KULICKE & SOFFA 01483-4047-000-05在井下采煤系統(tǒng)應(yīng)用
1、采煤機(jī)ACS-800變頻器的調(diào)試運(yùn)行
ACS-800變頻器有著優(yōu)良的調(diào)速性能和顯著的節(jié)能效果被廣泛應(yīng)用于煤礦及其它眾多行業(yè)。正確設(shè)置變頻器的基本參數(shù)是十分重要的。兗州礦業(yè)（集團(tuán)）公司濟(jì)寧二號煤礦總結(jié)了采煤機(jī)ACS-800變頻器調(diào)試運(yùn)行的經(jīng)驗。
①選擇語言，設(shè)置電動機(jī)啟動數(shù)據(jù)。有十五種語言可供選擇，應(yīng)選（ENGLISH）英語，（FACTORY）基本應(yīng) 用于工廠、（NO）不恢復(fù)出廠設(shè)置、（DTC）直接轉(zhuǎn)矩控制。根據(jù)電動機(jī)銘牌選擇合適的電壓、頻率范圍、電動機(jī)轉(zhuǎn)速和電動機(jī)功率等。
②KULICKE & SOFFA 01483-4047-000-05通過設(shè)置數(shù)字輸入端，實現(xiàn)外部啟動、停機(jī)和旋轉(zhuǎn)方向。加速時間就是變頻器輸出頻率由零頻升到最大頻率所需時間，一般8～10s。減速時間是從給定最大值降至零頻所需時間，一般3～5s。確保加速時不過流、減速時不過壓。加、減速時間可根據(jù)電動機(jī)功率進(jìn)行計算，實際應(yīng)用時根據(jù)現(xiàn)場情況適當(dāng)調(diào)整，以不出現(xiàn)過電流、過電壓為原則。
③加減速模式選擇。變頻器加減速有線形、非線形和S形曲線運(yùn)行模式。采煤機(jī)啟動和運(yùn)行負(fù)載變化較大，且加速度要緩慢，變頻器可選擇S形曲線運(yùn)行模式，以滿足不同的復(fù)雜地質(zhì)條件需要。
④設(shè)置轉(zhuǎn)矩補(bǔ)償。以此來提高電動機(jī)在低速啟動時轉(zhuǎn)矩提升，應(yīng)采取自動補(bǔ)償功能，確保電動機(jī)加速順利進(jìn)行。
⑤電子過流保護(hù)功能設(shè)置。這是為了保護(hù)電動機(jī)因過流而燒毀，漏電保護(hù)功能對電動機(jī)及電纜實時監(jiān)視絕緣情況。工作電流超過設(shè)定值時過流保護(hù)功能動作，絕緣值下降至設(shè)定值以下時漏電保護(hù)功能將切斷電源，實現(xiàn)保護(hù)牽引電動機(jī)的要求。
⑥KULICKE & SOFFA 01483-4047-000-05模擬加載調(diào)試采煤機(jī)。接上電源后仔細(xì)觀察有無異?，F(xiàn)象，然后進(jìn)行初加速。在加速時限制頻率給定時要緩慢，頻率上升率不要太陡，以防止出現(xiàn)過電流保護(hù)。此時觀察電動機(jī)轉(zhuǎn)速是否由小到大過渡運(yùn)行平穩(wěn)確保電動機(jī)接近滿載情況下可靠運(yùn)行。
2、電牽引采煤機(jī)變頻器故障分析與處理
電牽引采煤機(jī)應(yīng)用變頻器替代了原先的液壓牽引方式，提高了采煤機(jī)運(yùn)行的可靠性。兗州礦業(yè)（集團(tuán)）公司鮑店煤礦通過大量現(xiàn)場實踐，總結(jié)出使用和維護(hù)變頻器的經(jīng)驗，保障了電牽引采煤機(jī)的正常運(yùn)行。變頻器位于牽引控制箱的右前側(cè)，主要用于控制采煤機(jī)的左右行走速度。
KULICKE & SOFFA 01483-4047-000-05對于采煤機(jī)只能進(jìn)行單向行走的單向牽引事故，除平時經(jīng)常清理按鈕表面的粉塵，并做好防銹處理以防出現(xiàn)按鈕卡住現(xiàn)象外，還要加強(qiáng)對插座的維護(hù)和保護(hù)，控制線在壓接時用力適度，線頭壓得過緊易出現(xiàn)斷絲，采煤機(jī)振動時易造成線頭虛接。
