Analysis of the development of a new type of mine anti-damage lighting lamp
1 domestic application status of fluorescent lamps in downhole
At present, most of the explosion-proof lamps widely used at home and abroad use ordinary straight tube fluorescent lamps as the light source. The main structure consists of the explosion-proof light source cavity and the electrical explosion-proof cavity. The lamp tube is placed in the light source cavity, and the ballast is placed in the explosion-proof cavity. Inside, if an inductive ballast is used, two explosion-proof chambers are also required, and the ballast and the starter are respectively arranged, and the cavity-interrupted joint faces are connected by screws. When the lamp of this structure is repaired, after the explosion-proof chamber is opened, the internal power supply is exposed to the environment of flammable gas. According to the provisions of Article 21 of the national standard GB3836. 1-2000, it is strictly prohibited to open the lamp cover. Warning signs, the industry standard MY221-91 also made corresponding regulations. Downhole lighting fixtures often work continuously after one lighting until the lamps are damaged, ie the lamps are required to have a long life and a small amount of maintenance. At present, most of the explosion-proof lamps use the inductive ballast and the starter to match the ordinary straight tube fluorescent lamp. The ballast of this lamp itself consumes 8 9 W, and wastes energy up to 1 / 4 1 / 5, the actual lamp Life expectancy is only about 1 month. Since the underground lighting power supply voltage is 127 V, the working voltage of the straight pipe above 20 W is above 100V. When the lamp power is > 20 W, the inductive ballast cannot be driven. In recent years, some manufacturers have tried to replace inductive ballasts with electronic ballasts, but it is difficult to guarantee due to various factors such as high-order harmonics (THD), peak coefficients (BFB) and starting performance of electronic ballasts. The reliability of the luminaire will also cause electromagnetic pollution in the power supply network.
In actual use, the power supply of the explosion-proof luminaire is powered by a special explosion-proof switch (the lighting signal comprehensive protection device should be used according to the regulations), and an explosion-proof switch often drives 100 200 ç› lamps, which are arranged under the mine and have a length of 1000 2000 m. If you repair a lamp, you need to cut off the lighting power of almost the entire roadway. You have to walk 2000 4000 m once and for all. Since the explosion-proof lamps are installed at the top of the roadway, the high-altitude operation increases the difficulty of maintenance when there is no lighting, and the life of the lamp It was also decided that it was necessary to replace the lamp and repair the lamp frequently. At present, the phenomenon of illegal operation of electrified maintenance has occurred from time to time, posing a safety hazard to the workplace. The structural components of the luminaire are connected by bolts, which are easy to open with ordinary tools, and it is impossible to set a warning sign at each joint, which increases the possibility of misoperation and illegal operation. At present, most of the methods are adopted to install a front latching switch device on the luminaire, and the power supply in the cavity is pre-cut before the explosion-proof chamber is opened by an external control lever, and then repaired. However, in addition to increasing the complexity of the explosion-proof casing (the joystick must be opened outside the explosion-proof hole to reduce safety and reliability), the locking switch also has the possibility of damage, and necessary maintenance is required, and the maintenance lockout switch is also Also faced with a problem of electrified maintenance.
Therefore, it is necessary to design and study new types of lamps.
2 new lighting design ideas
The design concept is: adopting a new lamp light source and a new high-efficiency circuit system to improve the intrinsic quality of the lamp; structurally realize the reliability of the electrified maintenance, and fundamentally improve the safety performance of the explosion-proof lamp.
The specific design requirements are to use the internationally leading light source to develop small-diameter, high-illuminance H-type structural lamps, and adopt the three-color phosphor of the new rare earth metal material to greatly improve the luminous efficiency of the lamp.
In order to meet the requirements of special places such as underground, high color temperature lamps can be used for more than 8000 hours. Ballasts use new and efficient electronic circuits to reduce high-order harmonics (THD) and peak coefficients (BFB) to It is superior to national industry standards; it adopts measures such as delayed start (so-called soft start), lamp protection circuit and power failure protection circuit to develop a light source system that is reasonable in matching with the lamp. The problem of power failure maintenance is solved in the structure, so that it is not necessary to stop the entire line power supply for maintenance during maintenance, and it does not affect the explosion-proof performance. The main explosion-proof shell of the luminaire is combined with the fast-installing structure of the bayonet to replace the structure of the bolt connection of the old luminaire, which is convenient for maintenance; the main explosion-proof cavity is mechanically locked and adopts a new power connection form; the main part of the luminaire which will be easily damaged It is made into a whole, and is connected with the non-detrimental power supply main body by the card insertion method, and the lamp is functionally allowed to be inserted into the power card. Except for the main explosion-proof cavity, the other parts are made of non-detachable structure on the outside of the lamp housing to prevent the possibility of misoperation. The luminaire of this design has applied for the Chinese invention patent and obtained the authorization (patent number: ZL99108759. 3; international patent main classification number: F21V25 /12).
3 structural performance analysis
(1) Structural design
Built-in plug-in explosion-proof luminaire, the shape is as shown in 1. It consists of two separate components: the main body of the power supply and the main body of the work. The two parts are joined by a locking explosion-proof surface. There is no wire connection in the traditional luminaire. When the luminaire is in working condition, the parts of the luminaire cannot be disassembled using ordinary tools.
