Article(id=1201193881195999419, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1201193876590654455, articleNumber=1009-5438(2025)04-0075-03, orderNo=null, doi=null, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1742054400000, receivedDateStr=2025-03-16, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1764316538380, onlineDateStr=2025-11-28, pubDate=1756051200000, pubDateStr=2025-08-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764316538380, onlineIssueDateStr=2025-11-28, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764316538380, creator=13701087609, updateTime=1764316538380, updator=13701087609, issue=Issue{id=1201193876590654455, tenantId=1146029695717560320, journalId=1185652524569653253, year='2025', volume='51', issue='4', pageStart='1', pageEnd='98', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764316537282, creator=13701087609, updateTime=1764316948844, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1201195602878100389, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1201193876590654455, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1201195602878100390, tenantId=1146029695717560320, journalId=1185652524569653253, issueId=1201193876590654455, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=75, endPage=77, ext={EN=ArticleExt(id=1201193881544126665, articleId=1201193881195999419, tenantId=1146029695717560320, journalId=1185652524569653253, language=EN, title=Practices on Reducing Failure Rate of Heavy Duty Mining Truck in a Mine Enterprise, columnId=1187100786392711543, journalTitle=Science & Technology of Baotou Steel, columnName=Equipment and Automation, runingTitle=null, highlight=null, articleAbstract=

The stable operation of heavy duty mining truck is beneficial to safe production of mines. The failure rate of heavy duty mining truck in a mine is high and it is even higher in winter. It is found through analysis that the main causes are structural designs of accumulator and steering pump themselves for hydraulic system are not reasonable as well as control of mixture ratio of fuel to oil for engine is not accurate. The seal wear is reduced through changing single-point support to oriented multi-point support for piston of accumulator and adding unload groove; such problems as high pressure and temperature rise are solved as well as loss of parts is reduced through adding unloading valve on steering pump; temperatures of solidification point for different mixing ratios of 0# and -35# diesel are determined through experiments as well as auxiliary fuel tank is installed to choose different mixture ratios of fuel to oil and oil supply modes based on weather conditions. The failure rate of heavy duty mining truck is reduced through implementing the above measures.

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矿用重型汽车的稳定运行有益于矿山安全生产。某矿山的矿用重型汽车故障高发,且在冬季的时候更严重。分析发现,液压系统的储能器和转向泵自身结构设计不合理,以及发动机燃油混合比例控制不精确是主要原因。将储能器活塞单点式支撑改为导向式多点支撑,同时增加卸荷槽,减少密封磨损;转向泵增加卸荷阀,解决了高压与温升问题,减少部件损耗;通过试验确定了0#和-35#柴油不同混合比例的凝点温度,加装副油箱,根据天气状况选择不同混合比例的燃油和供油模式。以上措施的实施,降低了矿用重型汽车的故障率。

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慕园园(1986-),男,陕西省榆林市人,硕士,高级工程师,现从事安全技术管理工作。

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慕园园(1986-),男,陕西省榆林市人,硕士,高级工程师,现从事安全技术管理工作。

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慕园园(1986-),男,陕西省榆林市人,硕士,高级工程师,现从事安全技术管理工作。

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某矿山企业降低矿用重型汽车故障率实践
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包钢科技 | 设备与自动化 2025,51(4): 75-77
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某矿山企业降低矿用重型汽车故障率实践
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慕园园
作者信息
  • 包头钢铁(集团)有限责任公司安全管理部, 内蒙古 包头 014010
  • 慕园园(1986-),男,陕西省榆林市人,硕士,高级工程师,现从事安全技术管理工作。

Practices on Reducing Failure Rate of Heavy Duty Mining Truck in a Mine Enterprise
Yuanyuan Mu
Affiliations
  • Safety Management Dept. of Baotou Iron & Steel (Group) Co., Ltd., Baotou 014010, Inner Mongolia Autonomous Region, China
出版时间: 2025-08-25
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矿用重型汽车的稳定运行有益于矿山安全生产。某矿山的矿用重型汽车故障高发,且在冬季的时候更严重。分析发现,液压系统的储能器和转向泵自身结构设计不合理,以及发动机燃油混合比例控制不精确是主要原因。将储能器活塞单点式支撑改为导向式多点支撑,同时增加卸荷槽,减少密封磨损;转向泵增加卸荷阀,解决了高压与温升问题,减少部件损耗;通过试验确定了0#和-35#柴油不同混合比例的凝点温度,加装副油箱,根据天气状况选择不同混合比例的燃油和供油模式。以上措施的实施,降低了矿用重型汽车的故障率。

