Exploring Dynamic Cutting Process of Shearer's Drum
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摘要: 为研究采煤机螺旋滚筒动态截割过程动力传递规律，基于相似理论建立螺旋滚筒模型与原型的相似准则，确定了模拟螺旋滚筒结构参数、运动学参数及截割材料特性参数，应用三维实体建模软件Pro/E、离散元分析软件EDEM联合仿真分析验证原型滚筒和模型滚筒动态截割过程中煤颗粒运动轨迹、量变规律、滚筒装煤率、滚筒载荷等性能。验证结果表明：原型滚筒和模型滚筒在截割过程中煤颗粒流动轨迹一致，截落的煤分布规律相似，载荷波动规律一致，滚筒装煤率预测误差1.82%，载荷数值误差小于2.1%，装煤率和载荷均值均满足推导的相似关系，验证了螺旋滚筒相似准则正确性。Abstract: In order to study the dynamic cutting processes and coal power transfer laws of a shearer's drum, its model drum was built based on the similarity theory; the prototype was similar to the parameters of similarity criterion. The structural parameters, movement parameters and cutting material characteristics of the drum to be simulated are determined. The Pro/E and EDEM were applied. The simulation analysis and verification of the prototype drum, the dynamic cutting process, coal particles' motion trail, quantitative change rule, coal rate and drum loading are the same. The cylinder model validation results show that the prototype drum's coal particle distributions are similar in the cutting process; the drum's coal rate prediction error is 1.82%; the loading error is less than 2.1%; the coal rate and loading are satisfactory, verifying the accuracy of the drum's similarity criterion.
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Key words:
- shearer's drum /
- similarity theory /
- dynamic cutting process /
- discrete element method /
- coaling rate
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表 1 滚筒相关参数量纲
参数 符号 量纲 滚筒直径/mm D M0L1T0 螺旋叶片头数/个 Z M0L0T0 每条截线截齿数/个 m M0L0T0 叶片螺旋升角/(°) α M0L0T0 滚筒转速/(r·min-1) n M0L0T-1 牵引速度/(m·min-1) vq M0L1T-1 煤的密度/(kg·m-3) ρ M1L-3T0 齿体屈服强度/MPa σ M1L-1T-2 重力加速度/(m·s-2) g M0L1T-2 滚筒所受载荷/N F M1L1T-2 装煤率/% Q M0L0T0 
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表 2 量纲矩阵指数表
参数 D n vq ρ σ g F 指数 a1 a2 a3 a4 a5 a6 a7 M 0 0 0 1 1 0 1 L 1 0 1 -3 -1 1 1 T 0 -1 -1 0 -2 -2 -2
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表 3 滚筒主要参数π矩阵
参数 D n vq ρ σ g F 指数 a1 a2 a3 a4 a5 a6 a7 π1 1 0 0 0 1/2 0 -1/2 π2 0 1 0 0 -1/4 -1/2 1/4 π3 0 0 1 0 1/4 -1/2 -1/4 π4 0 0 0 1 -3/2 1 1/2
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表 4 滚筒相关参数相似系数
参数 原型 模型 滚筒直径/mm D D/3 螺旋叶片头数/个 Z Z 每条截线截齿数/个 m m 叶片螺旋升角/(°) α α 滚筒转速/(r·min-1) n 
牵引速度/(m·min-1) vq 
煤的密度/(kg·m-3) ρ ρ 齿体屈服强度/MPa σ σ/3 重力加速度/(m·s-2) g g 滚筒所受载荷/N F F/27 装煤率/% Q Q
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表 5 滚筒主要结构参数
参数 原型 模型 滚筒直径/mm 1 150 383 圆柱段长度/mm 700 233 筒毂直径/mm 530 176 筒毂内径/mm 460 153 螺旋叶片外缘直径/mm 930 310 叶片厚度/mm 70 23 圆柱段截线条数/条 11 11 截线距/mm 67 22 轴向倾斜角/(°) 0 0 安装角/(°) 40 40 叶片螺旋升角/(°) 13 13 螺旋叶片头数/个 2 2 每条截线截齿数/个 2 2 尾片与半个齿座距离和/mm 50 17
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表 6 煤的物理力学性质指标
真密度/(kg·m-3) 视密度/(kg·m-3) 抗拉强度/MPa 抗压强度/MPa 弹性模量/MPa 坚固性系数 1 332 1 309 1.08 17.71 4 388 2.0
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表 8 载荷数值结果
方向 原型滚筒 模型滚筒 相似预测滚筒载荷均值/N 误差/% 滚筒载荷均值/N 载荷波动系数 滚筒载荷均值/N 载荷波动系数 X 95 247.6 0.026 6 3 589.4 0.027 2 3 527.7 1.75 Y 1 152.1 0.031 4 44.3 0.032 3 42.7 3.74 Z 74 769.5 0.029 5 2 829.5 0.030 6 2 769.2 2.04
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