Hydraulic support for potassium salt mine and production process method of hydraulic support

Abstract

The invention relates to a potassium salt mine hydraulic support and a production process method thereof, and the production method comprises the following steps: S1, cutting and blanking steel, and carrying out groove processing to obtain a base body structural part and structural accessories; s2, the base body structural part is assembled and welded to obtain a structural prototype; s3, the structure accessories are installed in sequence, and a semi-finished product is obtained; and S4, the semi-finished product is subjected to thermal aging treatment, overall machining and surface anti-corrosion treatment, and a structural part is obtained and further assembled to form the hydraulic support. And in the steps S2-S3, after welding is completed, laser micro-textured surface treatment and surface passivation treatment are conducted on a weld joint area, and then a formed micro-textured structure is filled with corrosion inhibition coating. The technical problems that in an existing production technology, structural internal stress and deformation control of a hydraulic support are insufficient, and weak areas such as welding seams are prone to early corrosion, so that the bearing capacity of the hydraulic support is reduced rapidly in high-chlorine, high-humidity and high-ground-pressure environments such as sylvite ores, and the overall service life is short can be solved.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and in particular to a hydraulic support for potash mines and its manufacturing process. Background Technology

[0002] In recent years, with the continuous growth of domestic potash resource demand and the advancement of overseas potash mine exploration and development, deep potash resource mining has become a key development direction for the industry. However, deep potash deposits have special occurrence conditions, generally characterized by deep burial (usually exceeding 3000 meters), high ground pressure, and fractured ore bodies. At the same time, the mining environment has high chloride ion concentration and high humidity, which places extremely high demands on the load-bearing capacity, structural stability, and corrosion resistance of support equipment.

[0003] Hydraulic supports, as key support equipment in underground mining, directly affect the safety and economy of mining operations. Currently, hydraulic supports used in potash mines mainly draw on the design and manufacturing processes of hydraulic supports used in coal mines. Existing production methods for hydraulic supports in coal mines typically include: steel plate cutting, structural component assembly and welding, machining, and surface coating. Among these, structural components mostly use conventional strength steels such as Q345 and Q460, welding processes employ continuous welding or segmented welding, and surface anti-corrosion treatment uses solvent-based anti-rust paint spraying or ordinary hot-dip galvanizing.

[0004] However, directly applying the production method of hydraulic supports for coal mines to potash mine environments presents the following technical drawbacks:

[0005] First, insufficient corrosion resistance. Potash mining environments are characterized by high chloride ion concentrations and humidity, resulting in strong corrosive media penetration. Existing coatings are prone to pitting, blistering, and peeling under chloride ion penetration. This is particularly true in the weld areas of structural components. The welding thermal cycle leads to uneven material structure and coarse grains, while the welding process generates significant residual stress, making these areas sensitive to electrochemical corrosion. Furthermore, the complex geometry and stress conditions of the weld area cause stress concentration and uneven thickness in the surface coating, making it more susceptible to microcracks during use and providing penetration channels for corrosive media. These factors combined make the weld area a weak point where corrosion preferentially initiates and spreads. Often, localized corrosion occurs at the weld before the overall support coating shows significant failure, leading to stress concentration, reduced load-bearing capacity, and shortened service life.

[0006] Second, structural stress and deformation control is insufficient and lacks specificity. Existing processes directly adopt welding methods used in coal mine supports, lacking targeted design for the high ground pressure and asymmetric load conditions of potash mines. Crude control of process parameters such as welding sequence and method leads to significant residual stress and structural deformation after welding. These residual stresses and structural deformations not only reduce the load-bearing capacity of the supports but also further induce corrosion and accelerate its spread. These two factors reinforce each other, causing the support's load-bearing capacity to rapidly decline during service, making it difficult to meet the long-life mining requirements of deep potash mines.

[0007] To address the aforementioned issues, existing research has attempted optimizations through material upgrades and coating improvements, such as using higher-strength steel, increasing coating thickness, or employing zinc-rich primers. However, these improvements are mostly localized optimizations and cannot effectively solve key problems such as preferential corrosion in weld areas and structural stress and deformation control. They fail to provide hydraulic supports with both good structural load-bearing capacity and long-term corrosion resistance in the harsh environment of potash mines, and their cost-effectiveness is often low.

[0008] Therefore, developing a production process for hydraulic supports specifically designed for the highly corrosive and high ground pressure environment of potash mines, and achieving a synergistic improvement in structural strength and corrosion resistance, has significant practical implications and application value. Summary of the Invention

[0009] (a) Technical problems to be solved

[0010] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides a hydraulic support for potash mines and its manufacturing process, which solves the technical problems of insufficient control of internal stress and deformation of hydraulic supports prepared by existing hydraulic support manufacturing processes, and the susceptibility of early corrosion in weak areas such as welds, resulting in a rapid decline in load-bearing capacity and a short overall service life in potash mines and other high-chlorine, high-humidity, and high-ground-pressure environments.

[0011] (II) Technical Solution

[0012] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0013] In a first aspect, embodiments of the present invention provide a manufacturing process for hydraulic supports for potash mines, comprising the following methods for preparing hydraulic support structural components:

[0014] S1. Plate and base structure processing: Cut the steel to obtain the plate materials that make up the hydraulic support structure; beveling the corresponding plate materials to obtain the base structure and structural accessories.

[0015] S2, One-time assembly and welding: Assemble and weld the base structural components to obtain the structural prototype;

[0016] S3. Group assembly and welding: Assemble and weld structural accessories on the structural component prototype in the order of inside to outside to obtain a semi-finished structural component.

[0017] S4. Post-processing: The semi-finished structural components after forming are subjected to heat aging treatment, overall machining and surface anti-corrosion treatment to obtain hydraulic support structural components; among them, the hydraulic support structural components include top beam, shield beam and base, and the three are assembled with columns and other auxiliary components to form a hydraulic support;

[0018] In S2-S3, after welding, the easily corroded areas are subjected to laser micro-texturing surface treatment and surface passivation treatment, and then the formed micro-textured structure is filled with corrosion-inhibiting coating; the easily corroded areas include the weld and the heat-affected zones on both sides; in S4, the surface anti-corrosion treatment includes coating anti-corrosion treatment.

[0019] According to a preferred embodiment of the present invention, in S1, the material is cut using CNC flame cutting, CNC laser cutting, or CNC plasma cutting; the plate material used for the structural components is at least one of Q550D and Q690D low-alloy high-strength steel; in S2, when preparing the top beam and / or base, the horizontal ribs are spot-welded to the top plate or bottom plate or not welded; reinforcing horizontal ribs for suppressing deformation are also welded into the span of the top beam and / or base; in S3, reinforcing ribs are provided in the stress concentration areas, including the column socket connection and the root of the lug; the reinforcing ribs are cross ribs or diagonal bracing ribs.

[0020] According to a preferred embodiment of the present invention, when using CNC flame cutting, the cutting parameters are controlled in stages according to the steel plate thickness, as follows:

[0021] For steel plates with a thickness of 10-20mm, use a cutting nozzle with a throat diameter of 0.8mm±0.1mm, a cutting speed of 100-350mm / min, and a cutting oxygen pressure of 0.7-0.8MPa;

[0022] For steel plates with a thickness of 20-40mm, use a cutting nozzle with a throat diameter of 1.0mm±0.1mm, a cutting speed of 350-500mm / min, and a cutting oxygen pressure of 0.7-0.8MPa;

[0023] For steel plates with a thickness of 40-60mm, use a cutting nozzle with a throat diameter of 1.25mm±0.1mm, a cutting speed of 300-420mm / min, and a cutting oxygen pressure of 0.7-0.8MPa;

[0024] Furthermore, the oxygen used for cutting must be at least 99.5% pure, and the cutting method must be vertical.

[0025] According to a preferred embodiment of the present invention, in S2-S3, the laser micro-texturing surface treatment is as follows: a number of micron-sized pits and / or grooves, i.e. micro-textured structures, are prepared on the surface of the weld and the heat-affected zone on both sides by laser etching or imprinting process, which are used to store corrosion-inhibiting coatings and enhance the adhesion of anti-corrosion coatings.

[0026] According to a preferred embodiment of the present invention, in S2-S3, the surface passivation treatment is as follows: an acidic oxidizing passivation liquid is sprayed onto the weld and the heat-affected zones on both sides of the structural component, and after a passivation film is formed on the surface, it is cleaned and dried.

[0027] By weight, the acidic oxidizing passivation solution contains 10-30 parts hydrogen peroxide, 5-15 parts molybdate, 1-5 parts fluorozirconic acid, 2-6 parts phytic acid, 0.5-3 parts silane coupling agent, and 30-140 parts water; the pH of the acidic oxidizing passivation solution is 1.0-3.5.