對于采煤機(jī)運(yùn)行時能牽引，但在行走過程中經(jīng)常出現(xiàn)突然停機(jī)，停機(jī)后有時有故障顯示有時無故障顯示，復(fù)位后仍能開機(jī)的病態(tài)牽引事故，先不要急于動手，首先詢問司機(jī)關(guān)于采煤機(jī)工作運(yùn)行情況和故障現(xiàn)象，觀察功能顯示和參數(shù)顯示，仔細(xì)傾聽采煤機(jī)運(yùn)行聲音，分清是機(jī)械故障還是電氣故障，確定故障范圍，由點(diǎn)到面層層分析，然后再進(jìn)行事故處理。
對于采煤機(jī)不牽引的事故，其原因可分為硬故障和軟故障。硬故障是指采煤機(jī)出現(xiàn)不牽引后信息顯示直觀，能直接從顯示窗口上獲得故障信息。軟故障是指采煤機(jī)出現(xiàn)不牽引后從顯示窗口查不出各種信息，故障點(diǎn)信息較模糊，難以對事故進(jìn)行處理?，F(xiàn)場處理是更換功率平衡板。該板是易損件，出現(xiàn)類似事故時應(yīng)及時更換。平常應(yīng)加強(qiáng)對變頻器電源輸入聯(lián)接線的維護(hù)，采取隔離和包扎等措施，使變頻器電源輸入線不與器壁和其它元件接觸，可有效防止事故發(fā)生。
3、交流電牽引采煤機(jī)綜合試驗臺
兗州礦業(yè)（集團(tuán)）公司機(jī)械制修廠研制的電牽引采煤機(jī)綜合試驗臺，可對ＭＣＬＥ600-DR102102、SL300、MGTY400/900-3.3D三種常用交流電牽引采煤機(jī)的電氣系統(tǒng)進(jìn)行測試，并可同時對2臺變頻器進(jìn)行試驗，由2臺變頻器分別拖動2臺交流電動機(jī)，也可一拖一或一拖二。
3.1該綜合試驗臺由3個部分組成。
①交流變頻調(diào)速試驗單元：主要設(shè)備有油自冷式調(diào)壓器、三相異變電動機(jī)、直流電動機(jī)和數(shù)字式直流調(diào)速裝置、轉(zhuǎn)速轉(zhuǎn)矩傳感器、控制臺，實現(xiàn)交流變頻調(diào)速裝置電氣性能和牽引電機(jī)及機(jī)械性能的測試，完成變頻調(diào)速裝置保護(hù)功能的測試。能測試的項目主要有變頻器在空載狀態(tài)下的工作性能試驗、加載試驗、溫升試驗、電網(wǎng)電壓波動試驗、速度調(diào)節(jié)范圍試驗、制動與正反轉(zhuǎn)運(yùn)行試驗、機(jī)械調(diào)速特性試驗。
②計算機(jī)信號數(shù)據(jù)處理單元：核心設(shè)備有工業(yè)控制用計算機(jī)（含模擬量、數(shù)字量、輸入輸出接板）、寬行彩色打印機(jī)、信號調(diào)理變送電路，主要用來采集來自交流變頻調(diào)速單元的信號和數(shù)據(jù)，按照測試項目的要求進(jìn)行數(shù)據(jù)處理和顯示。
③KULICKE & SOFFA 01483-4047-000-05采煤機(jī)控制、監(jiān)測系統(tǒng)試驗單元：共包括監(jiān)測信號模擬發(fā)生電路（分別模擬采煤機(jī)牽引部、截割部等處的電流、溫度、壓力等檢測信號，能在規(guī)定量程內(nèi)變化，并具備計量校準(zhǔn)的功能，可以代替原信號送檢測中心）、采煤機(jī)操作信號模擬發(fā)生電路（模擬采煤機(jī)的各種信號，如送電、牽啟、左行、右行等，可以代替原信號控制采煤機(jī)各部的動作）、采煤機(jī)動作響應(yīng)顯示電路（代替采煤機(jī)各部在控制中心輸出信號后作出的響應(yīng)指示），主要對采煤機(jī)控制監(jiān)測系統(tǒng)的功能進(jìn)行測試。
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