Operating manual for roadheader kp 21. Information and analytical portal "mining"
This modification of the SEU system was developed for tunneling machines of selective action of the KP series, manufactured by Kopeysk Machine-Building Plant JSC.
The SES M2D system is the result of invested efforts 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 provide control of power electrohydraulics, power supply and protection of various components and elements of the mining machine.
Significant emphasis during development was placed not only on the safety of the machine, but also on the safety of the operating personnel and ensuring comfortable operation.
As a result, the efficiency of tunneling operations increases, including due to equipment downtime during unscheduled repairs.
The electro-hydraulic control system of the SEU "M2D" provides the following functions, which will be described in more detail below.
- Harvester radio remote control
- Combine harvester control from the control panel located at the driver's workplace
- Diagnostics of the presence of malfunctions in individual elements of the system
- Microprocessor protection and control of combine motors
- A set of sensors to control a wide range of parameters of the combine
- System for data transmission to the surface, visualization and generation of analytical reports at the workplace of the mining dispatcher and computers of the management staff
- Pre-start warning and emergency sound signaling
- Other
1. Control panel PU2 SEU2.10.00.000-01
The control panel PU2 is a microcontroller with a 7-inch full-graphic display, a reliable keyboard with 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 system of SEU "M2RD" performs the following functions:
- individual executive devices harvester from the workplace of the driver;
- displaying the parameters of the system and displaying operational information on the display;
- control and transmission of information about the state of the EMS system;
- diagnosing the presence of faults in individual elements of the system;
- event log entry, incl. in black box mode
2. A set of equipment for remote radio control of the KADRUK combine
The KADRUK equipment provides remote radio control of the harvester in the line of sight. The body of the Radio Remote Control 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 combines' actuators.
The RPDU battery is charged directly in the mine without lifting “to the surface” when the RPDU is connected by a cable jumper to PU2. At the same time, the RPDU continues to function as a wired remote control.
Also, to improve the safety of mining operations, the RPDU is equipped with an automatic general emergency “stop” function in case of a fall.
3. Set of equipment for installation in the Control Station
The kit includes auxiliary equipment of the system, which performs switching of individual functional units and their control, collection of information from various sensors, power control of electrohydro valves, power supply to the system, as well as MP1 drive monitors.
MP1 drive monitor
MP1 drive monitor is a microprocessor-based device for control, monitoring and protection of the electric motor. MP1 is equipped with a non-contact current sensor and is connected to the central microcontroller (Control panel PU2) via the CAN digital interface. The MP1 drive monitor has the ability to monitor the health of the vacuum contactor control unit circuit by switching the “afterburner” current modes to the “holding” current, which is necessary for vacuum contactors with electromechanical control modes.
Main functionality MP1 drive monitor:
- control of the technological overload current of the electric motor with the formation of a "reverse-current-time" protective characteristic (settings for t.overload, t.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;
- saving in the "Black Box" in real time information about the motor currents reaching the values of the overload settings and the values of 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 turning off the electric motor in the event of a “turnover” or “jamming”;
- control of the starting current with the preservation of the "profile of the starting current" in the memory. Determination of the completed start for various conditions of starting the electric motor and switching off the electric motor before the "failed" start;
- control of the short circuit current at the outgoing connection (in the load) with the electric motor switched off in the event of a "short circuit";
- control of 3-phase voltage (660/1140V) in the load, control of phase imbalance in the load. In the event of an "inadmissible phase imbalance" - alarm and shutdown of the electric motor;
- monitoring the status of temperature sensors (thermal relays or posistors) built into the stator windings and (or) bearing assemblies of electric motors, with automatic control of the closed state of the line to the temperature sensor and turning off the electric motor in case of overheating of the winding and bearings;
- 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 the measured value of the insulation resistance (30kΩ ... .5MΩ) stored in the module memory for automatic comparison with the value “from start to start” (prediction of resistance changes isolation for PPR);
- protection against "frequent starts" in accordance with the restrictions imposed in the specifications for electric motors;
- automatic calculation of the active power of the drive electric motor, taking into account the calculation and storage of energy consumption kWh (data transfer to the main control panel PU2 of the electro-hydraulic control system of the SEU). Accounting for the operating time of the drive (“motor hours”, the number of start-up cycles, including those with maximum load) with fixing these parameters in the non-volatile memory of the MP and the SEU system;
- control of vacuum contactor serviceability with automatic checking of time intervals of switching on (including in the “forcing” mode) and switching off according to the actual working out of the auxiliary contacts and according to the signals of the current sensors (in all three phases);
- detection of attempts to block the vacuum contactor "mechanically" with the preservation of this event in the ECS system;
- detection of malfunctions of vacuum contactor control units responsible for switching from the "Forsage" mode to the "Hold" mode by measuring the currents of the forced mode and the hold mode (relevant for vacuum contactors that have mode control by auxiliary contact, the so-called "electromechanical circuit switching").