[0028] According to a preferred embodiment of the present invention, in S2-S3, after the surface passivation treatment is completed, a corrosion-inhibiting coating is filled into the micro-textured structure formed by laser micro-textured surface treatment, and the filling amount is at least 90% of the volume of the micro-textured structure; the corrosion-inhibiting coating includes 200-450 parts of silica sol, 10-20 parts of molybdate, 5-15 parts of tungstate, and 5-20 parts of silane hydrophobic modifier; the silica content of the silica sol is 20-40 wt%; the silica sol is cured to form an aerogel during thermal aging treatment.

[0029] According to a preferred embodiment of the present invention, the molybdate is at least one of sodium molybdate and ammonium molybdate; the tungstate is selected from at least one of sodium tungstate, ammonium tungstate, and ammonium metatungstate; and the silane hydrophobic modifier is at least one of methyltrimethoxysilane, dimethyldimethoxysilane, and octyltriethoxysilane.

[0030] According to a preferred embodiment of the present invention, in S4, the coating anti-corrosion treatment includes:

[0031] Primer spraying: Spray water-based anti-corrosion primer for basic wear resistance and corrosion protection;

[0032] Topcoat spraying: Spray water-based hydrophobic topcoat. The hydrophobic topcoat has a micro-nano composite hydrophobic structure, which is used to reduce the adhesion strength of brine and its crystalline salts on the support surface.

[0033] The thickness of the primer is 30-80μm; the thickness of the topcoat is 30-60μm; the static water contact angle of the hydrophobic topcoat is ≥120°.

[0034] According to a preferred embodiment of the present invention, the preparation of the top beam includes the following steps:

[0035] A1: Cut the constituent plates of each structure, bevele the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main stiffening plates, top plates, balance lugs, and transverse stiffenings; the structural accessories include round steel bars, tongue plates, column sockets, cover plates, and pads.

[0036] A2: First assembly and welding: Using positioning shafts and tooling for positioning, the main stiffening plate, top plate, horizontal stiffening, and balance lugs are assembled and welded to obtain the basic shape of the top beam; during welding, the horizontal stiffening and main stiffening are welded first, and then the horizontal stiffening and top plate are welded; this welding includes fillet welding and filler welding.

[0037] A3: Internal Assembly and Welding: Assemble and weld round steel, pads, and column sockets onto the top beam prototype; this welding includes fillet welding;

[0038] External assembly and welding: Assemble and weld the cover plate and tongue plate on the top beam prototype to obtain the top beam semi-finished product: This welding includes bevel filling welding;

[0039] A4: The semi-finished top beam is subjected to heat aging treatment, overall machining and surface anti-corrosion treatment, and then the valve groups and pipelines are installed to obtain the top beam;

[0040] The fabrication of the protective beam includes the following steps:

[0041] A1: Cutting to obtain the constituent plates of each structure, beveling the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main stiffening plates, top plates, balance lugs, and transverse stiffenings; structural accessories include pads and cover plates.

[0042] A2: Primary Assembly and Welding: Using positioning shafts and tooling, the main stiffening plates, top plates, transverse stiffeners, and balance lugs are assembled and welded to obtain the basic shape of the shield beam; this welding includes fillet welds.

[0043] A3: Internal assembly and welding: Assemble and weld pads on the prototype of the shield beam;

[0044] External assembly and welding: Assemble and weld the cover plate on the prototype of the shield beam to obtain the semi-finished shield beam; this welding includes bevel filler welding;

[0045] A4: The semi-finished shield beam is subjected to heat aging treatment, overall machining and surface anti-corrosion treatment, and then the valve groups and pipelines are installed to obtain the shield beam;

[0046] The preparation of the base includes the following steps:

[0047] A1: Cut the constituent plates of each structure, bevel the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main stiffening plates, bottom plates, and transverse stiffening plates; the structural accessories include column sockets and cover plates.

[0048] A2: First assembly and welding: Using positioning shafts and tooling, the main stiffening plate, base plate and transverse stiffening plate are assembled and welded to obtain the base prototype; this welding includes fillet welding;

[0049] A3: Internal Assembly and Welding: Assemble and weld the column sockets on the base prototype; this welding includes fillet welding;

[0050] External assembly and welding: Assemble and weld the cover plate on the base prototype to obtain the base semi-finished product; this welding includes bevel filling welding;

[0051] A4: The semi-finished base is subjected to heat aging treatment, overall machining and surface anti-corrosion treatment, and then the valve groups and pipelines are installed to obtain the base.

[0052] In a second aspect, the present invention also provides a hydraulic support for potash mines prepared by any of the production processes described in the first aspect, wherein the weld area and the heat-affected zones on both sides of the hydraulic support structural component are provided with a micron-scale micro-textured structure; the surface of the micro-textured structure has a passivation film; the micro-textured structure is filled with a filler formed by the curing of a corrosion-inhibiting coating; the surface of the structural component is covered with an anti-corrosion coating; the hydraulic support structural component includes a top beam, a shield beam and a base.

[0053] (III) Beneficial Effects

[0054] The beneficial effects of this invention are as follows: The production process of the hydraulic support for potash mines of this invention, by first preparing the basic structural components and structural accessories and then welding them in the order of inside to outside, can effectively control welding deformation and residual stress accumulation compared with the prior art. This results in the hydraulic support structural components prepared by this invention having higher dimensional accuracy and lower residual stress levels after welding. Combined with the subsequent installation method of spot welding or non-welding between the transverse ribs and the top or bottom plate, as well as the setting of reinforcing transverse ribs, it can further reduce welding deformation and residual stress while maintaining high structural strength, significantly improving the overall stability and load-bearing capacity of the structural components.

[0055] Furthermore, after each welding cycle, the present invention performs laser micro-weaving surface treatment, surface passivation treatment, and corrosion-inhibiting coating filling on the weld area. Compared with the prior art, the micro-weaving structure formed in the laser micro-weaving surface treatment can enhance the adhesion of subsequent coatings through mechanical anchoring effect, while extending the path of corrosive substances to penetrate the substrate; its micron-sized pits or grooves can also collect the penetrated corrosive media and guide its directional flow to the corrosion inhibitor enrichment area, allowing the corrosion inhibitor coating to fully contact and act with the corrosive media. The surface passivation treatment forms a chemical passivation film on the surface of the weld area, reducing the corrosion rate of the weld area from an electrochemical level. Even if the outer coating is partially damaged, the passivation film can still act as a second line of defense to delay the corrosion process. The corrosion inhibitor coating is filled into the micro-weaving structure, and after the coating is damaged, it can directly contact and react with the penetrated corrosive media, inhibiting the spread of corrosion reaction and working synergistically with the passivation film to provide long-term and stable protection for the weld area. The above measures, working synergistically, effectively address the technical problem that existing hydraulic support manufacturing processes are prone to premature corrosion in high-chlorine, high-humidity, and high-ground-pressure environments such as potash mines, due to insufficient control of internal structural stress and deformation, and weak areas like welds. This leads to a rapid decline in load-bearing capacity and a short overall service life. Furthermore, treating exposed welds immediately after each welding cycle ensures that all welds (including internal welds that may be obscured during subsequent assembly) receive adequate reinforcement before closure. This fundamentally avoids the problem of some welds being untreated or inadequately treated due to structural obstruction, comprehensively improving the protective integrity and corrosion resistance of the weld area.

[0056] Furthermore, this invention further reduces problems such as residual stress that may be caused by welding and laser micro-weaving surface treatment by heat aging treatment of semi-finished products, thereby reducing deformation, stabilizing structural dimensions, and reducing the risk of deformation during long-term service.

[0057] By comprehensively applying the above-mentioned processes, the hydraulic support structure prepared by this invention exhibits superior dimensional stability and deformation resistance (initial welding deformation ≤ 3 mm / m). The corrosion resistance of weak weld areas is significantly enhanced, thus enabling a longer service life and more stable load-bearing capacity in harsh potash mining environments. This also reduces the frequency of maintenance and replacement due to corrosion and structural failure, effectively controlling the total life-cycle cost. Furthermore, the invention's precise reinforcement of easily corroded weak points such as welds achieves long-term protection while also considering material and process costs, resulting in a high cost-performance ratio. Attached Figure Description

[0058] Figure 1 This is a schematic diagram of the overall structure of the hydraulic support prepared in Embodiment 1 of the present invention;

[0059] Figure 2 This is a schematic longitudinal section of the top beam semi-finished product of the hydraulic support prepared in Embodiment 1 of the present invention;

[0060] Figure 3 This is a schematic diagram of the bottom surface of the top beam semi-finished product of the hydraulic support prepared in Embodiment 1 of the present invention;

[0061] Figure 4 A schematic longitudinal section of the shield beam semi-finished product of the hydraulic support prepared in Embodiment 1 of the present invention;

[0062] Figure 5 This is a longitudinal cross-sectional schematic diagram of the semi-finished base of the hydraulic support prepared in Embodiment 1 of the present invention;

[0063] [Explanation of Labels in the Attached Image]

[0064] 1: Top beam; 2: Protective beam; 3: Base; 4: Main reinforcement; 5: Top plate; 6: Balance lug; 7: Horizontal reinforcement; 8: Reinforcing horizontal reinforcement; 9: Round steel; 10: Column socket; 11: Cover plate; 12: Pad plate; 13: Bottom plate. Detailed Implementation

[0065] To better explain and facilitate understanding of the present invention, a detailed description of the invention is provided below with reference to the accompanying drawings and specific embodiments. In this document, directional terms such as "upper," "lower," etc., are used interchangeably with other directional terms. Figure 1 The orientation is used as a reference.