The main body of the power supply is mainly composed of a lead mechanism 1, a left shell 3, a terminal block 2, a connecting turntable 7, a locking screw 4, etc., and is responsible for the supply of the lamp power supply. The working body of the lamp is mainly composed of a housing 6, a conductive pin 8, a transparent tube 16, and a light source. The lamp tube 14, the ballast 9 and the protective cover are composed of the main body of the work that needs to be repaired during use of the lamp. The lead mechanism 1 of the power main body is disposed at the outer end of the left shell, and can also be disposed on both sides of the shell according to requirements, generally made of the same two, and the structure is designed according to national special standards, mainly by a nozzle, a flameproof board, Explosion-proof gaskets, seals, etc., respectively, to bear the introduction and extraction of power. On the inner side of the left casing, fittings such as a terminal block 3, a connecting turntable 7, and a locking screw 4 are also mounted.
The outer casing of the working body is manufactured by screwing the connecting rod 20 in the protective cover into the housing and then welding with the right casing 17, and then adding the spiral mesh 15 and the reflector 16 to the outside thereof; and then passing the transparent tube 14 through a rubber seal or the like. It is assembled inside, thus forming a non-detachable unitary structure. The light source tube 13 is inserted into the socket 12 and supported by the lamp holder 19; the support plate 11 fixed in the housing 6 mainly supports the fixing of the ballast 10, the conductive plug 8 and the socket 12. The support plate is fixed in the working body housing by two round nuts 9. The plug-in mechanism responsible for the electrical connection consists of a terminal block, a connecting turntable and a conductive plug. The terminal block is made of an insulating material, and two conductive static contacts are arranged on the front side thereof, respectively, and the two connecting screws are respectively connected; the connecting turntable is fixed on the terminal block by a spring-loaded screw, and a positioning block is arranged on the contact surface thereof. . When the explosion-proof cavity is separated, the connecting turntable can effectively cover the two conductive static contacts by rotating positioning. The two conductive copper rods in the conductive pin 8 connected to the ballast and the support plate are elastically provided by the spring to ensure reliable conduction with the terminal block.
The connection of the structure not only facilitates the disassembly and assembly of the lamp, but also realizes the power-off and lock-off of the open cover. The realization manner is that the outer edges of the flameproof joint surface of the left shell and the shell are made into a plurality of male and female opposite card slots. When assembling, first insert the flameproof surface at a predetermined angle. After the position, the male and female slots are just opposite each other. Rotate the housing to make the male and female slots interlock. When the position is to the specified position, it is fixed by the locking screw.
The locking screw is a triangular screw on the miner's lamp (cap lamp), and only the special tool can open the lamp.
Through structural analysis, the main function of the main body of the power supply is to connect the power supply. The structure is simple and stable. Generally, no maintenance is required after the initial installation of the lamp. When repairing, only the special tool is used to loosen the locking screw, and the work of connecting and connecting the housing is connected. The main body can be divided. Since the conductive plug 8 and the housing rotate synchronously, the two conductive rods in the conductive plug are separated from the static contacts on the terminal board after the rotation and before the opening, and the connecting turntable is corresponding to the spherical surface of the terminal block. The bump is positioned and covers the static contact. At this time, the power supply portion is substantially in an explosion-proof state to the outside, and does not affect the maintenance of the work portion. The reassembly after repair is opposite to the above method: the repaired work main body is pre-rotated at a certain angle, so that the flameproof joint surface is fully matched in position, and at this time, not only the mating male and female bayonet ports are opposed, but also the conductive plug is inserted into the connecting turntable. In the guiding slot, the housing is rotated, and the power supply is turned on by the static contact, the conductive pin and the ballast to make the lamp work.
(2) Installation and maintenance
The installation of the luminaire is horizontally hung on the upper part of the roadway by two lifting rings on the luminaire, or it can be tilted or vertically installed according to the needs of the site. The power supply wiring operation is performed when the first assembly is used. That is, the locking screw 1 is removed, the power supply main body 2 and the working main body 3 are unscrewed (unplugged after being rotated); the connecting turntable 7 is removed, the cable is introduced, and the power is connected. Then, the connecting turntable is assembled in the reverse order described above, and the connecting turntable is rotated to the position where the working body of the lamp is convenient for insertion. At this time, the connecting turntable covers the two power static contacts on the terminal block, and then inserts into the rotating card to work on the working body. The locking screw is tightened to complete the installation of the lamp. The main part of the power supply is generally not required to be repaired after installation, and is not a consumable part.
When the luminaire fails, the main body of the luminaire is unscrewed according to the above method, and the working body of the standby luminaire is directly replaced. The working body of the replaced fault lamp is screwed to the main body of the standby lamp and then brought to the well for specific maintenance. If it is necessary to repair the working body of the luminaire, remove the two round nuts 9 and take out the ballast and the support plate together with the guide pin 8 and the light source tube 13 from the outer casing to repair or perform the lamp on the ballast. After the replacement and overhaul are completed, the luminaires are restored and fixed according to the above installation method.
It can be seen from the installation and maintenance process that when the lamps are repaired underground, since it is not necessary to stop the lighting power supply of the roadway, the actual maintenance time of one lamp is only a few minutes, which will greatly reduce the workload of the lamp maintenance. More importantly, due to the structural problem of solving the problem that the power must be cut off to repair the lamps, the illegal operation behavior is fundamentally eliminated, and the safety of mine production is improved.
4 Conclusion
(1) The quick-fit structure of the bayonet is adopted, which greatly facilitates the maintenance operation; the peripheral locking screw increases the safety.
(2) Make the vulnerable part and the non-wearable part of the lamp into two relatively independent parts, and connect them in the form of rotating bolts to ensure that the main part of the vulnerable lamp is directly unscrewed without power failure, so as to realize electrification maintenance.
(3) The lamp is small in size, light in weight, high in illumination, long in life, energy-saving and efficient, beautiful in appearance, convenient in installation and maintenance.
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