Optimization of coal loading performance of shearer screw drum
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摘要: 螺旋滚筒是采煤机截割煤岩的直接机构，螺旋滚筒几何参数和截割策略的优化设计对提高滚筒装煤性能有重要影响。现有基于有限元和二维离散元法的螺旋滚筒优化设计大多基于单一或部分因素，未综合考虑多设计变量对螺旋滚筒装煤性能的影响，难以同时得到几何参数及运动学参数最优解。针对该问题，基于煤的物理力学特性参数测试结果，利用离散元分析软件EDEM构建采煤机螺旋滚筒截割煤壁耦合模型，对采煤机螺旋滚筒的装煤性能进行数值模拟，采用单因素法分析了螺旋滚筒螺旋升角、直径、筒毂直径、截割深度、转速及牵引速度对装煤性能的影响；基于离散元分析结果设计螺旋滚筒三因素三水平正交试验，通过极差分析得出几何参数中滚筒直径、筒毂直径、螺旋升角，运动学参数中截割深度、滚筒转速、牵引速度对螺旋滚筒装煤性能的影响依次减小；根据正交试验结果得出螺旋滚筒最优几何参数方案为13°螺旋升角、1 300 mm滚筒直径、475 mm筒毂直径，最优截割策略为600 mm截割深度、58 r/min滚筒转速、8 m/min牵引速度，最优参数下螺旋滚筒装煤率为76.39%，较优化前提高了15.82%。Abstract: The screw drum is the direct mechanism of the shearer cutting coal and rock. The optimization design of geometric parameters and cutting strategy of screw drum has an important impact on improving coal loading performance of drum. The existing optimization design schemas of the screw drum based on the finite element method and the two-dimensional discrete element method are mostly based on a single factor or part factors. The influence of multiple design variables on the coal loading performance of the screw drum is not comprehensively considered. It is difficult to obtain the optimal solution of the geometric parameters and kinematic parameters simultaneously. In order to solve this problem, based on the test results of the physical and mechanical properties of coal, the coupling model of the shearer's screw drum cutting coal wall is established by using discrete element analysis software EDEM. The numerical simulation of coal loading performance of the shearer's screw drum is carried out. The single-factor method is used to analyze the influence of the spiral angle, diameter, hub diameter, cutting depth, drum rotation rate and traction speed of the screw drum on the coal loading performance. The three factors and three levels orthogonal test of the screw drum is designed based on the results of discrete element analysis. Through range analysis, the influence of geometric parameters of drum diameter, drum hub diameter and spiral rise angle, and kinematic parameters of cutting depth, drum rotation rate and traction speed on the coal loading performance of the screw drum is reduced in turn. According to the orthogonal test results, the optimal geometric parameters of the screw drum are 13° spiral rise angle, 1300 mm drum diameter and 475 mm drum hub diameter. The optimal cutting strategy is that the cutting depth is 600 mm, the drum rotation rate is 58 r/min, and the traction speed is 8 m/min. Under the optimal parameters, the coal loading rate of the screw drum is 76.39%, which is 15.82% higher than before.
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图 8 螺旋升角对采煤机装煤率的影响规律
Figure 8. Influence law of spiral rising angle on coal loading rate of shearer
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图 9 滚筒直径对采煤机装煤率的影响规律
Figure 9. Influence rule of drum diameter on coal loading rate of shearer
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图 10 筒毂直径对采煤机装煤率的影响规律
Figure 10. Influence rule of hub diameter on coal loading rate of shearer
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图 11 截割深度对采煤机装煤率的影响规律
Figure 11. Influence law of cutting depth on coal loading rate of shearer
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图 12 滚筒转速对采煤机装煤率的影响规律
Figure 12. Influence of drum rotation rate on coal loading rate of shearer
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图 13 牵引速度对采煤机装煤率的影响规律
Figure 13. Influence law of traction speed on coal loading rate of shearer
表 1 正交试验因素水平
Table 1 Factor levels of orthogonal test
设计变量 符号 水平 1 2 3 螺旋升角/（°） a 11 13 15 滚筒直径/mm b 1050 1150 1300 筒毂直径/mm c 475 525 570 截割深度/mm d 600 700 800 滚筒转速 /(r·min−1) e 54 58 62 牵引速度/(m·min−1) f 7 8 9 
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表 2 几何因素正交试验结果
Table 2 Orthogonal test results of geometric factors
试验
编号因素水平 装煤率/% a b c 1 a1 b1 c1 61.47 2 a1 b2 c2 58.07 3 a1 b3 c3 63.87 4 a2 b1 c2 59.06 5 a2 b2 c3 57.54 6 a2 b3 c1 74.23 7 a3 b1 c3 58.08 8 a3 b2 c1 67.48 9 a3 b3 c2 71.38
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表 3 几何因素极差分析
Table 3 Range analysis of geometrical factors
指标 a/（°） b/mm c/mm L1 183.41 178.61 203.18 L2 190.83 183.09 188.51 L3 196.94 209.48 179.49 l1 61.14 59.54 67.73 l2 63.61 61.03 62.84 l3 65.65 69.83 59.83 极差 4.51 10.29 7.90
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表 4 运动学因素正交试验结果
Table 4 Orthogonal test results of kinematic factors
试验
编号因素水平 装煤率/% d e f 1 d1 e1 f1 61.47 2 d1 e2 f2 62.66 3 d1 e3 f3 61.94 4 d2 e2 f1 60.13 5 d2 e3 f2 61.37 6 d2 e1 f3 58.25 7 d3 e3 f1 57.72 8 d3 e1 f2 56.54 9 d3 e2 f3 55.82
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表 5 运动学因素极差分析
Table 5 Range analysis of kinematic factors
指标 d/mm e/(r·min−1) f/(m·min−1) L1 186.07 176.26 179.32 L2 179.75 178.61 180.57 L3 170.08 181.03 176.01 l1 62.02 58.75 59.77 l2 59.92 59.54 60.19 l3 56.69 60.34 58.67 极差 5.33 1.59 1.52
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