[0066] This invention provides a manufacturing process for hydraulic supports in potash mines, which involves preparing hydraulic support structural components using the following methods:

[0067] S1. Plate and Base Structure Processing: Steel is cut and prepared to obtain the constituent plates of the hydraulic support structure. The constituent plates are then beveled to obtain the base structure and structural accessories. Precise cutting and beveling provide dimensionally accurate constituent plates for subsequent assembly and welding, ensuring the basic quality of the hydraulic support structure (hereinafter referred to as the structure).

[0068] S2. Single-stage assembly and welding: The base structural components are assembled and welded to obtain the basic structural shape. A basic framework for the structure is formed through a single columnar welding process, providing a solid foundation for the subsequent installation of structural accessories. After obtaining the basic structural shape, it is cooled to room temperature before any other operations are performed to avoid the accumulation of thermal stress.

[0069] S3. Group Assembly and Welding: Structural accessories are assembled and welded sequentially on the structural component prototype, following an inside-out order, to obtain a semi-finished structural component. Adopting an inside-out welding sequence, and welding the external structure only after the internal structure has been welded and cooled, effectively controls welding deformation while ensuring efficiency. This avoids stress concentration and structural distortion that may result from improper welding sequence or concentrated welding, ensuring the overall accuracy and load-bearing capacity of the structural component.

[0070] S4. Post-processing: The semi-finished structural components undergo heat aging, overall machining, and surface anti-corrosion treatment to obtain the structural components. Heat aging eliminates residual stress from welding, reduces overall deformation, and improves the stability and basic accuracy of the overall structure. Overall machining, performed after heat aging, further ensures the precision of machining fits on top of the already good basic accuracy, improving the overall precision of the structural components. Surface anti-corrosion treatment provides long-term anti-corrosion protection for the entire structural components, offering overall corrosion resistance. The structural components include a top beam 1, a protective beam 2, and a base 3. Assembling these three components with the columns and other auxiliary parts forms a hydraulic support.

[0071] In S2-S3, after welding, the easily corroded areas are subjected to laser micro-texturing surface treatment and surface passivation treatment, and then the formed micro-textured structure is filled with corrosion-inhibiting coating (the above two treatments and one filling step are simplified and combined into a strengthening treatment). The easily corroded areas are mainly the weld and the heat-affected zone of 10-60mm on both sides. According to historical corrosion data and actual conditions, the above treatment can also be performed on easily corroded points such as the end area of ​​the guard plate, the top and bottom areas of the column, the area around the column socket 10 of the top beam 1 and the base 3 (the connection of the column socket 10), the root area of ​​the ear seat, and the area around the hinge hole.

[0072] In S4, surface anti-corrosion treatment includes coating anti-corrosion treatment. Specifically, the anti-corrosion coating (referred to as coating) prepared by coating anti-corrosion treatment serves as an outer barrier to further block corrosive media. Together with the inner corrosion-inhibiting coating and passivation treatment, it forms a synergistic protection system.

[0073] It should be noted that this invention does not abandon overall protection of non-weak areas. Instead, it employs surface anti-corrosion treatment to ensure overall anti-corrosion effectiveness, while specifically strengthening critical areas prone to corrosion, such as welds. For the remaining surfaces of the hydraulic support, conventional coating anti-corrosion treatment (such as primer + topcoat) is generally sufficient to meet its basic protection requirements. Furthermore, in non-weak areas, such as the bottom of base 3 and other non-critical load-bearing parts, even slight corrosion usually does not significantly affect the overall load-bearing capacity and safety of the support. Of course, heavy-duty anti-corrosion coatings or other anti-corrosion coatings with better corrosion resistance can be used to further improve the anti-corrosion effect, which does not contradict the strengthening treatment of this invention. Therefore, the strengthening treatment method of this invention can ensure the long-term reliability of critical weak areas while avoiding the increased costs caused by excessive protection, achieving a balance between protective effect and economy, resulting in high cost-effectiveness. It also has good adaptability, providing greater operational flexibility for subsequent surface anti-corrosion treatment. In addition, if cost is not a concern or there are extreme protection requirements, the strengthening treatment method of this invention can be applied to the entire structural component. However, this may lead to problems such as reduced welding strength, and needs to be determined based on actual conditions.

[0074] Optionally, in S1, before cutting, the steel plate undergoes shot blasting surface pretreatment to remove oxide scale, rust, and oil stains, obtaining a clean metal surface and increasing its roughness, providing a good adhesion base for subsequent welding and painting. During shot blasting surface pretreatment, steel shot or steel grit is used, with a blasting speed of 60-80 m / s, a coverage rate of 100%, and a cleanliness level not lower than Sa2.5.

[0075] Optionally, in S1, the specific anti-corrosion operation during beveling can be determined according to the actual plate thickness and welding process requirements. In this invention, optionally, in S1, the beveling angle is controlled at 30-45 degrees, and the blunt edge thickness is controlled at 2-4mm. For steel plates with a thickness greater than 30mm, an X-type or double U-type beveling can be used to reduce the amount of weld filler and heat input, and reduce welding deformation.

[0076] Optionally, in S1, CNC flame cutting, CNC laser cutting, or CNC plasma cutting methods are used for material cutting. The structural components are made of at least one of Q550D and Q690D low-alloy high-strength steel to ensure that the support itself can provide sufficient strength and toughness to meet the load-bearing requirements of high ground pressure environments.

[0077] Optionally, in S2, when preparing the top beam 1 and / or base 3, the transverse ribs 7 are spot-welded to the top plate 5 and / or base plate 13 or not welded. The top beam 1 and / or base 3 are also welded with reinforcing transverse ribs 8 to suppress deformation, which increases structural rigidity and effectively controls the overall deformation of the structural components.

[0078] Optionally, in S3, reinforcing ribs are provided in stress concentration areas, including the connection of the column socket 10 and the root of the ear seat. The reinforcing ribs are either cross ribs or diagonal bracing ribs. These ribs enhance local stiffness, improving the structural member's resistance to eccentric loads and impact loads, thus improving structural stability. Furthermore, it is understood that cross ribs and diagonal bracing ribs are simple steel structure reinforcement structures, consisting only of simple steel plates or reinforcing bars. This invention uses them in stress concentration areas to achieve a strengthening effect; their specific structure, installation locations, and installation angles are not detailed here, and can be determined according to actual conditions.

[0079] Optionally, in S1, when using CNC flame cutting, the cutting parameters are controlled in stages according to the steel plate thickness, as follows:

[0080] For steel plates with a thickness of 10-20mm, use a cutting nozzle with a throat diameter of 0.8mm±0.1mm, a cutting speed of 100-350mm / min, and a cutting oxygen pressure of 0.7-0.8MPa.

[0081] For steel plates with a thickness of 20-40mm, use a cutting nozzle with a throat diameter of 1.0mm±0.1mm, a cutting speed of 350-500mm / min, and a cutting oxygen pressure of 0.7-0.8MPa.

[0082] For steel plates with a thickness of 40-60mm, use a cutting nozzle with a throat diameter of 1.25mm±0.1mm, a cutting speed of 300-420mm / min, and a cutting oxygen pressure of 0.7-0.8MPa.

[0083] Furthermore, the oxygen used for cutting has a purity of no less than 99.5%, and the cutting method is vertical cutting. By precisely controlling the cutting parameters and angle, the quality of the cut surface is ensured, material utilization is improved, and the subsequent processing effect is guaranteed.

[0084] Optionally, in S2-S3, before laser microtexturing surface treatment, the weld and the heat-affected zones on both sides are lightly ground to remove welding spatter, oxide scale, and surface contaminants, ensuring the precision of laser processing and the uniformity of the microtexture. The grinding depth is sufficient to remove the surface oxide layer, avoiding damage to the base metal.

[0085] Optionally, in S2-S3, the laser micro-texturing surface treatment involves using laser etching or imprinting processes to prepare several micron-sized pits and / or grooves, i.e., micro-textured structures, on the surface of the weld and its heat-affected zones on both sides. The micro-textured structure, constructed on the weld surface through laser micro-texturing, serves two purposes: firstly, it acts as a physical anchoring structure, enhancing coating adhesion through mechanical interlocking; secondly, it provides storage space for corrosion-inhibiting coatings. When the micro-textured structure is a groove network structure, it can also form a continuous aerogel skeleton, enabling directional guidance and overall adsorption of corrosive media.