矿用重型汽车  /  技术改造  /  液压系统  /  储能器活塞  /  转向泵  /  凝点

The stable operation of heavy duty mining truck is beneficial to safe production of mines. The failure rate of heavy duty mining truck in a mine is high and it is even higher in winter. It is found through analysis that the main causes are structural designs of accumulator and steering pump themselves for hydraulic system are not reasonable as well as control of mixture ratio of fuel to oil for engine is not accurate. The seal wear is reduced through changing single-point support to oriented multi-point support for piston of accumulator and adding unload groove; such problems as high pressure and temperature rise are solved as well as loss of parts is reduced through adding unloading valve on steering pump; temperatures of solidification point for different mixing ratios of 0# and -35# diesel are determined through experiments as well as auxiliary fuel tank is installed to choose different mixture ratios of fuel to oil and oil supply modes based on weather conditions. The failure rate of heavy duty mining truck is reduced through implementing the above measures.

heavy duty mining truck  /  technical transformation  /  hydraulic system  /  piston of accumulator  /  steering pump  /  solidification point
慕园园. 某矿山企业降低矿用重型汽车故障率实践. 包钢科技, 2025 , 51 (4) : 75 -77 .
Yuanyuan Mu. Practices on Reducing Failure Rate of Heavy Duty Mining Truck in a Mine Enterprise[J]. Science & Technology of Baotou Steel, 2025 , 51 (4) : 75 -77 .
矿用重型汽车是目前国内外大型露天矿山普遍采用的高效运输设备[1]。露天矿山采场工艺流程分为“穿、爆、采、运、排”等五大工序,其中“采、运、排”三个工序均由矿用重型汽车来完成,因此矿用重型汽车的车辆状态直接关系采场生产能否稳定顺行[2]
某矿山企业统计数据显示,矿用重型汽车的年平均系统故障率为4.2%,受矿区冬季气候影响,矿车的故障率在一季度和四季度更高,远高于企业的计划指标。矿用重型汽车故障频发,不仅会造成备件消耗增加,导致矿车周转率下降,而且给生产组织、设备管理等带来严重影响。
矿用重型汽车(简称矿车)由车体结构、电气驱动系统、液压系统组成,集成了电气、机械、发动机等专业技术[3]。矿用重型汽车的故障类型分为电气故障、机械故障和发动机故障。
矿用重型汽车液压系统运转是否正常与车辆运行安全有极大关系。在发生故障的矿车系统中,液压系统的问题最为突出。由于液压系统备件大多为国外进口,频繁换新备件导致维修成本增高。减少矿车备件消耗,降低汽车维护成本,提升作业效率,有助于生产任务的顺利完成[4]
液压系统的储能器和转向泵出现故障频次高,解体后发现其自身结构设计存在不合理的地方,分别针对储能器活塞、转向泵的内部结构进行优化设计和技术改造。
储能器活塞重量达到20 kg,活塞行程2 000 mm,单点密封、单点支撑的结构形式极易造成密封件磨损,导致活塞卡死,从而出现储能器内泄、压力不足等问题。统计分析检修记录,发现储能器内泄故障和活塞密封失效现象同步出现,更换活塞密封,可以解决储能器内泄的问题。
转向泵故障记录显示,在转向泵压力不足21 MPa的时候,转向泵温度超过60 ℃。转向泵长时间带负荷工作,泵体温度不断上升,加剧泵体磨损,造成泵压不足。若转向泵增加卸荷阀,高压与温升的问题迎刃而解。
