矿用带式输送机承载托辊的磁性液体润滑与密封性能

doi:10.3901/JME.2021.21.211

摘要/Abstract

摘要： 托辊密封不可靠会引发轴承润滑失效，进而导致托辊旋转阻力急剧增加直至完全卡阻，已成为煤矿井下带式输送机的主要故障原因之一，提高托辊密封与润滑性能对于提升带式输送机工作效率具有重要现实意义。基于纳米磁性液体密封与润滑理论设计了新型托辊样机，利用可模拟井下环境的托辊旋转阻力试验台在不同试验条件下与普通托辊进行了性能对比试验。结果表明，常规环境定载荷试验中，磁性液体密封润滑托辊的旋转阻力较普通托辊最大降低45%，平均降低17%；常规环境定带速试验中，磁性液体密封润滑托辊的旋转阻力较普通托辊最大降低73%，平均降低54%；模拟井下煤尘环境试验中，磁性液体密封润滑托辊的旋转阻力较普通托辊平均降低26%；煤泥水淋水24 h试验后，普通托辊的旋转阻力增大至原来的7倍，而磁性液体密封润滑托辊的旋转阻力基本无变化。采用磁性液体密封润滑的托辊在不同试验条件下具有低旋转阻力、高抗水淋性等优异性能，可为井下带式输送机向低能耗、高可靠、长寿命方向发展提供有力技术支撑。

关键词: 托辊, 带式输送机, 磁性液体, 密封, 润滑, 旋转阻力

Abstract: Unreliable sealing will lead to lubrication failure of the roller, which results in quick rising of rotational resistance and even turning blocked, is one of the most important failure reason of the belt conveyor used in coal mine. In order to solve the problem of excessive rotation resistance and service life of the roller conveyor belt, a roller prototype is designed and manufactured on the basis of nano magnetic liquid seal and lubrication principles. The test was carried out under different conditions between the magnetic liquid sealed & lubricating (MLSL) roller and the traditional roller, to compare their working performance. The results show that under the normal environment and the determined load, the rotational resistance of the MLSL roller is reduced by 45% compared with the traditional roller, and the average reduction is 17%. Under the normal environment and the determined belt speed, the maximum reduction of rotational resistance of the MLSL roller compared with the traditional roller is 73%, and the average value is 54%. In the simulated underground coal dust environment, the rotational resistance of the MLSL roller is reduced by 26% compared with the traditional roller. After spraying by the coal slurry water for 24 hours, the rotational resistance of the traditional roller is increased by 7 times. However, the rotational resistance of the MLSL roller is substantially unchanged. It is proved that the roller with magnetic liquid sealing and lubrication structure has excellent performances such as low rotation resistance and high anti-water performance under different test conditions, which can provide powerful technical support for the development of low-energy, high-reliability and long-life roller for belt conveyors.

Key words: roller, belt conveyor, magnetic liquid, sealing, lubrication, rotational resistance

中图分类号:

TD528

赵少迪, 鲍久圣, 徐浩, 阴妍, 谢厚抗, 刘同冈. 矿用带式输送机承载托辊的磁性液体润滑与密封性能[J]. 机械工程学报, 2021, 57(21): 211-219.

ZHAO Shaodi, BAO Jiusheng, XU Hao, YIN Yan, XIE Houkang, LIU Tonggang. Magnetic Fluid Lubrication and Sealing Performance of Mining Belt Conveyor Roller[J]. Journal of Mechanical Engineering, 2021, 57(21): 211-219.