[0086] Optionally, in S2-S3, during laser microtexturing surface treatment, conventional laser etching or imprinting methods can be used to process welds or other easily corroded areas in planar regions. For welds or other easily corroded areas in complex structures such as curved surfaces or corners, a multi-axis CNC platform or robot can be used to hold the laser head, adjust the laser head's attitude and focal length, and ensure that the laser beam is always perpendicular to the surface during processing, thus ensuring that the microtexture maintains a uniform morphology and distribution even on complex structures.

[0087] Laser microtexturing surface treatment utilizes nanosecond, picosecond, or femtosecond lasers with laser power ranging from 10 to 100 W, scanning speeds from 50 to 500 mm / s, and spot diameters from 10 to 100 μm. The microtextured structure consists of micron-sized pits and / or trenches. The pits have a diameter of 30 to 100 μm, a depth of 20 to 50 μm, and an areal density of 20% to 30%. The trenches have a width of 30 to 50 μm, a depth of 40 to 60 μm, and a spacing of 100 to 300 μm between adjacent trenches. The trenches are distributed in a grid-like or herringbone-like pattern, forming a connected network structure.

[0088] Optionally, in S2-S3, the surface passivation treatment is as follows: an acidic oxidizing passivation solution is sprayed onto the weld seam and the heat-affected zone on both sides of the structural component. After a passivation film is formed on the surface, it is cleaned and dried.

[0089] Optionally, in S2-S3, the surface passivation treatment time is 10-30 minutes to ensure complete passivation. After the surface passivation treatment is completed, immediately rinse the treated area with a large amount of clean water (deionized water or pure water) under high pressure to thoroughly remove residual passivation solution and reaction products. The rinsing time should be no less than 30 seconds, and the rinsing pressure should be 0.3-0.5 MPa. After rinsing, dry with hot air at a temperature of 80-120℃ until the surface is dry. Allow the dried structural parts to cool naturally to room temperature before proceeding with subsequent processes.

[0090] By weight, the acidic oxidizing passivation solution comprises 10-30 parts hydrogen peroxide, 5-15 parts molybdate, 1-5 parts fluorozirconic acid, 2-6 parts phytic acid, 0.5-3 parts silane coupling agent, and 30-140 parts water. The pH of the acidic oxidizing passivation solution is 1.0-3.5. The use of hydrogen peroxide as the oxidant in the passivation solution has high environmental value, avoiding the nitrogen oxide pollution problems that may arise from using traditional oxidants such as nitric acid. Molybdate acts as the main film-forming agent to form an anodic passivation film, while fluorozirconic acid assists in forming a dense zirconium oxide layer, synergistically providing a protective effect. Furthermore, the chelating effect of phytic acid enhances the adhesion of the passivation film and provides hydroxyl functional groups, while the silane coupling agent reserves chemical anchor points for efficient bonding of silica sol. Through the synergistic effect of the above components, this invention forms a dense passivation film rich in hydroxyl groups on the weld surface, providing basic corrosion protection and laying a good foundation for the subsequent filling and bonding of corrosion-inhibiting coatings.

[0091] Optionally, in S2-S3, after the surface passivation treatment is completed, a corrosion-inhibiting coating is filled into the micro-textured structure formed by the laser micro-texturing surface treatment. The amount of corrosion-inhibiting coating should be at least 90% of the volume of the micro-textured structure to avoid leaving large pores due to volume shrinkage after drying and curing. An excess of corrosion-inhibiting coating can be filled to ensure that the volume of the aerogel formed after drying and curing can still effectively fill the pores.

[0092] Optionally, the corrosion-inhibiting coating includes 200-450 parts of silica sol, 10-20 parts of molybdate, 5-15 parts of tungstate, and 5-20 parts of silane hydrophobic modifier. The silica content of the silica sol is 20-40 wt%. The silica sol solidifies into an aerogel during heat aging. During subsequent heat aging, the silica sol, acting as an inorganic carrier, transforms into a stable silica aerogel framework at high temperatures, uniformly embedding the molybdate and tungstate within it. The high specific surface area of ​​the aerogel adsorbs penetrating corrosive media. The molybdate and tungstate are slowly released into the media, exerting a dual corrosion-inhibiting effect of anodic passivation and heteropolyacid deposition, mitigating the impact of corrosive substances and repairing the passivation film to some extent. The silane hydrophobic modifier imparts hydrophobic properties to the aerogel itself, further blocking moisture penetration. Through a triple synergistic mechanism of micro-pit reservoir – aerogel fixation and adsorption – corrosion inhibitor slow release, long-term active protection is achieved for easily corroded areas, especially weld areas.

[0093] Optionally, the molybdate is at least one of sodium molybdate and ammonium molybdate. The tungstate is selected from at least one of sodium tungstate, ammonium tungstate, and ammonium metatungstate to ensure that the corrosion-inhibiting coating has stable and long-lasting corrosion-inhibiting properties. The silane hydrophobic modifier is at least one of methyltrimethoxysilane, dimethyldimethoxysilane, and octyltriethoxysilane to ensure hydrophobic effect.

[0094] Optionally, in S2-S3, the corrosion-inhibiting coating also contains 25-150 parts of reinforcing components. These reinforcing components are selected from at least one of alumina sol (active ingredient: alumina), zirconium sol (active ingredient: zirconium oxide), and titanium sol (active ingredient: titanium oxide), with a solid content of 20-40 wt%. During the thermal aging process, the oxides in the reinforcing components are distributed within the aerogel framework formed by the silica in the silica sol, creating a composite aerogel structure. This composite aerogel exhibits higher thermal stability and structural strength, resulting in superior overall mechanical properties. It is less prone to cracking or collapse during long-term service and can maintain its adsorption capacity for an extended period. Furthermore, the composite aerogel can form a uniformly distributed mesoporous structure (pore size 6-8 nm), which facilitates the adsorption of corrosive media and the slow release of corrosion inhibitors, enhancing the active protection effect.

[0095] Optionally, in S2-S3, after filling with the slow-release coating, the structural component filled with the corrosion-inhibiting coating is dried at 100-120℃ for 1-2 hours (using a mobile infrared heating device or similar structure). During the drying process, the silica sol dehydrates and condenses, forming a dry gel with a certain strength, which firmly adheres to the microwoven structure. The dried dry gel is a semi-transparent solid, filling at least 80% of the volume of the microwoven structure, preferably not less than 90%.

[0096] Optionally, in S2-S3, the corrosion-inhibiting coating also includes a thickener. The thickener is used to adjust the dynamic viscosity of the corrosion-inhibiting coating to within the range of 800-1500 mPa·s, ensuring a good filling effect and preventing flow within 30-60 minutes after filling. This allows for stable adhesion to complex curved and inclined surfaces, preventing detachment before drying. It should be noted that the thickener is only used to adjust the rheological properties of the slow-release coating. If the viscosity of the slow-release coating meets the above requirements without a thickener (e.g., when selecting a silica sol with a high solids content and adding reinforcing components), then a thickener is not necessary.

[0097] Optionally, in S2-S3, the amount of thickener added is 2-8 parts, and the thickener is at least one of hydroxymethyl cellulose, hydroxyethyl cellulose, polyacrylamide and sodium polyacrylate, to avoid generating a large amount of residual carbon.

[0098] Optionally, in S2-S3, the pH of the slow-release coating is in the range of 2-6, preferably in the range of 2-4. Within this pH range, the silica sol exhibits good gelation effects and can stably form a dry gel after drying. Simultaneously, the molybdate portion is converted to polymolybdate, further enhancing its corrosion inhibition effect. In actual preparation, if the pH deviates significantly from the above range, the pH can be adjusted by adding a small amount of inorganic acid (such as nitric acid) or inorganic alkali (such as ammonia), or by checking for any abnormalities in the raw materials.

[0099] Optionally, in S2-S3, before filling with the corrosion-inhibiting coating, the micro-textured structure is cleaned to ensure that there are no dust, oil, or other impurities in the micro-pits or trenches. When filling with the corrosion-inhibiting coating, a scraping and / or brushing method is used to fill the micro-textured structure with the corrosion-inhibiting coating. For example, the corrosion-inhibiting coating can be applied to the micro-textured area first by brushing, and then the coating can be applied by scraping repeatedly with a rubber scraper on the micro-textured structure. This allows the corrosion-inhibiting coating to fully penetrate into the micro-textured structure and its edges under shear force, and avoids a large amount of corrosion-inhibiting coating residue on the surface outside the micro-textured structure. A small amount of corrosion-inhibiting coating residue on the surface outside the micro-textured structure after scraping will not affect the bonding effect of subsequent coatings and can be removed after drying to form a dry adhesive.

[0100] Of course, methods such as applying glue with a glue gun can also be used to directly inject glue into the microwoven structure, and further modification can be done by methods such as scraping, but the efficiency may be reduced to some extent.