4. Harvester electrohydraulic control kit
Designed for electro-hydraulic control of power hydraulics of tunneling machine mechanisms: executive body(moving, telescoping), feeder, combine travel, conveyor, supports, crepe lifter, loading.
In the SEU "M2D" System, the EGR SEU.14.00.000 Electrohydraulic Distributor is used as a control electro-hydro valve, which is a control electro-hydraulic block for 2 commands. The SEU "M2D" serially supplied to roadheaders KP21-02, KP21-04, KP21-150, KP220 includes a set of 14 electrohydraulic distributors.
The EGR is controlled remotely using the Control Panel PU2 or other control device, incl. according to a given program and algorithm in automatic mode, either in manual mode, using the lever for moving the electromagnet spool.
5. Equipment for monitoring automatic transmission parameters and radio monitoring equipment
It is a set of digital sensors for collecting data on the state of roadheader elements:
- pressure monitoring in hydraulic lines;
- monitoring the position of the executive body;
- temperature monitoring of gearboxes, oil and other elements;
- oil level monitoring in 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 that transmit measurement results via a radio channel to a readout device installed on the combine (radio modem - Stationary Radio Frequency Unit URChS-JN).
Advantages of radio monitoring equipment:
- Ability to transmit data over a radio channel at a distance of up to 30m;
- No external power supply, battery backup;
- The absence of cables and connectors, which allows you to place equipment components 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;
DDR1 radio pressure sensor
All radio sensors have built-in battery power. Battery life: 9 months.
One radio modem (Unit radio frequency stationary URCHS-JN) collects data from 16 radio sensors. Data transfer from the radio modem to the controller (Control panel PU2) is carried out via the digital interface MODBUS (RS485).
Roadheader KP25
The roadheader KP25 is designed for mechanization of breaking and loading of rock mass during horizontal and inclined workings of ±12°. improving working conditions at the driver’s workplace. The use of hydraulic motors as a drive for the undercarriage and feeder provides convenience and safety in maintenance and reliability. maintenance of the hydraulic system. There is no work on the construction of lining convenient and safe. The combine can be dismantled into component parts that are convenient for descending into the mine and transporting through mine workings.
Specifications
|
Technical performance: |
|
| - for coal, m3/min (t/min) | 2,4 |
| - by breed STszh<100МПа, м3/мин | 0,2...0,3 |
| Specific pressure on the soil, MPa | 0,12 |
|
Chassis: |
|
| - drive unit |
hydraulic |
| - travel speed, m3/min | 6 |
| - pulling force, t | 36 |
|
Executive limit: |
|
| - cutting speed, m/s | 2 |
| - bit rotation frequency, min-1 | 50 |
|
Hydraulic system |
|
| - maximum pressure in the hydraulic system, MPa | |
| - working fluid | industrial sectional oil |
| - hydraulic distributors | manually operated |
|
Feeder |
|
| - drive unit | electric |
| - number of paw swings, min-1 | 46 |
| - feeder width, mm minimum | 2200 |
| - feeder width, mm maximum | 3200 |
|
Irrigation system |
|
| - working pressure, MPa | 1,5 |
| - maximum flow, l/min | 150 |
|
Conveyor |
|
| 1,0 | |
| - chute width, mm | 550 |
|
Conveyor |
|
| - scraper chain speed, m/s | 1,0 |
| - chute width, mm | 550 |
|
electrical equipment |
|
| - voltage of power circuits, V | 660
|
| - total power of electric motors, kW | 216,5 |
| - drive power, kW of the executive body | 196,5 |
| - feeder | 110/55 |
| - conveyor | 30 |
| - pumping station | 55 |
| Harvester weight, t no more | 40 |
The results of industrial studies of the reliability of mining machines of selective action
A.S. Nosenko, A.A. Domnitsky, I.A. Nosenko
Shakhty Institute (branch) SRSPU (NPI) named after M.I. Platova
Abstract: The article presents the results of production studies of the reliability of KP21 roadheaders manufactured by OAO Kopeysk Machine-Building Plant in the conditions of the Almaznaya mine of Gukovugol Management Company during development workings with a cross section of up to 16 m2 with a hardness of host rocks up to 7 units. according to the scale of prof. M.M. Protodyakonova. With the help of the mathematical apparatus, the mathematical expectation, variance, standard deviation, coefficient of variation, etc. are established.
Key words: tunneling machine of selective action, reliability, operating time to failure.
