Research On The Design Theory Of Super Heavy-duty Armored Face Conveyor Planetary Transmission

Armored Face Conveyors are developing new features of ultra-high power, large volume, long transport distance, high strength, long service life and high reliability in order to improve the output and work efficiency of the coal face, reduce production costs, enhance market competitiveness and improve economic efficiency. It must be equipped with the planetary gear because of its working environment. The planetary gear of the Super Heavy-duty Armored Face Conveyor should have small volume and high reliability. Its main design method is static design with little regard for its dynamic characteristics, and the analysis of its all working conditions and performance. But when this planetary transmission works, it has these characteristics ,the speed being slow, transmission torque large, load uneven, and lubricity and heat dissipation poor, and is easy to result in wear failure and short service life, so it's different from Conventional gear transmission in the selection of gear surface hardness, meshing parameters and lubricity in its design. Supported by the" research and development of large mining height fully mechanized caving face rear scraper conveyor", sub-topic of the major projects of the "Eleventh Five-Year" national scientific and technological supporting plan, this paper studies the design theory of the planetary gear of the Super Heavy-duty Armored Face Conveyor in order to improve its reliability ,working stability and prolong its service life. The main contents are as follows:(1)On the basis of the motion analysis of the planetary gear, time-varying meshing stiffness of multiple gear pairs, comprehensive error of clearance and gear pair and the influence of the input and output terminals, the nonlinear dynamic model of the planetary gear based on friction is established to lay a foundation for the study of its natural and dynamic characteristics.(2)The impact of the changes in design parameters on natural frequency and vibration mode is studied to determine these parameters'effect tendency on the system dynamic performance to provide a theoretical basis to predict the transmission's dynamic characteristics in the design,and improve its dynamic performance.(3)The effect of gear back lash on system dynamic response, load sharing coefficient and dynamic load is studied after using numerical calculation method to compute the time domain response of the nonlinear dynamic model of the planetary gear with friction and without friction. The result shows that the impact of friction on the planetary gear of the Super Heavy-duty Armored Face Conveyor can not be ignored, especially in transient vibration phase, and it provides a basis when determining the dynamic load coefficient and the load sharing coefficient.(4)Accurate boundary conditions needed by the temperature field of the planetary gear and thermo-elastic coupling stress analysis are accurately calculated based on the principle of gear engagement, tribological and heat transfer. Temperature field distribution and thermal stress coupling of the multiple gears of the planetary gear is studied to get the impact of the distribution of the temperature field and temperature effect on structural stress using finite element analysis and ANASYS software, and it provides a basis when choosing tooth profile parameters.(5)The variables and objective function of the system optimization design are established based on the analysis of the influence of tooth profile parameters on the planetary gear lubricity.Then the mathematic mode of the gear transmission robust reliability optimization design based on sensitivity analysis is established and optimized with MATLAB optimization toolbox.Example analysis shows that optimization results of this method is better that the original design because it improves its quality robustness and design efficiency.(6)Test on temperature rise, efficiency and noise of the reducer of the Super Heavy-duty Armored Face Conveyor that has been conducted according to《MT/T101-2000 scraper conveyor reducer test specification》, The test result shows that the reducer meets standards and has good performance.There are 101 figuers,23 tables and 163 references in the thesis.