[0101] Optionally, in S4, a closed-loop thermal aging furnace is used for thermal aging treatment. During thermal aging, the heating rate is controlled at 50-100℃ / h to avoid uneven thermal stress in the structural components due to excessively rapid heating. The holding temperature is 400-600℃, and the holding time is 2-6 hours. The specific holding temperature and time should be determined based on the type of steel used. The temperature uniformity inside the furnace is controlled within ±10℃ during holding. After holding, the steel is cooled in the furnace to below 200℃ before being air-cooled to prevent secondary stress caused by rapid cooling. During the thermal aging process, the corrosion-inhibiting coating dry gel in the micro-pits is sintered in situ and transformed into aerogel, while the residual welding stress is effectively eliminated.

[0102] Preferably, when using Q550D low-alloy high-strength steel, the heat aging treatment holding temperature is controlled at 520-560℃, and the holding time is 3-5 hours. When using Q690D low-alloy high-strength steel, the heat aging treatment holding temperature is controlled at 500-550℃, and the holding time is 3-5 hours.

[0103] In S4, the overall machining process needs to be carried out according to the actual design requirements, and it is sufficient to meet the design and installation requirements. It will not be described in detail in this invention.

[0104] Optionally, in S4, the coating anti-corrosion treatment includes:

[0105] Primer spraying: Spray water-based anti-corrosion primer for basic wear resistance and corrosion protection.

[0106] Topcoat application: Apply a water-based hydrophobic topcoat. The topcoat has a micro-nano composite hydrophobic structure, used to reduce the adhesion strength of brine and its crystalline salts to the support surface. The primer thickness is 30-80 μm. The topcoat thickness is 30-60 μm. The static water contact angle of the hydrophobic topcoat is ≥120°.

[0107] This invention does not impose strict requirements on the spraying methods, related parameters, and formulations of the primer and topcoat. As long as the performance requirements are met and a conventionally qualified coating is formed, it is acceptable. For example, the water-based anti-corrosion primer can be a commercially available conventional water-based epoxy anti-corrosion primer (composed of modified epoxy resin, anti-rust pigments, additives, etc., component A used in combination with epoxy curing agent component B), water-based special epoxy primer, water-based epoxy zinc-rich anti-rust primer, water-based epoxy ester anti-corrosion primer, etc. The water-based hydrophobic topcoat can be a commercially available conventional water-based two-component fluorocarbon topcoat, water-based two-component polyurethane topcoat, water-based superhydrophobic topcoat, etc.

[0108] Taking a typical formulation of a conventional waterborne epoxy anti-corrosion primer as an example, by weight, the primer may contain: 40-60 parts waterborne epoxy emulsion, 10-20 parts water, 10-20 parts anti-rust pigment (such as zinc phosphate, aluminum tripolyphosphate, etc.), 5-15 parts filler (such as titanium dioxide, calcium carbonate, talc, etc.), 0.5-2 parts dispersant, 0.2-0.5 parts defoamer, and 0.3-1 parts rheology modifier. When using, it can be mixed with waterborne amine curing agent according to the design ratio.

[0109] Optionally, in S4, the raw materials of the waterborne hydrophobic topcoat, by weight, include 40-80 parts of film-forming substance, 3-10 parts of nanofiller, and 5-20 parts of additives. The film-forming substance is selected from at least one of fluoropolymers, including at least one of fluoroolefin-vinyl ether copolymers, fluorinated acrylate copolymers, fluorinated modified epoxy resins, and fluorinated modified polyurethanes. The fluoropolymers provide low surface energy hydrophobic groups such as -CF3 in the coating to achieve hydrophobicity.

[0110] The nanofiller is selected from at least one of inorganic nanoparticles, including at least one of nano-silica, nano-titanium dioxide, and nano-alumina, preferably nano-silica. The nanofiller creates nanoscale roughness on the coating surface, forming a micro-nano composite hydrophobic structure together with the film-forming material, ensuring the hydrophobic effect. Optionally, the particle size of the nanofiller is 10-50 nm.

[0111] Additives include at least one of wetting and dispersing agents, defoamers, leveling agents, thickeners, and curing agents, used to adjust the application and film-forming properties of the coating. The specific type and dosage can be added according to actual needs. For example, wetting and dispersing agents can be polyacrylic acid copolymers, defoamers can be mineral oils or polyether siloxanes, thickeners can be polyurethane-associated types or acrylic derivatives, and curing agents can be water-based blocked isocyanate crosslinking agents, etc.

[0112] Optionally, electrostatic spraying can be used to apply the primer and topcoat. The spraying voltage is 60-90kV, and the distance from the spray gun nozzle to the workpiece is 150-300mm. After spraying, leveling, curing, and cooling are performed. The curing temperature is 150-180℃, and the curing time is 20-30 minutes, ensuring the curing effect is achieved.

[0113] Optionally, the preparation of the top beam 1 includes the following steps:

[0114] A1: Cut the structural components to obtain the constituent plates, and bevele the corresponding constituent plates to obtain structural accessories and basic structural components. Basic structural components include main reinforcement 4, top plate 5, balance lugs 6, and transverse reinforcement 7. Structural accessories include round steel 9, tongue plate, column socket 10, cover plate 11, and pad plate 12.

[0115] A2: First Assembly and Welding: Using positioning shafts and tooling, the main reinforcement 4, top plate 5, transverse reinforcement 7, and balance lug 6 are assembled and welded to obtain the prototype of the top beam 1. During welding, the transverse reinforcement 7 is welded to the main reinforcement 4 first, and then the transverse reinforcement 7 is welded to the top plate 5. This welding includes fillet welds and filler welds.

[0116] A3: Internal Assembly and Welding: Assemble and weld the round steel 9, pad plate 12, and column socket 10 onto the initial shape of the top beam 1. This welding includes fillet welding.

[0117] External assembly and welding: Assemble and weld the cover plate 11 and the tongue plate on the prototype of the top beam 1 to obtain the semi-finished product of the top beam 1: This welding includes bevel filling welding.

[0118] A4: The semi-finished top beam 1 undergoes heat aging treatment, overall machining, and surface anti-corrosion treatment. Then, the valve assemblies and pipelines are installed to obtain top beam 1, as shown below. Figure 2-3 As shown.

[0119] The fabrication of shield beam 2 includes the following steps:

[0120] A1: Cut the structural components to obtain the constituent plates, and bevele the corresponding constituent plates to obtain structural accessories and basic structural components. The basic structural components include main reinforcement 4, top plate 5, balance lugs 6, and transverse reinforcement 7. Structural accessories include pad plate 12 and cover plate 11.

[0121] A2: First Assembly and Welding: Using positioning shafts and tooling, the main reinforcement 4, top plate 5, transverse reinforcement 7, and balance lug 6 are assembled and welded to obtain the prototype of the shield beam 2. This welding includes fillet welds.

[0122] A3: Internal assembly and welding: Assemble and weld pad 12 on the prototype of shield beam 2.

[0123] External assembly and welding: Assemble and weld the cover plate 11 on the prototype of the shield beam 2 to obtain the semi-finished shield beam 2. This welding includes bevel filling welding.

[0124] A4: The semi-finished shield beam 2 undergoes heat aging treatment, overall machining, and surface anti-corrosion treatment. Then, the valve assemblies and pipelines are installed to obtain shield beam 2. Figure 4 As shown.

[0125] The preparation of base 3 includes the following steps:

[0126] A1: Cut the structural components to obtain the constituent plates, and bevele the corresponding constituent plates to obtain structural accessories and basic structural components. The basic structural components include main reinforcement 4, base plate 13, and transverse reinforcement 7. Structural accessories include column sockets 10 and cover plates 11.

[0127] A2: First Assembly and Welding: Using positioning shafts and tooling, the main rib 4, base plate 13, and transverse rib 7 are assembled and welded to obtain the prototype of base 3. This welding includes fillet welding.

[0128] A3: Internal Assembly and Welding: Assemble and weld the column socket 10 onto the base prototype 3. This welding includes fillet welding.

[0129] External assembly and welding: Assemble and weld the cover plate 11 on the base 3 prototype to obtain the base 3 semi-finished product. This welding includes bevel filling welding.

[0130] A4: The semi-finished base 3 undergoes heat aging treatment, overall machining, and surface anti-corrosion treatment. Then, the valve assemblies and pipelines are installed to obtain base 3, as shown below. Figure 5 As shown.

[0131] It should be noted that, since hydraulic supports are existing mature structures, this invention does not elaborate on all their structures, parts, and installation sequences. The assembled structures described above are all necessary assembly processes for the corresponding hydraulic support structural components. Those skilled in the art can flexibly install other structures or determine the specific installation sequence according to the actual situation, as long as orderly assembly is ensured. Furthermore, although this invention uses the same structural names such as main rib 4, top plate 5, balance lug 6, transverse rib 7, column socket 10, cover plate 11, and pad plate 12, it should be understood that these are all structures with certain differences but the same name in hydraulic support structural components. Those skilled in the art can cut, process, and assemble plates of corresponding specifications and quantities according to the specific manufacturing object (such as top beam, shield beam, or base) and its design requirements to achieve the preparation of different structural components.

