This study investigates the critical factors influencing the performance of hydro-pneumatic suspension systems (HPSS) in mining explosion-proof engineering vehicles operating in complex underground coal mine environments. To address challenges such as poor ride comfort and insufficient load-bearing capacity under harsh mining conditions, a two-stage pressure HPSS was analyzed through integrated numerical modeling and field validation. A mathematical model was established based on the structural principles of the suspension system, focusing on key parameters including cylinder bore (195–255 mm), piston area (170–210 mm), damping orifice diameter (7–8 mm), check valve flow area, and accumulator configurations (low-pressure: 1.2 MPa, high-pressure: 6 MPa). Experimental trials were conducted in active coal mines, simulating typical mining scenarios such as uneven road surfaces (120 mm obstacles), heavy-load gangue transportation, and confined-space operations in thin coal seams (<1.5 m).
This study conducted experimental validation of a hydro-pneumatic suspension system (HPSS) for mining explosion-proof engineering vehicles under multi-condition operational scenarios in active coal mines. Field tests were performed to simulate typical mining environments, including uneven road surfaces (120 mm obstacles), variable-speed driving (constant speed, acceleration, deceleration), and inclined terrains (uphill, downhill, and near-horizontal road surfaces). Comprehensive performance evaluations focused on dynamic stroke stability, vibration attenuation, and safety metrics were carried out by replicating real-world mining conditions.
Results demonstrated that optimizing the cylinder bore diameter and adjusting the piston area significantly enhanced dynamic stroke stability, ensuring consistent load-bearing capacity across diverse mining terrains. Furthermore, tuning the damping orifice diameter effectively improved anti-rollover capability while maintaining ride comfort, achieving a balanced trade-off between vibration suppression and operational safety. Parameter adjustments to the HPSS, validated through rigorous field trials, proved critical for enhancing driving stability and safety in complex underground mining environments. These findings provide actionable insights for designing robust suspension systems tailored to the extreme demands of mineral extraction operations.