Welding repair of the top beam ear plate for the 203200 person support system was conducted by Liu Lizhi and Yin Xiang. The work was carried out by the Electromechanical Branch of Panjiang Coal and Electricity Group Co., Ltd. in Panxian, Guizhou (561609), as well as Tucheng Mine in Panzhou, Guizhou (56121). The 3200 support is a shielded hydraulic support designed for coal mining operations. The top beam ear plate is subjected to high alternating loads, making it prone to deformation or failure. Traditionally, replacing the entire top beam is time-consuming and costly, which is not practical for on-site maintenance. Instead, using a 13-welded oxo-recording process provides a simpler and more economical solution. In analyzing the strength of the ear plate welding seams, B 0320 recognizes that the performance and structural integrity of each component directly impact coal mine safety. Therefore, force analysis and strength checks are essential during repairs. The ear plate welding seam is a butt joint, with the length of the weld increased to form an arc-shaped seam. This design distributes stress more evenly, improving overall stability. The similar hydraulic valve control system used in the 2401.02.6 bracket includes 12532 units, two control columns, one balanced push-pull side protection jack, one hydraulic control check valve, and two-way lock. Each component is configured separately to ensure reliable operation. For the hydraulic control system, a single-direction valve is used, while the double lock employs an 861 hydraulic control one-way valve. The two-way lock controls the balance cylinder’s vertical locking mechanism, and a safety valve rated at 22 ensures system reliability. The shut-off valve uses a plane shut-off valve model 13191332 to manage both liquid inlet and return. During the hydraulic system upgrade, we maintained the original cylinder diameter to preserve the initial support force, working resistance, and overall performance of the hydraulic support. Regarding the column transformation, many components have been in use for years and show significant wear. Although some parts can be repaired, others, like the ear plate and balance jack, require replacement. The balance jack adjusts the angle between the top beam and cover beam, ensuring the top beam remains parallel to the roof under various mining conditions, thus effectively controlling the roof. Under different stress conditions, the balance jack undergoes repeated stretching and compression. Therefore, all columns were replaced. In the new column configuration, a drum ring sealing system was introduced to enhance seal stability. The structure was changed from screw fixing to clamping block fixing, facilitating easier disassembly and future repairs. The original double-telescopic column structure was retained. After four transformations, over 120 sets of liquid-throwing supports operated smoothly in multi-roof conditions. The use of multi-layer winding hoisting wire ropes was analyzed by Yang Houhua from Guizhou University of Technology. Common failures include cumulative broken strands and diameter reduction, leading to reduced strength. On-site investigations showed that worn sections often become wrapped around and caught in the drum. Most failures occur at layer transitions and where the rope contacts the drum. When welding, the thickness of the welded parts and allowable tensile stress must be considered, especially under alternating loads. The welding length should be calculated accordingly. For low-carbon steel and low-carbon alloy steel, stress concentration areas require special attention. Butt welding, right-angle side welding, and end welding are common techniques. Holes in the weldment should be pre-processed, and tooling should be used to maintain position and alignment. Equal-strength electrodes are recommended, followed by leveling and correction after welding to reduce residual stresses. In conclusion, this method has been practically applied and achieved excellent results. It is simple, reduces processing difficulty, and allows small factories to perform repairs. It saves time and materials while ensuring reliability. Strength checks confirm the structural integrity, making it suitable for repairing ear plate-shaped components. Qiu Xuan's work on mechanical design, published by Beijing Higher Education Press, is referenced. The "Mechanical Design Manual" is also cited, along with contributions from the School of Engineering specializing in mechanical manufacturing technology and equipment. Currently, the author works in the mine repair workshop of the Electromechanical Branch of Panjiang Coal and Electricity Group Corporation. Received date: 20th, eye 18.

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