[0132] Secondly, the present invention also provides a hydraulic support for potash mines prepared using the production process method described in any one of the first aspects, wherein the weld area and the heat-affected zones on both sides of the hydraulic support structural component are provided with a micron-scale microtextured structure. The surface of the microtextured structure has a passivation film. The microtextured structure is filled with a filler formed by the curing of a corrosion-inhibiting coating. The surface of the structural component is covered with an anti-corrosion coating. This microtextured structure can alleviate stress concentration in the weld area and simultaneously provide mechanical anchoring points for the anti-corrosion coating. The hydraulic support structural component includes a top beam 1, a shield beam 2, and a base 3.

[0133] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0134] Example 1

[0135] This embodiment provides a hydraulic support for potash mines and its manufacturing process, which includes the following steps:

[0136] S1. Select Q550D low-alloy high-strength steel plates for shot blasting surface pretreatment, then use a CNC flame cutting machine to cut the plates into the components of top beam 1, shield beam 2, and base 3. During cutting, for steel plates with a thickness of 10-20mm, use a 0.8mm throat nozzle at a cutting speed of 200mm / min and a cutting oxygen pressure of 0.75MPa. For steel plates with a thickness of 20-40mm, use a 1.0mm throat nozzle at a cutting speed of 420mm / min and a cutting oxygen pressure of 0.75MPa; for steel plates with a thickness of 40-60mm, use a 1.25mm throat nozzle at a cutting speed of 360mm / min and a cutting oxygen pressure of 0.75MPa. The oxygen purity used for all cutting operations is 99.5%, and the cutting method is vertical cutting.

[0137] The corresponding component plates of the obtained top beam 1, shield beam 2, and base 3 are beveled to obtain the corresponding main reinforcement 4, top plate 5, bottom plate 13, transverse reinforcement 7, reinforcing transverse reinforcement 8, balance lug 6, round steel 9, tongue plate, column socket 10, cover plate 11, and pad plate 12. Among them, the main reinforcement 4, top plate 5, bottom plate 13, transverse reinforcement 7, reinforcing transverse reinforcement 8, and balance lug 6 are the basic structural components for subsequent assembly into the prototype of top beam 1, shield beam 2, and base 3; the round steel 9, tongue plate, column socket 10, cover plate 11, and pad plate 12 are structural accessories that are subsequently welded to the prototype of top beam 1, shield beam 2, and base 3 according to structural requirements.

[0138] S2. Preliminary Assembly and Welding: The main reinforcement 4, top plate 5, bottom plate 13, transverse reinforcement 7, and balance lugs 6 are assembled and welded to obtain the prototypes of top beam 1, shield beam 2, and base 3. Positioning shafts and fixtures are used for positioning during assembly. Cross reinforcement plates are installed at the column sockets 10 of top beam 1 and at the root of the lugs. Diagonal bracing plates are installed around the column sockets 10 of base 3. The transverse reinforcement 7 is spot-welded to top plate 5 and bottom plate 13. Reinforcing transverse reinforcement 8 is welded into the spans of top beam 1 and base 3.

[0139] After the preliminary shapes of the top beam 1, the shield beam 2, and the base 3 are completed and the welds have cooled, the weld area formed in S2 is treated as follows:

[0140] 1. Laser micro-textured surface treatment: A nanosecond laser is used for laser etching with a laser power of 30W, a scanning speed of 200mm / s, and a spot diameter of 50μm. Several micron-sized pits are prepared on the surface of the weld and the heat-affected zone of 30mm on both sides, forming an array. The pits have a diameter of 60μm, a depth of 30μm, and a surface density of 25%.

[0141] 2. Surface passivation treatment: Prepare a passivation solution comprising, by weight: 20 parts hydrogen peroxide, 10 parts sodium molybdate, 3 parts fluorozirconic acid, 4 parts phytic acid, 1.5 parts silane coupling agent KH-550, with the remainder being water. Spray the passivation solution onto the weld area with microtexture and the heat-affected zones on both sides, react at room temperature for 20 minutes, then clean and dry.

[0142] 3. Corrosion Inhibiting Coating Filling: Corrosion inhibiting coating is applied to the weld and a 30mm heat-affected zone on both sides by scraping into the pits. The coating is then dried at 100°C for 1 hour to complete the filling. A dry gel is formed after filling, which sintersects into an aerogel during the subsequent S4 heat aging treatment. By weight, the corrosion inhibiting coating comprises 300 parts silica sol, 15 parts sodium molybdate, 5 parts sodium tungstate, and 5 parts methyltrimethoxysilane. The silica sol contains 20 wt% silica, and the solvent is water.

[0143] S3. Group Assembly and Welding: Internal Assembly and Welding: According to the structural design requirements, round steel 9, pad plate 12, and column socket 10, etc., are welded to the prototype top beam 1, prototype shield beam 2, and prototype base 3. After the internal assembly and welding are completed, the surface is cooled, and then the weld area formed during the internal assembly and welding is subjected to laser micro-texturing surface treatment, surface passivation treatment, and corrosion-inhibiting coating filling, following the same method as in S2.

[0144] External Assembly and Welding: After the internal structural accessories are welded, according to the structural design requirements, external structural accessories such as the cover plate 11 and the tongue plate are welded. After external assembly and welding, the assembly is cooled, and then, following the same method as in S2, the weld area formed during external assembly and welding is subjected to laser micro-texturing surface treatment, surface passivation treatment, and corrosion-inhibiting coating filling to obtain the semi-finished top beam 1. Figure 2-3 As shown, the protective beam 2 is a semi-finished product. Figure 4 As shown, the base 3 is a semi-finished product, such as Figure 5 As shown.

[0145] S4. Post-treatment: The semi-finished top beam 1, shield beam 2, and base 3 are subjected to heat aging treatment at 550℃ for 4 hours. Then, overall machining is performed: the aged structural components are machined by boring and milling. After machining, surface anti-corrosion treatment is applied: a water-based epoxy anti-corrosion primer and a water-based hydrophobic topcoat are sprayed sequentially, covering the entire surface. In the water-based epoxy anti-corrosion primer, component A includes: 60 parts water-based epoxy resin emulsion, 15 parts deionized water, 10 parts zinc phosphate, 5 parts aluminum tripolyphosphate, 8 parts titanium dioxide, 5 parts talc, 0.3 parts polyether siloxane defoamer, and 0.3 parts polyurethane associative thickener. Component B includes: 20 parts water-based polyamide curing agent and 5 parts deionized water. Components A and B are mixed evenly at a mass ratio of 5:1. The spray thickness of the water-based epoxy anti-corrosion primer is controlled at 30-80 μm.

[0146] The waterborne hydrophobic topcoat comprises 65 parts of fluoroolefin-vinyl ether copolymer resin, 3 parts of nano-silica filler with an average particle size of 50 nm, 15 parts of titanium dioxide, 1 part of ammonium polyacrylate dispersant, 0.3 parts of polyether siloxane defoamer, 0.5 parts of polyether-modified polysiloxane wetting agent, 3 parts of dipropylene glycol butyl ether film-forming aid, 0.5 parts of polyurethane associative thickener, and 20 parts of deionized water. When using, it is mixed with waterborne isocyanate curing agent at an 8:1 ratio. The spraying thickness is controlled at 30-60 μm, and the static water contact angle after curing is ≥120°.

[0147] After the surface anti-corrosion treatment is completed, each pipeline and valve group is installed on the semi-finished top beam 1, the semi-finished shield beam 2, and the semi-finished base 3 to obtain the structural components of top beam 1, shield beam 2, and base 3.

[0148] The prepared top beam 1, shield beam 2, and base 3 structural components are assembled with the columns and other auxiliary components to form a hydraulic support, thus completing the production of the hydraulic support and obtaining the present invention. Figure 1 The hydraulic support shown is for potash mines.

[0149] Example 2

[0150] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this embodiment and Embodiment 1 is that the passivation liquid formulation for surface passivation treatment in S2-S3 is different.

[0151] The passivation solution, by weight, comprises 25 parts hydrogen peroxide, 12 parts sodium molybdate, 4 parts fluorotitanic acid, 5 parts phytic acid, 2 parts silane coupling agent KH-560, and the remainder is water. All other steps are the same as in Example 1.

[0152] Example 3

[0153] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this embodiment and Embodiment 1 lies in the formulation of the corrosion-inhibiting coating used in steps S2-S3. The corrosion-inhibiting coating, by weight, comprises: 300 parts silica sol (liquid, 20 wt% silica content), 50 parts boehmite sol liquid (20 wt% alumina content), 20 parts sodium molybdate, and 8 parts sodium tungstate. The silica sol and boehmite sol are combined to form a composite aerogel. The remaining steps are the same as in Embodiment 1.

[0154] Example 4

[0155] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this embodiment and Embodiment 1 is that, in S1, Q690D steel is used. In S2-S3, a connected trench network is prepared during laser micro-weaving surface treatment: a grid-like trench array is prepared on the surface of the weld and the heat-affected zone (30mm on each side) using laser etching. The trench width is 40μm, the depth is 50μm, the longitudinal trench spacing is 120μm, and the transverse trench spacing is 200μm, forming a connected network structure. The remaining steps are the same as in Embodiment 1.

