Theory and technology of efficient roadway advance with driving and bolting integration
WANG Hong1,2 ,WANG Jianli3 ,ZHANG Xiaofeng4
为提高巷道掘进效率,提出了掘锚一体化高效掘进的概念,指出高预应力锚固理论、空顶区顶板稳定控制理论、软岩流变理论、松动圈理论和锚杆支护动态信息设计方法等是掘锚一体机高效掘进的理论基础,进一步采用数值模拟和试验,发现了高效掘进围岩破坏变形规律和低比能耗高效截割的有关规律。
针对综掘工艺平行作业率低的难题,攻克了高效掘进系统集成配套技术,创新研制掘锚一体机、锚杆转载机、跨骑式锚杆钻车和柔性连续运输系统等装备,构建掘进、支护、运输、除尘等工序的同步作业线,掘支运平行作业时间由 25% ~ 35% 增至 50% ~70% 。 攻克了掘锚一体化技术和全宽截割技术,研制了国产掘锚一体机,优化了截割功率、空顶距、接地比压,行走采用千伏级交流变频调速技术,解决了国外设备截割能力不足、适应性差等难题,研制了双驱动高速合流重型截割减速器,实现截割功率达 340 kW,研制前探式临时支护,将临时支护空顶距由1 m 减至0.4m,研制宽型履带底盘,整机接地比压由0.28MPa 降至0.2MPa;针对锚杆支护与转载运输平行作业的难题,攻克了空间多维度同步支护技术,研制了锚杆转载机和跨骑式锚杆钻车等设备,通过多组钻机实现多排多臂分段平行支护,掘进工作面采用低密度强力锚杆支护控制顶板,后部同步实施增强永久支护,形成“前疏后密,快速推进”协同支护体系;攻克了多钎杆钻孔自动接续技术,钎杆由机械手自动续装、由钎杆仓存储,解决了锚索钻装不连续的技术难题;针对胶带长距离搭接的难题,研制出柔性连续运输系统,设计了位姿锁定的蛇形关节架体、偏置摆动式油气悬挂、具有减摩降阻机构的迈步式自移机尾、穿梭动力站等核心部件,实现小半径 90°转弯和 150 m 往复搭接、连续转载;针对高效掘进粉尘防治的难题,提出了固液气三幕组合控尘方法,将粉尘控制在掘进工作面并形成粉尘池,防止粉尘扩散;研制了可随主机设备移动的除尘装置,实现除尘装置与掘进设备同步移动;攻克了小体积无龙骨自承式菱形滤袋过滤技术,研制了矿用全自动紧凑型袋式除尘器,总尘除尘率达99.7% ;攻克了滤网表面超疏水改性、双面两级流线形气液分离等技术,研制了矿用机载湿式负压除尘器。 应用表明,与原有掘进方法相比,掘锚一体化高效掘进技术在稳定围岩和中等稳定围岩条件下提高掘进速度1 ~ 2倍。
In order to improve the heading efficiency,the theory and technology of efficient roadway advance with driving and bolting integration is put forward. The concept of efficient roadway advance with driving and bolting integration is advanced,its rationales are consist of the high pre-stressed bolt,roof stability control in empty-sup- port roof area,rheological theory of soft rock,loose circle theory and design methods of bolt support with dynamic information,etc. By further numerical simulation and experiment,the damage deformation law of surrounding rock of efficient heading and the related law of low specific energy and high efficient cutting are discovered. For the problem of low parallel operation efficiency of comprehensive heading technology,the efficient heading system in- tegration technology is solved,some innovative equipment are developed including bolter miner,bolter conveyor, straddle bolter and flexible continuous conveyor system,etc. Then,a synchronous working line is formed with its ability to cut,bolt,convey and dust simultaneously,which makes parallel working time increase from 25% -35%to 50% -70% . The driving and bolting inte-gration technology and full width cutting technology are also solved, and a bolter miner is developed. By optimizing the cutting power,the distance between the coal face and tempora- ry roof support,the ground pressure and the utilization of kV Ac variable frequency traction drive,the problem of insufficient cutting ability and poor adaptability of foreign equipment are solved. Heavy cutting reducer by double drive and confluence at high-speed stage is developed,which realizes the cutting power of 340 kW. Forepole tem- porary support is developed,which makes the distance between the coal face and temporary roof support decrease from 1 m to 0. 4 m. Wide track chassis is designed that makes the machine ground pressure reduce from 0. 28 MPa to 0. 2 MPa. For the problem of bolting and haulage in simultaneous operations,the space multidimensional synchronization support technology is overcome. Bolter conveyor and straddle bolter are developed, multiple row support is achieved by multiple bolting rigs,the roof control of coal face is realized by using low density strength bolting,the enhanced permanent support is implemented synchronously in back area, the collaborative support system of “ dredge after close before,rapid advance” is formed. The automatic connection technology of multi-bit drill rod is obtained,and the technical problem of discontinuous drilling installation of anchor cable is solved by means of automatic continuous installation of multi-bit drill rod by manipulator and multi-carrier. In order to solve the problem of long distance lapping of belts,the flexible continuous transport system is developed,by designing core components,such as serpentine articular frame body with posture locking,offset oscillating oil and gas sus- pension,strike-type self-moving tail with anti-friction and anti-friction mechanism, and shuttle power station, which realizes the 90° turning with small radius and 150 m reciprocating lapping as well as continuous transfer. For the problem of inefficient dust prevent and control,a combination of solid,liquid and gas dust control method is put forward,which can control the dust effectively in the coal face and form a dust pool to prevent the dust from spreading. The dust removal device that can move with the host equipment is developed to realize the synchronous movement of the dust removal device and the tunneling equipment. The small-size no-keel self-acting rhombic bag filtration technology is obtained,and the fully automatic compact bag filter for mining is developed that makes the total dust removal rate up to 99. 7% . The technologies of surface super-hydrophobic modification of filter screen and two-stage linear gas-liquid separation are obtained,and the airborne wet negative pressure precipitant for min- ing is developed. The application shows that comparing with the original heading method,the heading speed is in- creased by 1 -2 times under the condition of stable surrounding rock and medium stable surrounding rock.
driving and bolting integration;rapid development;synchronous support;continuous conveyor;coordinated control
主办单位:煤炭科学研究总院有限公司 中国煤炭学会学术期刊工作委员会