Abstract: In view of the problems of frequent replacement of belt conveyor rollers, heavy manual replacement tools, high labor intensity and low shutdown replacement efficiency, taking the belt conveyor in the main adit of Wangjialing Coal Mine as the research object, the roller replacement robots with non-stopping were studied according to roadway parameters and roller replacement processes, and the overall research plan of the robots was formulated. Based on the functional analysis method and the theory of roller replacement with non-stopping, the 3D solid model of the robots was established by using SolidWorks software, and the parameters of the walking mechanism, attitude adjustment platform, telescopic support platform and disassembling manipulator were optimized. The finite element analysis of the support platforms and belt lifting mechanisms was carried out by ANSYS Workbench software. The telescopic support platform adopted a sliding rail structure, and the stresses of the sliding rail under the cantilever and lifting rated load are as 15.647 MPa and 66.395 MPa respectively. The maximum deformation and displacement occur under the rated load. The displacement is as 1.0742 mm. Belt lifting mechanism adopted shear fork structure, the rated lifting maximum stress is as 152.82 MPa, the maximum displacement is as 0.7331 mm. According to the design parameters, the robot prototype was processed with the power of 64 kW diesel engine as the power, and the crawler was driven by the hydraulic motor. The speed range is as 3~8 km/h. The attitude adjustment platform may realize the lifting height 0~357 mm, the pitch angle ±15°, the roll angle -4°~7°, the rotation angle -10°~20°, the transverse movement range 0~400 mm, the longitudinal movement range 0~ 350 mm, the multi-stage telescopic mechanism adopted the combined slide to achieve the platform 0~2.1 m telescopic. Using a five-degree-of-freedom manipulator may disassemble and assemble rollers in different positions. Through the ground and underground tests, the robot prototype walking, attitude adjustment, lifting belt, disassemble roller functions were verified experimentally. The results show that the robots may pass well in the narrow tunnel of the main tunnel, and the maximum height of the lifting belt of the telescopic support platform is as 241 mm when the conveyor is not stopped, which provides enough operating space for the robots to disassemble and assemble the rollers under different positions to meet the design performance requirements. The study of roller replacement robots with non-stopping for belt conveyor provides a new way for the maintenance of coal mine belt conveyor.

Key words: belt conveyor, maintenance robot, roller replacement, non-stop lifted belt

摘要： 针对带式输送机托辊更换频繁、人工更换工具笨重、作业劳动强度大、停机更换效率低等问题，以王家岭煤矿主平硐带式输送机为研究对象，根据巷道参数和更换托辊流程，研究不停机更换托辊机器人，制定机器人总体研究方案。基于功能分析法与不停机更换托辊理论研究，利用SolidWorks软件建立机器人三维实体模型，并对行走机构、姿态调整平台、伸缩支撑平台、拆装机械手参数进行优化。通过ANSYS Workbench软件对支撑平台和皮带举升机构进行有限元分析，伸缩支撑平台采用滑轨式结构，滑轨在悬臂和举升额定载荷下应力分别为15.647 MPa和66.395 MPa，最大变形位移出现在额定载荷条件下，位移为1.0742 mm。皮带举升机构选用剪叉式结构，额定举升时最大应力为152.82 MPa，最大位移为0.7331 mm。依据设计参数加工机器人样机，以功率为64 kW的柴油发动机为动力，通过液压马达驱动履带行走，速度范围在3~8 km/h，姿态调整平台可实现升降高度0~357 mm、俯仰角度±15°、侧倾角度-4°~7°、旋转角度-10°~20°、横移范围0~400 mm、纵移范围0~350 mm，多级伸缩机构采用组合滑轨方式实现平台0~2.1 m伸缩，采用五自由度机械手可实现对不同位置托辊进行拆装。通过地面及井下试验测试对机器人样机的行走、姿态调整、举升皮带、拆装托辊功能进行试验验证，结果表明：机器人在主平硐狭窄巷道行驶通过性良好，伸缩支撑平台在输送机不停机状态下举升皮带最大高度为241 mm，为机械手拆装不同位置托辊提供足够操作空间以达到设计性能要求，研究带式输送机不停机更换托辊机器人可为煤矿带式输送机维修提供新途径。

关键词: 带式输送机, 维修机器人, 更换托辊, 不停机举升皮带