[0156] Comparative Example 1

[0157] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this comparative example and Example 1 is that the welding process of S2 and S3 does not follow the order of inside to outside. The horizontal rib 7 and the top plate 5 and the bottom plate 13 are welded in multiple layers and multiple passes instead of spot welding. All structural accessories are assembled at one time and then continuously welded. The remaining steps are the same as in Example 1.

[0158] Comparative Example 2

[0159] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this comparative example and Example 1 is that laser micro-weaving surface treatment is not performed in S3. Instead, surface passivation treatment is performed directly on the weld and its surrounding area. After passivation, an anti-corrosion coating is applied. The composition of the passivation liquid and the slow-release coating is the same as in Example 1. All other steps are also the same as in Example 1.

[0160] Comparative Example 3

[0161] This embodiment provides a hydraulic support for potash mines and its manufacturing process. The difference between this comparative example and Example 1 is that, in step S3, the corrosion-inhibiting coating, by weight, comprises 300 parts of sodium silicate sol, 15 parts of sodium molybdate, 5 parts of sodium tungstate, and 5 parts of methyltrimethoxysilane. The solid content of the sodium silicate sol is 20 wt%, and the solvent is water. The remaining steps are the same as in Example 1.

[0162] In the above embodiments and comparative examples, after all welding in S3 is completed and before the heat aging treatment in S4, the flatness of the main plane of the top beam 1 is measured using a coordinate measuring machine, and the maximum deformation value (mm / m) is recorded, which is the initial welding deformation. Simultaneously, a simulated load is applied to the column socket 10 position of the top beam 1, reaching 1.5 times the working resistance (12000kN in this invention). The vertical displacement of the center point of the bottom plate 13 of the top beam 1 is measured using a laser displacement sensor, and the deformation value (mm) is recorded, which is the initial compressive deformation. After the heat treatment in S4 is completed, the data is tested using the same method to obtain the finished product deformation and the finished product compressive deformation. The test results are shown in Table 1.

[0163] Using the hydraulic support structural components obtained in the above embodiments and comparative examples as samples, a cross-cut test was conducted on the weld area according to GB / T 9286-1998 standard. After peeling with tape, the components were rated (0 being the best and 5 the worst). Then, a neutral salt spray test was conducted according to GB / T10125-2012 standard. The test adopted a continuous spray method, with the temperature inside the chamber maintained at 35℃±2℃, and the salt spray deposition rate controlled at 1-2mL / (80cm²). 2 •h), When placing the sample, the test surface should form an angle of 20°±5° with the vertical direction. Before the test, on another weld area of ​​the same structural component, use a scribing tool to penetrate the water-based epoxy anti-corrosion primer and water-based hydrophobic topcoat coatings, forming a cross-line with a length of 20mm. Record the time (in hours) for red rust to appear at the scribing line. After the experiment is interpreted, select another weld area on the same structural component to test the coating bonding strength. The test results are shown in Table 2.

[0164] Table 1: Welding deformation and compressive deformation of the top beam 1 prepared in each embodiment and comparative example

[0165]

[0166] As shown in Table 1 above, Examples 1-4 all exhibit low initial welding deformation and initial compressive deformation. Comparative Examples 2-3, due to the use of the processing method of this invention, also show low initial welding deformation and initial compressive deformation. However, Comparative Example 1, employing a conventional welding method, has poor control over thermal effects and deformation, resulting in significantly higher initial welding deformation and initial compressive deformation than all other examples. This indicates that the internal-to-external welding sequence and tack welding used in this invention are effective in controlling welding deformation. Furthermore, this invention employs heat aging treatment to further eliminate defects such as residual heat stress after welding, reduce the weld deformation of the finished product, and improve the structural strength of the hydraulic support components, thus reducing the compressive deformation of the finished product. However, it can be observed that although the deformation of each example and comparative example is reduced to varying degrees after heat aging treatment, the deformation of Comparative Example 1 is still much higher than that of Example 1 and other examples, making it difficult to eliminate the performance differences caused by the welding process through subsequent processing.

[0167] Furthermore, Example 4 used Q690D high-strength steel and fabricated a connected groove network. Its initial welding deformation was slightly higher than that of Example 1. This was due to the higher strength of Q690D and the slightly increased welding heat input requirement, but the deformation was still within a controllable range. The initial compressive deformation was slightly lower than that of Example 1, indicating that the higher strength of Q690D steel resulted in less deformation of the structure under load.

[0168] Table 2: Coating adhesion strength and corrosion time of coatings prepared in each example and comparative example

[0169]

[0170] According to Table 2 above, Example 1, due to the adoption of the microtexturing + passivation + corrosion-inhibiting coating + heat aging sintering and aerogel formation technical solution of the present invention, achieved an initial coating bonding strength of 0, red rust appeared after 2000 hours of scribing salt spray test, and the bonding strength remained at 1 after salt spray. This indicates that the solution of the present invention achieves excellent coating adhesion and long-term protective function, which is significantly superior to the performance of existing mining hydraulic supports (hydraulic supports prepared by conventional production processes in existing coal mines, using Q345 steel for cutting and blanking; using conventional grid-shaped stiffener layout, continuous welding for structural components; heat aging treatment after welding; surface anti-corrosion treatment using solvent-based epoxy anti-rust paint spraying, with a single layer coating thickness of about 80-100μm, without laser microtexturing, weld passivation treatment and corrosion-inhibiting coating filling, and the testing method is the same as that of the examples and comparative examples).

[0171] In Example 2, after changing the passivation solution formulation, the salt spray time was slightly lower than that in Example 1 but still at a similar level, and the bonding strength after salt spray was grade 1, indicating that the passivation solution formulation of the present invention has a good protective effect when fluctuating within the reasonable range of the present invention.

[0172] Example 3 uses a corrosion-inhibiting coating with added alumina and a higher content of corrosion inhibitor. The composite aerogel skeleton structure formed after the addition of alumina can improve the stability and adsorption capacity of the aerogel, further enhancing the fixation and long-term release effect of the corrosion inhibitor. This allows the corrosion inhibitor to be more firmly fixed in the composite skeleton and released for a longer period of time. Therefore, its initial coating bonding strength remains at the optimal level, and the salt spray test duration is higher than that of Example 1. Moreover, after the salt spray test, due to the more stable aerogel structure and more sufficient corrosion inhibitor reserves, its coating bonding strength can still maintain a good level.

[0173] In Comparative Example 1, improper welding sequence led to significant structural deformation. Due to the excessive welding deformation, the internal stress of the structure increased, and the coating was affected by additional stress during the curing process. Therefore, although the initial coating bonding strength remained at the optimal level due to the presence of microtexture, the salt spray test duration was significantly shorter than that of Example 1, and the bonding strength after salt spray also decreased slightly.

[0174] Comparative Example 2 did not undergo laser micro-texturing surface treatment, only passivation treatment was retained. Due to the lack of mechanical anchoring effect brought by micro-texture, the corrosion inhibitor coating and subsequent coatings only relied on chemical bonding for adhesion, resulting in a weak adhesion foundation. Therefore, its initial coating bonding strength was significantly lower than that of Example 1. The single passivation film had limited protective ability when used alone. During the salt spray test, the corrosion inhibitor coating could not be effectively fixed and was easily washed away during the thermal aging process, which led to a significant reduction in its corrosion resistance time. In the salt spray test, the coating was easily peeled off further due to the diffusion of corrosive media along the interface, and its coating bonding strength decreased rapidly.

[0175] In Comparative Example 3, the corrosion inhibitor coating carrier was changed to sodium silicate (water glass). Since sodium silicate is a true solution system, it cannot form a porous aerogel structure during the 550℃ thermal aging process; instead, it transforms into a dense silicate glassy substance. Although molybdate and tungstate still exist in the coating and play a certain role in corrosion inhibition, the dense silicate matrix cannot achieve the aerogel adsorption-release function of this invention. After the corrosive medium penetrates, it directly contacts the corrosion inhibitor instead of being adsorbed and guided by the aerogel network. Its salt spray resistance time is only 1100 hours, significantly lower than that of Example 1, and the bonding strength after salt spray is also lower.

[0176] In summary, this invention solves the technical problems of existing hydraulic supports in potash mines with high chlorine, high humidity, and high ground pressure environments, which lead to a rapid decline in load-bearing capacity and a short service life due to insufficient control of internal stress and deformation, and easy early corrosion in weak areas such as welds.

