摘 要 制动器是采煤机安全制动装置，本课题研制具有在线监测功能的采煤机用智能干式多片制动器，该制动器除了满足普通盘式液压制动器性能参数外，还应具备在制动器工作时对摩擦材料磨损量、温度进行实时监测，并具有判断是否超出极限，超出极限值时则发出警报信号的功能。 本文研究利用微电子新技术、传热理论、有限元分析方法、防爆电气理论和技术对液压制动器进行了设计研究。主要工作如下： （1）详细介绍了盘式制动器的发展现状、结构原理，在此基础上，采用防爆电气理论和技术对采煤机用智能干式多片制动器的总体方案进行了设计。 （2）根据制动器的结构及工作原理，建立了三维制动器模型，并对其紧急制动工况下的相关参数进行了计算，使用有限元分析软件ABAQUS进行了其紧急制动工况下的热-结构耦合温度场的分析，得出了采煤机紧急制动工况下的三维摩擦温度场的分布变化规律。目前现有的二维模型施加热流密度的分析方法不能准确反映制动器的实际制动过程，采用三维模型的摩擦热分析方法可以真实地反映实际的制动过程，该模型克服了二维模型分析方法中因忽略摩擦温度场的不完全对称及盘片之间的应力分布关系而存在的缺陷，使温度场的分布变化规律更符合实际。 （3）通过研究温度场沿制动器轴向的分布规律，对制动器最高温度处的延轴向的坐标点的温度值进行曲线拟合，建立了温度沿轴向位移变化的方程，为温度传感器的安装位置选择及监测提供了理论支持。 （4）研制了一种单片机智能监测系统。该系统以C8051F334为控制核心，实现了传感器对温度和磨损量采集与处理、数据存储以及超限报警，上位机实现温度和磨损量的实时监控、记录以及保存。

ABSTRACT The brake is shearer safety braking device, this topic developed an intelligent dry multi-disc brake for shearer with functions of on-line detection. The brake in addition to meet the common performance parameters of the hydraulic disc brake, it also be able to detecte friction material erosion rate and temperature in real time, and determine whether beyond the limit, beyond the limit value the shearer alarm. In this paper, author used microelectronics technology, heat transfer theory, finite element analysis method, electrical explosion-proof theory and technology for hydraulic brake design and research. The main work is as follows: (1) Detaily introduced the development status、the structure and working principle of disc brake. On this basis, using the electrical explosion-proof theory and technology design the overall scheme of the intelligent dry multi-disc brake of shearer. (2) Based on the structure and working principle of brake, established a three-dimensional brake model, and calculated relevant parameters of the emergency braking conditions, used the finite element analysis software ABAQUS to analyze its hot-structure coupling temperature field of emergency braking conditions, obtained three dimensional temperature field distribution change law of friction under emergency braking condition. At present the existing analysis method-applying heat flux density of two-dimensional model can not accurately reflect the actual brake braking process, the three-dimensional model of friction heat analysis method can real reflect the actual braking process, the model overcomes the two-dimensional model analysis method ignoring the asymmetry of the friction temperature field and stress distribution between the disc,make the distribution of temperature field variation more practical. (3) By study the brake axis distribution regularity of temperature field, curve fitting the highest temperature of the point along the axial, established equation of temperature along the axial displacement, provide theoretical guidance for temperature sensor installation location choice and monitoring. (4) Developed a single chip microcomputer intelligent monitoring system, the system with the C8051F334 as the core, achieved the sensor for temperature and abrasion quantity acquisition and processing, data storage, and beyond the limit value alarm, PC realize the temperature and wear real-time monitoring, record and save.