参考文献

[1] 曲建平. 煤矿带式输送机现状与发展趋势[J]. 煤炭科技, 2015(4):146-147. QU Jianping. Current situation and development trend of belt conveyor in coal mine[J]. Coal Science and Technology Magazine. 2015, (4):146-147.
[2] 刘振. 带式输送机高速托辊的应用研究[J]. 矿山机械, 2011, 39(6):66-69. LIU Zhen. Study on application of high-speed idlers of conveyors[J]. Mining and Processing Equipment, 2011, 39(6):66-69.
[3] 刘振, 刘静. 带式输送机托辊的分析[J]. 机电信息, 2011(3):86-87. LIU Zhen, LIU Jing. Analysis of belt conveyor idlers[J]. Mechanical and Electrical Information, 2011(3):86-87.
[4] 陈恒新. 带式输送机托辊密封设计[J]. 矿山机械, 2010, 38(17):86-87. CHEN Hengxin. Design of idler sealing of belt conveyor[J]. Mining and Processing Equipment, 2010, 38(17):86-87.
[5] 朱华, 吴兆宏, 李刚, 等. 煤矿机械磨损失效研究[J]. 煤炭学报, 2006(3):380-385. ZHU Hua, WU Zhaohong, LI Gang, et al. Study on wear failures of mining machinery[J]. Journal of China Coal Society, 2006(3):380-385.
[6] 宋彤菊. 矿用带式输送机常见故障分析及预防措施[J]. 机械管理开发, 2009, 24(3):68-69. SONG Tongju. Common fault analysis and preventive measures of mine belt Conveyor[J]. Mechanical Management and Development, 2009, 24(3):68-69.
[7] 樊祥. 煤矿带式输送机常见事故与预防措施分析[J]. 机械管理开发, 2017, 32(7):20-21+24. FAN Xiang. Analysis of common accidents and preventive measures of belt conveyor in coal mine[J]. Mechanical Management and Development, 2017, 32(7):20-21+24.
[8] 李仟. 带式输送机托辊失效原因与改进措施分析[J]. 陕西煤炭, 2019, 38(5):72-75. LI Qian. Analysis of failure reasons and improvement measures of belt conveyor roller[J]. Shaanxi Coal, 2019, 38(5):72-75.
[9] 江旗. 胶带输送机托辊密封结构机理及托辊强度分析[D]. 唐山:华北理工大学, 2019. JIANG Qi. Structural mechanism and strength analysis of roller seal for belt conveyor[D]. Tangshan:North China University of Science and Technology, 2019.
[10] 彭兆辉, 吴桐. 皮带机的托辊密封结构分析[J]. 中国新技术新产品, 2017(1):72-73. PENG Zhaohui, WU Tong. Analysis of roller seal structure of belt conveyor[J]. New Technology and New Products of China, 2017(1):72-73.
[11] 郭覃, 周哲波, 刘大利, 等. 带式输送机托辊的长寿命密封设计[J]. 机械设计与制造, 2008(3):18-19. GUO Qin, ZHOU Zhebo, LIU Dali, et, al. The long life seal design of belt conveyor[J]. Machinery Design and Manufacture, 2008(3):18-19.
[12] 刘杰, 于涛, 孙丽英. 新型复合密封托辊的结构设计与试验研究[J]. 铸造设备与工艺, 2015(3):20-22. LIU Jie, YU Tao, SUN Liying. Design and experimental research of the new composite sealing roller[J]. Foundry Equipment and Technology, 2015(3):20-22.
[13] 李小磊. 新型密封结构托辊及其试验机的设计研究[D]. 北京:北京化工大学, 2011. LI Xiaolei. The design and research of a new type of roller Sealing structure and its testing machine[D]. Beijing:Beijing University of Chemical Technology, 2011.
[14] 刘广建, 陈冲冲, 马艳娥, 等. 新型密封结构高分子托辊的摩擦磨损试验研究[J]. 煤矿机械, 2011, 32(11):49-51. LIU Guangjian, CHEN Chongchong, MA Yane, et, al. Test research on friction and wear of new sealing structure polymer roller[J]. Coal Mine Machinery, 2011, 32(11):49-51.
[15] 王伟平. 煤矿用带式输送机托辊的密封设计[J]. 煤矿机械, 2009, 30(6):9-10. WANG Weiping. Seal design of belt conveyor carrier roller used in coal mines[J]. Coal Mine Machinery, 2009, 30(6):9-10.
[16] 孙明礼, 李德才, 何新智, 等. 磁流体密封的磁场数值分析及优化设计[J]. 真空科学与技术学报, 2007(3):269-272. SUN Mingli, LI Decai, HE Xinzhi, et, al. Simulation and design of magnetic fluid sealing devices[J]. Chinese Journal of Vacuum Science and Technology, 2007(3):269-272.