矿车的液压泵由发动机提供动力,若发动机不能正常启动,将影响液压泵的正常运行。据统计,矿山的矿车发动机一次启动成功率平均为91.5%,低于95%的计划要求。分析原因,在环境温度处于0 ℃到20 ℃之间,矿车燃油通常采用0#和-35#柴油按比例混合使用的方法,由于混合比例控制不精确,导致发动机一次启动成功率低。
通过测量实物尺寸绘制图纸,按照图纸对储能器进行机加改造。优化设计储能器活塞密封及导向结构,在加工后的导向套上安装密封圈,上下两个导向套的密封圈对称安装,实现多点支撑。在导向套上增加密封槽,安装唇形密封,唇口朝外。唇形密封的唇口在液压系统压力作用下发生变形,使唇边紧贴密封面而增强密封效果。液压系统压力越高,唇边与密封面贴得就越紧,而且密封唇边磨损后,具有一定的自动补偿功能。
改造完成后,进行静态和动态试车检测。静态试车检测结果显示,储能系统补压较快,车辆驾驶转向轻快,动作灵敏。动态试车检测结果显示,系统转向制动压力正常,无报警,车辆运行正常。储能器改造效果跟踪记录显示,在3个月连续运转周期内仅发生了2次储能器内泄,远低于过去上百次的记录,储能器密封效果显著提升。
针对转向泵运转长时间受高压与温升双重困扰的问题,最优方案是在转向泵的回路中并联接入卸荷阀。卸荷阀采用电磁溢流阀,具有溢流和补偿作用。当液压系统压力达到溢流阀的开启压力时,溢流阀开启,转向泵卸荷;当液压系统压力降至溢流阀的关闭压力时,溢流阀关闭,转向泵自动加载系统压力。液压系统压力在安装卸荷阀后重新调定,将转向泵循环工作压力调定在21.72~24.13 MPa之间。在无卸荷的情况下,转向泵为液压系统提供主压力,当卸荷操作时,通过电磁溢流阀动作转换,压力油直接返回油箱,液压油泵压力下降,确保回路压力正常,从而提高油泵寿命,减少功耗。
改造完成后,进行矿车测试。两个保养周期(500 h)的连续测试结果显示,运行过程中的矿车在转向、制动、抬升时,液压泵压力均正常,转向制动系统无卡滞,液压系统压力达到21.72 MPa,符合设计要求,车辆运行正常。
在实验室0#和-35#柴油混合试验中,试验温度从室温逐步降低,当混合燃油中出现絮状物(俗称“挂蜡”)时,所对应的试验温度就是“凝点温度”。混合燃油在凝点温度使用时,油液中的絮状物将沉积在油管、滤芯、喷油口等部位,造成发动机无法正常启动。通过试验确定不同混合比例燃油的凝点,从而确定不同凝点温度下对应的燃油混合比例。
根据环境温度或季节变化等实际情况,以及燃油混合比例和凝点温度的对应关系,精确调配两种型号柴油的混合比例,发动机一次启动成功率大幅提升。
在矿车主油箱旁安装一个副油箱,将其接上油管与主供油管路相连,在连接部位分别安装两个三通电磁阀(供油和回油),与主管路组成闭合回路。通过电控按钮完成电磁阀动作切换。在主油箱中加注混合柴油,在副油箱中加注-35#柴油。遇到寒冷天气,在车辆启动前,将电磁阀切换至副油箱供油模式,待车辆启动后,发动机产生的热量通过热交换器加热主油箱,当主油箱温度达到0 ℃以上,再将电磁阀切换至主油箱供油模式。
改造后的矿车半年运行结果表明,故障率由改造前的4.2%下降到3.1%。在完成改造投入生产的第一个月,矿车故障率仅为2%,达到了历史最好水平。通过定期维护保养,减缓车辆的关键部件如发动机、变速器、轮胎等的磨损速度,延长了矿车的服役寿命。
矿车故障率下降,车辆能够保持更为稳定的运行状态,生产效率获得显著提升,一是减少了矿车停机时间,作业时间大幅增加;二是物料运输更加顺畅高效,矿山开采和运输环节得以紧密衔接,生产流程的连贯性得到极大增强。
改造前,各种故障频繁发生,零部件消耗和人工成本持续攀升,导致维修成本大幅增加。由于车辆故障而停产,导致产量下降。成本增加加上产量损失,抬高了矿山的运营成本,压缩了企业的利润空间。
改造后,车辆维护成本下降,矿石产量增加,运营成本大幅下降,企业效益增加。
改造后,车辆故障引发的安全事故风险下降,矿车运行更为稳定,显著提升了作业安全性,为矿山的安全生产创造了良好条件。
矿用重型汽车在运行过程中会产生尾气排放和噪声污染[5]。改造后的车辆发动机燃烧效率提高了,不仅减少了尾气排放中的有害物质,而且噪声污染也相应减小了,改善了矿工的工作环境和矿山的生态环境,生态环保效益明显。
通过改造液压泵、发动机燃油系统,优化储能器活塞密封结构,增加卸荷阀,矿用重型汽车的系统故障率明显降低,减少了车辆的养护成本,有效延长了矿车的作业时间,取得了经济效益和生态环保效益的双赢。
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  • 接收时间:2025-03-16
  • 首发时间:2025-11-28
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2种不同金属材料的力学参数

Family
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Number of
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Number of
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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