, dynamic pressure drops and vibrations due to the design features of the sensors;
Significant simplification of installation due to the absence of cable jumpers;

Radio pressure sensor DDR1

All radio sensors have a built-in battery power supply. Battery life: 9 months.

One radio modem (Radio frequency stationary unit URCHS-JN) collects data from 16 radio sensors. Data transmission from the radio modem to the command controller (Control Panel PU2) is carried out via the digital interface MODBUS (RS485).

The completion of the first stage of structural transformations in the mining industry of the Russian Federation is characterized by a change in the formation of its financial resources, now this is happening exclusively through the sale of industry products.

Remained in the past is the period of a prolonged decline in production volumes during the restructuring of the industry; in recent years, one can observe a clear trend of growth in mining, and changes for the better in the technical and economic indicators of the development of the mining industry. The government of the country has adopted the "Energy Strategy

Russia for the period up to 2020 ”, which set the task to increase the volume of coal production to 410-450 million tons per year and increase the share of coal in electricity generation from 34 to 44%.

To fulfill this strategic task by the specified time, it is necessary to significantly increase the production capacity of the industry's enterprises.

This can be achieved by modernizing existing enterprises, as well as building new ones. At the same time, the Government's Program provides for the increase in capacity until 2010 through technical renovation, and the period 2011–2020. should be characterized by a radical change in the technical level of the production process itself.

As the advanced foreign experience shows, high performance in coal mining can be achieved by concentrating production at promising mines. This process is based on the technical re-equipment of treatment facilities, which leads to major changes in the preparatory work.

This means that, first of all, such events should affect the most progressive harvester method. Today, shearer tunneling at the leading coal enterprises of Kuzbass covers up to 98% of the total volume of work.

In the mining equipment park of the Russian coal industry, there are up to 400 roadheaders, of which about 250 are in Kuzbass. The main mass is made up of GPKS-type combines manufactured by the Kopeysk Machine-Building Plant. Analyzing the state of tunneling equipment, one can state a steady decline in the technical level of the fleet of machines.

The wear and tear of miners at major coal companies is a warning sign of possible disruption in an ever-increasing volume of preparatory work.

Heading machine GPKS

Produced by the Kopeysk Machine-Building Plant. Its purpose is mechanized breaking and loading of rock mass during horizontal and inclined mining of coal and rock. Combine 1GPKS-00 in the basic model was designed for horizontal and inclined workings with a slope of up to ± 12 °. On the latest modifications of the combine, devices are already provided that can hold the combine on slopes up to ± 25 °.

The fleet of roadheaders in the Russian coal industry is mainly equipped with roadheaders of the GPCS model, in particular in Kuzbass, up to 97% of the total number of roadheaders.

Roadheader P 110

A harvester with selective action, has a boom working body, the harvester is used for mechanized destruction with subsequent shipment of rock mass. It is used when it is necessary to make an arched, trapezoidal or rectangular tunnel with a cross-sectional area of \u200b\u200b7 to 25 m2. Driving can be made with a slope of ± 12 ° in a coal or mixed face with a maximum rock strength of 95 MPa (f \u003d 7) and an abrasiveness of about 15 mg in mines where there is a danger of gas and dust.

Roadheader KP 21

It has been produced by the Kopeysk Machine-Building Plant since 2000; over the past period, only positive reviews have been received about its work. His excellent work was appreciated both in Russia and in foreign countries. Roadheaders KP21 are designed for mechanization of destruction and subsequent shipment of rock mass when horizontal and inclined mine workings are performed.

Combine KP21 was presented at a number of international exhibitions and has deserved awards. As one of the best exhibits, he was awarded a diploma and a medal at an exhibition held last June in Novokuznetsk.

OJSC “KMZ” and a large Iranian company “Sabir” have established productive cooperation, in March last year, fulfilling an order from this company, a batch of two KP21 roadheaders was manufactured and sent to Iran.

Roadheader KSP 32

Heading combines of the middle series KSP-32 are intended for mechanized destruction and subsequent shipment of rock mass from the place of mine workings horizontal and inclined up to ± 12 degrees.

The cross-section of the workings can reach up to 33 sq. m with coal sinking and in a mixed face. It is allowed to work under conditions with the ultimate strength of the destroyed rock up to 95 MPa (f \u003d 8) and abrasiveness up to 15 mg in mines where there is a danger of gas contamination (methane) and coal dust.

The KSP-32 roadheader is controlled from a portable remote control. The harvester was designed and manufactured in 1998 at the Yasinovatskiy Machine-Building Plant in Donetsk.

Roadheader KPD

It is intended for destruction of rock, followed by cleaning and transportation of the destroyed rock mass during the development of development workings. The cross-section of the workings in shape can be arched, trapezoidal and rectangular in cross-section from 11 to 25 m2.

The design features possessed by the harvester are a swept telescopic type of executive body, on which the axis of lateral rotation, this device allows you to effectively destroy rocks and at the same time ensure a stable position of the harvester;

there are options for installing electric motors of different power on the executive body, which allows, depending on the strength of the rocks to be destroyed, to choose the most cost-effective cutting mode;

the loading body, made in the form of shoveling stars, shows a high loading intensity, it is possible to work effectively in flooded workings.

Roadheader EBZ 160

It is used to work in mine workings for coal, on mixed faces, they are also used when driving tunnels. When driving tunnels and breaking coal seams, the most suitable conditions for a shearer are considered to be rock hardness up to 75 MPa.

Under these conditions, the combine shows the highest results in cutting, loading and transporting rocks. The roadheader has an excellent layout, which provides a low center of gravity, a convenient control system, and reliably operates in uprising.

Chinese roadheaders

In Ukraine, the Donetsk company DTEK and the Chinese SANY Heavy Equipment Co., Ltd (China) signed a memorandum in which they expressed mutual understanding and intention to supply Ukraine with the latest mine equipment and coal mining technologies. The signed document also determined the priority areas of cooperation, which will consist in the supply of equipment and technologies, the procedure for the provision of warranty and maintenance services has been agreed. By 2014, it is planned to purchase cleaning equipment and several dozen units of roadheaders.

At a press conference, a representative of SANY Heavy Equipment stressed that several Chinese roadheaders are already operating at the mines of the Donbass company, and they show good results in the conditions of Donbass.

Andrey Smirnov, speaking at the same press conference on behalf of the DTEK Directorate, explained that along with the purchases of domestic equipment, given the significant increase in coal production, the DTEK Directorate also decided to purchase Chinese roadheaders. A. Smirnov explained this decision by the fact that the equipment planned for purchase is distinguished by reliability, safety and a fairly high degree of computerization, which is not the case with domestic combines. The resource declared by the Chinese manufacturer for its equipment is 30-50% higher than that of domestic combines, and the warranty period is 20 months, which shows how confident Chinese manufacturers are in the quality of their machines.

Roadheader JOY

Starting in 2005, new JOY roadheaders have been supplied to the mines of OJSC SUEK. This model of the harvester was designed specifically for work in the conditions of Kuzbass mines.

The harvester is equipped with semi-automatic drilling rigs of the HFX type, which made it possible to abandon the primitive method of drilling with manual rigs and thereby increased the level of work safety. Since 2008, dust extraction systems have appeared on new combines, which have created more comfortable conditions for the operators of the combine.

The JOY roadheader allows the company to increase the pace of work in mine workings three to four times compared to the average per crew. In the future, equipment of this class will allow to increase the level of preparation of the clearing front - up to 1000 meters per month per brigade.

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