[0177] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0178] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0179] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," or "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0180] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0181] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A manufacturing process for hydraulic supports used in potash mines, characterized in that, The hydraulic support structural components were prepared using the following methods: S1. Plate and base structure processing: Cut the steel to obtain the plate materials that make up the hydraulic support structure; beveling the corresponding plate materials to obtain the base structure and structural accessories. S2, One-time assembly and welding: Assemble and weld the base structural components to obtain the structural prototype; S3. Group assembly and welding: Assemble and weld the structural accessories on the structural component prototype in the order of inside to outside to obtain the structural component semi-finished product; S4. Post-processing: The semi-finished structural components after forming are subjected to heat aging treatment, overall machining and surface anti-corrosion treatment to obtain hydraulic support structural components; among them, the hydraulic support structural components include top beam (1), shield beam (2) and base (3), and the three are assembled with columns and other auxiliary components to form a hydraulic support; In S2-S3, after welding is completed, the easily corroded areas are subjected to laser micro-weaving surface treatment and surface passivation treatment, and then corrosion-inhibiting coating is filled into the formed micro-weaving structure; the easily corroded areas include the weld and the heat-affected zones on both sides; in S4, the surface anti-corrosion treatment includes coating anti-corrosion treatment.

2. The manufacturing process for hydraulic supports for potash mines according to claim 1, characterized in that, In S1, the blanking is carried out by CNC flame cutting, CNC laser cutting or CNC plasma cutting; the plate material used for the structural parts is at least one of Q550D and Q690D low alloy high strength steel; in S2, when preparing the top beam (1) and / or the base (3), the horizontal ribs (7) are spot-welded or not welded to the top plate (5) or the bottom plate (13); the spacing of the top beam (1) and / or the base (3) is also welded with reinforcing horizontal ribs (8) to suppress their deformation; in S3, reinforcing ribs are set in the stress concentration area, the stress concentration area includes the column socket (10) connection and the ear seat root; the reinforcing ribs are cross ribs or diagonal bracing ribs.

3. The manufacturing process for hydraulic supports for potash mines according to claim 2, characterized in that, When using CNC flame cutting, the cutting parameters are controlled in stages according to the thickness of the steel plate, as follows: For steel plates with a thickness of 10-20mm, use a cutting nozzle with a throat diameter of 0.8mm±0.1mm, a cutting speed of 100-350mm / min, and a cutting oxygen pressure of 0.7-0.8MPa; For steel plates with a thickness of 20-40mm, use a cutting nozzle with a throat diameter of 1.0mm±0.1mm, a cutting speed of 350-500mm / min, and a cutting oxygen pressure of 0.7-0.8MPa; For steel plates with a thickness of 40-60mm, use a cutting nozzle with a throat diameter of 1.25mm±0.1mm, a cutting speed of 300-420mm / min, and a cutting oxygen pressure of 0.7-0.8MPa; Furthermore, the oxygen used for cutting must be at least 99.5% pure, and the cutting method must be vertical.

4. The manufacturing process for hydraulic supports for potash mines according to claim 1, characterized in that, In S2-S3, laser micro-textured surface treatment involves using laser etching or imprinting processes to prepare several micron-sized pits and / or grooves, i.e., micro-textured structures, on the surface of the weld and the heat-affected zone on both sides. These structures are used to store corrosion-inhibiting coatings and enhance the adhesion of the anti-corrosion coating.

5. The manufacturing process for hydraulic supports for potash mines according to claim 1, characterized in that, In S2-S3, the surface passivation treatment is as follows: an acidic oxidizing passivation liquid is sprayed onto the weld seam and the heat-affected zone on both sides of the structural component. After a passivation film is formed on the surface, it is cleaned and dried. The acidic oxidizing passivation solution comprises, by weight, 10-30 parts hydrogen peroxide, 5-15 parts molybdate, 1-5 parts fluorozirconic acid, 2-6 parts phytic acid, 0.5-3 parts silane coupling agent, and 30-140 parts water; the pH of the acidic oxidizing passivation solution is 1.0-3.

5.

6. The manufacturing process for hydraulic supports for potash mines according to claim 1 or 4, characterized in that, In S2-S3, after the surface passivation treatment is completed, a corrosion-inhibiting coating is filled into the micro-textured structure formed by the laser micro-textured surface treatment, and the filling amount is at least 90% of the volume of the micro-textured structure; the corrosion-inhibiting coating includes 200-450 parts by weight of silica sol, 10-20 parts by weight of molybdate, 5-15 parts by weight of tungstate, and 5-20 parts by weight of silane hydrophobic modifier; the silica sol has a silica content of 20-40 wt%; the silica sol is cured to form an aerogel during thermal aging treatment.

7. The manufacturing process for hydraulic supports for potash mines according to claim 6, characterized in that, The molybdate is at least one of sodium molybdate and ammonium molybdate; the tungstate is selected from at least one of sodium tungstate, ammonium tungstate, and ammonium metatungstate; and the silane hydrophobic modifier is at least one of methyltrimethoxysilane, dimethyldimethoxysilane, and octyltriethoxysilane.

8. The manufacturing process for hydraulic supports for potash mines according to claim 1, characterized in that, In S4, the coating anti-corrosion treatment includes: Primer spraying: Spray water-based anti-corrosion primer for basic wear resistance and corrosion protection; Topcoat spraying: Spraying water-based hydrophobic topcoat, wherein the hydrophobic topcoat is a micro-nano composite hydrophobic structure, used to reduce the adhesion strength of brine and its crystalline salts on the surface of the support. The thickness of the primer is 30-80μm; the thickness of the topcoat is 30-60μm; and the static water contact angle of the hydrophobic topcoat is ≥120°.

9. The manufacturing process for hydraulic supports for potash mines according to claim 1, characterized in that, The preparation of the top beam (1) includes the following steps: A1: Cut the constituent plates of each structure to obtain the structural components, beveling the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main reinforcement (4), top plate (5), balance lug (6), and transverse reinforcement (7); the structural accessories include round steel (9), tongue plate, column socket (10), cover plate (11), and pad plate (12). A2: First assembly and welding: Using positioning shafts and tooling for positioning, the main reinforcement (4), top plate (5), horizontal reinforcement (7) and balance ear seat (6) are assembled and welded to obtain the prototype of the top beam (1); during welding, the horizontal reinforcement (7) is welded to the main reinforcement (4) first, and then the horizontal reinforcement (7) is welded to the top plate (5); this welding includes fillet welding and filler welding; A3: Internal assembly and welding: Assemble and weld round steel (9), pad plate (12) and column socket (10) on the prototype of the top beam (1); This welding includes fillet welding; External assembly and welding: Assemble and weld the cover plate (11) and tongue plate on the prototype of the top beam (1) to obtain the semi-finished product of the top beam (1): This welding includes bevel filling welding; A4: The top beam (1) semi-finished product is subjected to heat aging treatment, overall machining and surface anti-corrosion treatment, and then the valve group and pipeline are installed to obtain the top beam (1). The preparation of the shield beam (2) includes the following steps: A1: Cut the constituent plates of each structure, bevel the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main reinforcement (4), top plate (5), balance lug (6), and transverse reinforcement (7); the structural accessories include pad plate (12) and cover plate (11). A2: First assembly and welding: Using positioning shafts and tooling, the main reinforcement (4), top plate (5), transverse reinforcement (7), and balance lug (6) are assembled and welded to obtain the prototype of the shield beam (2); this welding includes fillet welding. A3: Internal assembly and welding: Assemble and weld pads (12) on the prototype of the shield beam (2); External assembly and welding: Assemble and weld the cover plate (11) on the prototype of the shield beam (2) to obtain the semi-finished shield beam (2); This welding includes bevel filling welding; A4: Heat aging treatment, overall machining and surface anti-corrosion treatment are carried out on the semi-finished shield beam (2), and then each valve group and pipeline are installed to obtain the shield beam (2). The preparation of the base (3) includes the following steps: A1: Cut the constituent plates of each structure, bevel the corresponding constituent plates to obtain structural accessories and basic structural components; the basic structural components include main reinforcement (4), bottom plate (13), and transverse reinforcement (7); the structural accessories include column sockets (10) and cover plates (11). A2: First assembly and welding: Using positioning shafts and tooling for positioning, the main rib (4), base plate (13) and transverse rib (7) are assembled and welded to obtain the base (3) prototype; this welding includes fillet welding; A3: Internal assembly and welding: Assemble and weld the column socket (10) on the base (3) prototype; this welding includes fillet welding; External assembly and welding: Assemble and weld the cover plate (11) on the base (3) prototype to obtain the base (3) semi-finished product; this welding includes bevel filling welding; A4: The base (3) semi-finished product is subjected to heat aging treatment, overall machining and surface anti-corrosion treatment, and then each valve group and pipeline are installed to obtain the base (3).

10. A hydraulic support for potash mines prepared using the production process described in any one of claims 1-9, characterized in that, The weld area and the heat-affected zone on both sides of the hydraulic support structure are provided with a micron-level micro-textured structure; the surface of the micro-textured structure has a passivation film; the micro-textured structure is filled with a filler formed by the curing of corrosion-inhibiting coating; the surface of the structure is covered with an anti-corrosion coating; the hydraulic support structure includes a top beam (1), a shield beam (2) and a base (3).

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