[17] 李德才. 磁性液体密封的理论及应用[M]. 北京:科学出版社, 2010. LI Deicai. The theory and application of magnetic liquid sealing[M]. Beijing:Science Press, 2010.
[18] 朱景建. 爪型干式真空泵磁流体密封的研究[J]. 真空科学与技术学报, 2017, 37(7):660-664. ZHU Jingjian. Sealing of claw-type dry vacuum pump with magnetic fluid[J]. Chinese Journal of Vacuum Science and Technology, 2017, 37(7):660-664.
[19] 于振燕, 张玮. 磁流体密封在水轮机主轴中的应用[J]. 排灌机械工程学报, 2014, 32(2):151-155. YU Zhenyan, ZHANG Wei. Application of magnetic fluid seal in hydraulic turbine shaft[J]. Journal of Drainage and Irrigation Machinery Engineering, 2014, 32(2):151-155.
[20] 刘训涛, 吴卫东, 张岩, 等. 基于TRIZ理论的托辊密封的研究[J]. 矿山机械, 2009, 37(13):62-65. LIU Xuntao, WU Weidong, ZHANG Yan, et al. TRIZ theory based the idler roll sealing research[J]. Mining and Processing Equipment, 2009, 37(13):62-65.
[21] SAURABH PARMAR, VENKAT RAMANI, R.V. UPADHYAY et. al. Design and development of large radial clearance static and dynamic magnetic fluid seal[J]. Vacuum, 2018, 156:325-333.
[22] YOSHINORI M, KAZUMITSU S, EIJI O. Magnetic fluid seals working in liquid environments:Factors limiting their life and solution methods[J]. Journal of Magnetism and Magnetic Materials, 2020, 500166293.
[23] LI Jingbing, DAI Qingwen, HUANG Wei, et al. Feasibility study of magnetic fluid support and lubrication behaviors on micro magnet arrays[J]. Tribology International, 2020, 150.
[24] 徐浩. 纳米磁性液体密封润滑的托辊设计及性能研究[D]. 徐州:中国矿业大学, 2019. XU Hao. Design and performance of nano magnetic liquid sealed and lubricated idler[D]. Xuzhou:China University of Mining and Technology, 2019.
[25] 鲍久圣, 徐浩, 葛世荣, 等. 一种纳米磁性液体密封与润滑的带式输送机托辊[P]. 中国, CN201810430112.9, 2018-11-30. BAO Jiusheng, XU Hao, GE Shirong, et al. The utility model relates to a belt conveyor idler sealed and lubricated by nano magnetic liquid[P]. China, CN201810430112.9, 2018-11-30.
[26] 杨松. 钠堆主轴径向微动工况下磁性液体密封的研究[D]. 北京:北京交通大学, 2018. YANG Song. Study on magnetic fluid under radial fretting condition of sodium cooled fast reactor[D]. Beijng:Beijing Jiaotong University, 2018.
[27] 杨文明, 李德才, 赵晓光, 等. 磁性液体密封结构的优化设计[J]. 真空科学与技术学报, 2010, 30(1):80-83. YANG Wenming, LI Decai, ZHAO Xiaoguang, et al. Simulation and optimization of magnetic fluid seal structures[J]. Chinese Journal of Vacuum Science and Technology, 2010, 30(1):80-83.
[28] 国家安全生产监督管理总局, 国家煤矿安全监察局. 煤矿安全规程[M]. 北京:煤炭工业出版社, 2011. State Administration of Work Safety, State Administration of Coal Mine Safety. Coal mine safety regulations[M]. Beijing:China Coal Industry Publishing House, 2011.
[29] 蔡雪晴, 鲍久圣, 阴妍, 等. 带式输送机托辊性能测试技术研究进展[J]. 煤炭技术, 2018, 37(3):271-274. CAI Xueqing, BAO Jiusheng, YIN Yan, et al. Research progress of idler performance testing technology of belt conveyor[J]. Coal Technology, 2018, 37(3):271-274.
[30] 程艳红, 李德才, 戴荣坤. 氟醚油基磁性液体密封启动力矩的实验分析[J]. 哈尔滨工程大学学报, 2017, 38(8):1316-1321. CHENG Yanhog, LI Decai, DAI Rongkun. Experimental analysis of starting torque of perfluoro polyethers-based magnetic fluid seal[J]. Journal of Harbin Engineering University, 2017, 38(8):1316-1321.