The selective tunneling machine KP21 (Fig. 1) of domestic production is used for high-speed excavation 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. Protodyakonova. It is used, in particular, in the construction of transport tunnels. The difference between the model under consideration and 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 Gukovugol when hauling roadway No. 109, 1200 meters long, at the Almaznaya mine.
On the basis of the “Methodology for organizing the collection and analysis of information on the performance of mining equipment in the conditions of the Russian Donbass” by the Shakhty Institute (branch) of the SRSPU (NPI) named after M.I. Platov together with JSC "KMZ" conducted a production study to obtain information about its operation.
Observations were carried out for 20 months. During the reporting period, 2
workings with a length of 2200 meters (30 thousand m) and 1200 meters (17450 m). The penetration rate was 252 m/month. In general, 100 failures were identified for the combine.
Rice. 1. - Roadheader KP21
The most serious ones are: detachment of the heads of the bolts for fastening the crown brake flanges, failure of the bearings of the gears of the raking paws and the working body, breakage of the conveyor star, wear of the sheets of the rotary part of the conveyor.
During the operation of the combine, roofing rocks with a strength of up to 12 units were undercut, which affected the resource of the combine. 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 obtained data, the time to failure was determined, as well as a list of parts and assemblies that affect the reliability of the combine (table No. 1).
The results of the research formed the basis for further improvement of tunneling machines of this size. Reinforced fastening of the brakes of the cutting body. A new design of the raking part has been developed, in which the raking paws are replaced by corrugated disks. The layout of the undercarriage gearboxes has been changed. Options for using a combine harvester together with a hopper reloader are considered.
Rice. 2. - Distribution of the number of failures of the combine in parts
Table No. 1 Indicators of reliability of the combine harvester KP21 factory. No. 20
Assembly Out of order Quantity Operating time up to
unit node of failures 3 failures, m
Working body Reducer: bearing No. 2 14000
Brake clutches 4 7500
Electric motor 3 9000
Loading Reducer:
organ bearing No. 7612, 8 6000
pinion shaft No. 0202087,
conical wheel 2 27500
№ 0202009 2 24000
Backstage bearing 1 29000
Conveyor Reducer:
bearing №7610 3 9000
Star 2PNB2.13.86.220-01 2 20000
Scraper chain 2 19000
Stava sheets 6 12000
Chassis 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 random values of time to failure. The operating conditions of combines are given in table No. 2.
Table number 2
Working conditions of harvesters KP21
No. Serial No. Production No. Production Observation period, months Dimensions of the working in the rough / in the 2nd light, m Fortress of the rocks, 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 nodes of each of the investigated combine are shown in Figure 3.
As can be seen from the diagrams, a significant amount of failures belongs to the reloader and amounts to 40%. The weakest elements in terms of reliability are the chain rollers (80%) and the drive star (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%).
Statistical analysis of the results of observations of the performance of combine harvesters KP21 was carried out in accordance with the recommendations.
Based on the experimental data obtained, a statistical series of random variables (CV) was formed from 83 implementations of X time to failure, while Xtp = 23.0 r.m, Xmax = 177.4 r.m. In this case A1 = 10; k = 18.
For each interval calculated: n - the number of values of random
values that fell into the interval: w / n - frequency, ^ - - accumulated
frequency, p / pL1 - empirical probability density, p.m-1.
Rice. 3. - Distribution of failures by parts of tunneling machines KP-21. a) - harvester KP-21 No. 20; b) - harvester KP-21 No. 34; 1 - executive body, 2 - raking part, 3 - conveyor, 4 - support lifter, 5 - running gear.
As a result, the values of the statistical standard deviation of SW were calculated: cx" = 32.2 p.m and the coefficient of variation y/ = 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.
Rice. 4. - Histogram of exponential distribution
/ (X) \u003d 0.025 e "" CB time to failure
As a result of processing the obtained results, it was found that the random values of the time to failure of X tunneling machines obey the exponential distribution law.
The probability density of a random variable subject to an exponential distribution law is described by the expression:
Taking the values mx = 41 lm as the mathematical expectation, we get / (X) = 0.025 e -0 "025X.
As a result of the studies and calculations, a leveling distribution curve was constructed (Figure 6), which is a graph of the theoretical function /(X).
To establish the correspondence of the put forward hypothesis to the statistical materials, K. Pearson's goodness-of-fit criterion x was used, the value of which is calculated by the formula:
where k is the number of C intervals, ni is the number of SW values in the i-th interval, n is the total number of SW values obtained, pi is the theoretical probability of SW falling into the i-th interval.
Rice. 5. - Graph of the theoretical function f (X) \u003d 0.0244-e - "
The probability p=0.01 obtained as a result of calculations is sufficient (p<0,1). Таким образом, считаем, что экспериментальные данные удовлетворяют принятому закону распределения СВ.
Literature
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