刮板输送机可靠性研究进展与未来发展趋势

Research Progress and Future Trends in the Reliability of Scraper Conveyors

  • 摘要: 随着综采工作面向大采高、长运距和高产能方向发展,刮板输送机运行负荷与连续作业时间显著增加。受重载冲击、磨粒磨损、偏载波动及复杂煤流扰动影响,链条断裂、中部槽磨损和链轮啮合异常等问题日益突出,制约工作面煤流连续运输与设备稳定运行。为系统梳理刮板输送机可靠性研究进展,本文首先分析链条、中部槽和链轮的典型失效形式,阐明冲击载荷、摩擦磨损、张紧异常及啮合失稳对关键部件性能退化的影响。针对上述失效问题,全文围绕可靠性设计、可靠性制造和运行监测与维护3个环节展开综述。可靠性设计方面,重点总结概率可靠性分析、故障逻辑评价、多物理场仿真、关键部件结构优化及机电耦合调控等研究;可靠性制造方面,系统归纳耐磨抗冲材料、精密成形、焊接、热处理及表面强化等技术,分析材料性能、制造缺陷和工艺参数对部件服役可靠性的影响;运行监测与维护方面,梳理振动、电流、温度、张力和图像等多源信息在状态监测、故障诊断、异常预警和维护决策中的应用。现有研究仍存在复杂工况表征不足、关键部件耦合作用认识不充分、材料与制造工艺协同性较弱、多源监测信息融合程度较低及现场长期验证不足等问题。针对上述研究短板,未来应加强多物理场与不确定性融合的可靠性设计,推进材料、结构与制造工艺协同优化,完善复杂工况下的机电耦合与多驱调控方法,并构建设计、制造、运行监测与维护相互衔接的可靠性技术体系,为提升刮板输送机的运行可靠性与稳定性提供参考。

     

    Abstract: With the development of fully mechanized mining faces toward greater mining heights, longer conveying distances, and higher production capacities, the operating loads and continuous service durations of scraper conveyors have increased significantly. Under heavy impact loads, abrasive wear, eccentric load fluctuations, and complex coal-flow disturbances, failures such as chain breakage, middle trough wear, and abnormal sprocket meshing have become increasingly prominent, thereby restricting continuous coal transportation and stable equipment operation. To systematically review advances in scraper conveyor reliability, this paper first analyzes the typical failure modes of chains, middle troughs, and sprockets, and clarifies the effects of impact loading, friction and wear, abnormal tensioning, and meshing instability on the degradation of key components. These failure problems are then reviewed from three stages: reliability design, reliability-oriented manufacturing, and operational monitoring and maintenance. For reliability design, the review focuses on probabilistic reliability analysis, fault logic assessment, multiphysics simulation, structural optimization of key components, and electromechanical coupling control. For reliability-oriented manufacturing, wear- and impact-resistant materials, precision forming, welding, heat treatment, and surface strengthening are systematically summarized, with emphasis on the effects of material properties, manufacturing defects, and process parameters on component reliability. For operational monitoring and maintenance, the applications of multisource information, including vibration, current, temperature, tension, and images, in condition monitoring, fault diagnosis, anomaly warning, and maintenance decision-making are reviewed. Existing studies remain limited by insufficient representation of complex operating conditions, inadequate understanding of coupling effects among key components, weak coordination between materials and manufacturing processes, limited fusion of multisource monitoring information, and insufficient long-term field validation. Future research should strengthen reliability design by integrating multiphysics coupling and uncertainty analysis, promote the coordinated optimization of materials, structures, and manufacturing processes, improve electromechanical coupling and multi-drive control under complex operating conditions, and establish an integrated reliability framework linking design, manufacturing, operational monitoring, and maintenance. These efforts will provide theoretical and technical support for the highly reliable and stable operation of scraper conveyors.

     

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