Design and Simulation on Powerful Screw Drum of Thin Coal Seam Shearer
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摘要: 为提高夹矸煤岩开采效率,运用理论计算和离散元数值模拟的方法对采煤机螺旋滚筒进行设计研究。利用PRO/E、EDEM构建离散元仿真煤壁模型,导入螺旋滚筒三维实体模型进行耦合模拟截割、破碎含夹矸煤岩过程;以MATLAB为基础利用正交试验法研究夹矸坚固性系数、滚筒螺旋升角、截齿排列方式对滚筒载荷的影响,根据实际工况进行模拟仿真。研究表明:利用正交试验法得出对滚筒受载影响由大到小的顺序为:夹矸坚固性系数、截齿排列方式、螺旋升角;对滚筒载荷波动影响顺序为:截齿排列方式的影响最大、夹矸坚固性系数的影响略次之、螺旋升角的影响要小得多;通过对仿真结果的分析,得到不同煤层赋存条件下螺旋滚筒最优的结构参数,截割夹矸坚固性系数在6.8以上恶劣工况时,相对比于利用交叉式滚筒波动系数最大降低了39.2%;利用设计的强力滚筒对8种典型工况进行模拟仿真试验,验证滚筒设计的可靠性。Abstract: In order to improve the mining efficiency of gangue coal rock, theoretical calculation and discrete element numerical simulation are used to design and study powerful screw drum of thin coal seam shearer. The coal wall discrete element simulation model was established by use of PRO/E and EDEM, the 3D model of the screw drum is introduced to simulate cutting and crushing complicated coal and rock processes. The orthogonal test method was used to study the influence trend of solidity coefficient of gangue, spiral angle of drum, arrangement of cutting teeth on the load of the shearer's screw drum by MATLAB, and then a simulation according to actual working condition was carried out. The research results indicate that:the order of influence on the force on the screw drum is obtained as follows:the solidity coefficient of gangue, arrangement of cutting teeth, spiral angle of drum. The order of influence on the load fluctuation of screw drum is as follows:arrangement of cutting teeth, the solidity coefficient of gangue, spiral angle of drum. The optimum structural parameters of screw drum under different coal seam occurrence conditions are obtained through the analysis of simulation results. When the solidity coefficient of gangue is over 6.8, the load fluctuation of the sequential screw drum decreases by 39.2% compared with that of cross drum. The designed strong drum is used to simulate the typical working conditions and verify the reliability of drum design.
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Key words:
- thin coal seam /
- discrete element method /
- powerful screw drum /
- orthogonal test method /
- MATLAB /
- simulation /
- design
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表 1 煤岩体材料参数
材料名称 弹性模量/MPa 密度/(kg·m-3) 泊松比μ 抗压强度/MPa 坚固性系数f 纯煤 2 010 1 280 0.28 12 1.4 铝质煤岩(夹矸1) 3 260 2 460 0.24 30 3.5 灰色煤岩(夹矸2) 12 100 2 630 0.23 42 5.1 石灰岩(夹矸3) 18 300 2 610 0.21 52 6.8 粉砂岩(夹矸4) 21 500 2 600 0.19 64 8.4 表 2 因素水平表
水平 螺旋升角A/(°) 夹矸坚固性系数B 截齿排列方式C 1 10 3.5 顺序式 2 12 5.1 交叉式 3 14 6.8 - 4 16 8.4 - 表 3 试验配置方案及正交试验结果
试验方案 因素编码 受力均值/N 载荷波动系数 A B C 1 1 1 1 48 400 0.186 3 2 1 2 2 71 286 0.251 1 3 1 3 1 115 643 0.234 5 4 1 4 2 139 611 0.419 9 5 2 1 2 39 594 0.227 6 6 2 2 1 79 178 0.237 8 7 2 3 2 101 370 0.361 8 8 2 4 1 147 925 0.261 3 9 3 1 1 46 012 0.189 5 10 3 2 2 70 741 0.329 1 11 3 3 1 109 074 0.240 8 12 3 4 2 134 927 0.427 4 13 4 1 2 40 895 0.223 1 14 4 2 1 80 127 0.243 7 15 4 3 2 102 720 0.372 4 16 4 4 1 149 072 0.263 1 表 4 因素影响程度分析表
受力均值/N 载荷波动系数 A B C A B C K1 374 940 174 901 775 431 1.091 8 0.826 5 1.857 0 K2 368 067 301 332 701 144 1.088 5 1.061 7 2.612 4 K3 360 754 428 807 - 1.046 8 1.209 5 - K4 372 814 571 535 - 1.102 3 1.371 7 - k1 93 735.00 43 725.25 101 928.8 0.273 0 0.206 6 0.232 1 k2 92 016.75 75 333.00 85 643.00 0.272 1 0.265 4 0.326 6 k3 90 188.50 107 201.75 - 0.261 7 0.302 4 - k4 93 203.50 142 883.75 - 0.275 6 0.342 9 - R 3 546.50 99 158.50 16 285.8 0.013 9 0.094 5 0.136 3 S 1 572 42 537 6 566.1 0.010 7 0.057 9 0.066 8 表 5 螺旋滚筒受力信息
工况 夹矸坚固性系数 截齿排列方式 滚筒受力/N 载荷波动系数 最小值 最大值 均值 1 3.5 顺序式 26 837.18 61 836.49 48 400.00 0.186 3 交叉式 20 948.40 60 273.91 39 594.00 0.227 6 2 5.1 顺序式 47 836.28 107 928.63 79 178.00 0.237 8 交叉式 37 893.51 107 394.38 71 286.00 0.251 1 3 6.8 顺序式 40 275.40 180 495.16 115 643.00 0.234 5 交叉式 55 924.27 156 683.02 107 370.00 0.361 8 4 8.4 顺序式 75 026.81 216 904.03 147 925.00 0.261 3 交叉式 70 280.39 194 813.93 139 611.00 0.419 9 表 6 滚筒受力情况及截齿应力值
工况 滚筒结构参数 滚筒运动参数 煤层赋存条件 滚筒受力最大值/N 滚筒载荷波动系数 截齿最大应力值/MPa 截齿安全系数 叶片升角/(°) 排列方式 截深/mm 牵引速度/(m·min-1) 滚筒转速/(r·min-1) 夹矸厚度/m 夹矸坚固性系数 1 10 交叉式 530 5 85 0.2 3.5 57 983.51 0.204 9 347.04 3.11 2 12 交叉式 530 3 80 0.3 3.5 56 354.27 0.213 7 308.18 3.50 3 14 交叉式 630 5 85 0.3 3.5 64 972.14 0.232 7 409.24 2.64 4 16 交叉式 630 3 80 0.2 3.5 62 876.93 0.219 8 358.91 3.01 5 10 顺序式 530 5 85 0.2 6.8 161 490.24 0.220 3 497.60 2.17 6 12 顺序式 530 3 80 0.3 6.8 170 715.56 0.233 7 529.07 2.04 7 14 顺序式 630 5 85 0.3 6.8 197 241.75 0.247 6 611.56 1.77 8 16 顺序式 630 3 80 0.2 6.8 189 948.20 0.240 2 570.16 1.89 -
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