液压支架液控单向阀降柱冲击试验系统

Impact test system for lowering column of hydraulic support pilot-operated check valve

  • 摘要: 针对大采高工作面的高应力、大流量工况,为满足液压支架液控单向阀冲击试验的工程需求,设计了一套液控单向阀降柱冲击试验系统。该试验系统由液压和测控2个子系统组成,其中液压系统的核心部件为双级增压缸,采用阶梯结构设计,能在一台常规矿用乳化液泵供液的情况下实现保压、增压、卸载等功能,并基于加载腔、高压腔、细长孔等结构复现液控单向阀解锁过程中的弹性储能效应,为冲击试验提供更贴近实际工况的测试条件。测控系统则以虚拟仪器技术为框架,基于100 KS/s高频采集准确捕捉测试过程的压力变化,通过上位机软件实现液压系统远程控制,以及数据处理与分析,保证了测试过程的安全性与自动化程度。以FDY1600/50型液控单向阀样件为被试阀进行试验,结果表明,该试验系统能反映出液控单向阀冲击试验中剧烈压力冲击、快速卸压、平稳卸流等特征,与实际工况试验结果契合;能够较好复现出液控单向阀在工作面进行降柱动作时的冲击效果,为判断被试阀性能提供了直观的数据支撑。

     

    Abstract: A pilot-operated check valve lowering impact test system was designed to address the engineering requirements of hydraulic support pilot-operated check valve impact tests under the high-stress and large-flow conditions of large mining-height longwall faces. The test system consisted of two subsystems: a hydraulic subsystem and a measurement and control subsystem. The core component of the hydraulic subsystem was a two-stage booster cylinder with a stepped structure design, which was able to realize functions such as pressure maintaining, pressurization, and unloading under the liquid supply of a conventional mine emulsion pump. Based on the structures of the loading chamber, high-pressure chamber, and slender orifice, the elastic energy storage effect during the unlocking process of the pilot-operated check valve was reproduced, providing test conditions closer to actual working conditions for impact tests. The measurement and control subsystem was built on virtual instrument technology, which, based on 100 KS/s high-frequency acquisition, accurately captured the pressure changes during the test process. Through host computer software, remote control of the hydraulic system as well as data processing and analysis were achieved, ensuring the safety and automation of the test process. Taking an FDY1600/50 type pilot-operated check valve specimen as the tested valve, the results showed that the test system reflected the characteristics of intense impact, rapid pressure relief, and stable flow unloading during the impact test of the pilot-operated check valve, which were consistent with the actual working condition test results. The system is able to reproduce the impact effect when the pilot-operated check valve performs a lowering action on the working face, providing intuitive data support for evaluating the performance of the tested valve.

     

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