Study on the spatiotemporal distribution of coal flow in the scraper conveyor of fully mechanized mining face
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摘要: 基于传感器的煤流特征研究受传感器监测范围有限的影响，无法对刮板输送机整机煤流特征进行研究；基于模型仿真的煤流特征研究缺乏对开采工艺的考虑，不能预测刮板输送机整机的煤流时空分布。针对综采工作面刮板输送机整机运载煤流特征难以监测的问题，结合综采工作面开采工艺，通过分析采煤机截割装载和刮板输送机运载煤流过程，建立了各工艺段下不同装载方式的刮板输送机瞬时装载体积、截面积的数学模型；将刮板输送机运载煤流过程划分为煤流平移和装载煤流叠加，基于有限元方法构建了综采工作面刮板输送机煤流时空分布预测模型。利用该模型仿真分析了开采工艺周期内刮板输送机的煤流时空分布特征：相比于中部正常截割阶段，端头截割阶段的煤流时空分布较为复杂；中部槽装载煤流的最大截面积出现在调换滚筒位置阶段；刮板输送机运载煤流体积在采煤机上行和下行过程中变化趋势相反，变化趋势由采煤机牵引方向决定。利用某矿工作面采煤机和刮板输送机实际运行数据作为模型的输入参数，根据预测的煤流时空分布计算过煤量，结果表明：过煤量预测结果与现场实测的变化趋势一致，累计过煤量预测误差为9.24%，在采煤机进刀过程和上行阶段的固定时间段内过煤量预测误差分别为13.19%和13.78%，证明了煤流时空分布预测模型的正确性。Abstract: Research on coal flow characteristics based on sensors is limited by the restricted monitoring range of sensors, making it impossible to study the coal flow characteristics of the entire scraper conveyor. Additionally, research on coal flow characteristics based on model simulations often lacks consideration of mining processes, preventing the prediction of the spatiotemporal distribution of coal flow across the entire scraper conveyor. To address the issue of difficulty in monitoring the coal flow characteristics of the entire scraper conveyor in a fully mechanized mining face, this study integrated the mining process of the fully mechanized face. By analyzing the processes of coal cutting and loading by the shearer and the coal transportation by the scraper conveyor, a mathematical model for the instantaneous loading volume and cross-sectional area of the scraper conveyor under different loading methods in various process segments was established. The coal flow transportation process of the scraper conveyor was divided into coal flow translation and loaded coal flow superposition, and a spatiotemporal distribution prediction model for coal flow on the fully mechanized face scraper conveyor was developed based on the finite element method. Using this model, the spatiotemporal distribution characteristics of coal flow on the scraper conveyor during the mining process cycle were analyzed through simulation. Compared to the normal cutting stage in the middle, the spatiotemporal distribution of coal flow was more complex during the cutting stage at the ends. The maximum cross-sectional area of the loaded coal flow in the middle trough occurred during the stage of drum swapping. The volume of coal flow transported by the scraper conveyor changed in opposite trends during the upward and downward movements of the shearer, with the trend determined by the shearer's traction direction. Actual operating data from a shearer and scraper conveyor in a mine were used as input parameters for the model, and the coal volume was calculated based on the predicted spatiotemporal distribution. The results showed that the predicted trend of coal volume was consistent with on-site measurements, with a cumulative coal volume prediction error of 9.24%. The coal volume prediction errors during the fixed time periods of the shearer's cutting process and upward movement stage were 13.19% and 13.78%, respectively, demonstrating the accuracy of the spatiotemporal distribution prediction model for coal flow.
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图 1 综采工作面端部斜切进刀开采工艺
Figure 1. Inclined cutting feed mining technology at the end of fully mechanized mining face
图 2 截割顶煤时刮板输送机装载体积
Figure 2. Loading volume of scraper conveyor during top coal cutting
图 3 截割底煤时刮板输送机装载体积
Figure 3. Loading volume of scraper conveyor during bottom coal cutting
图 5 前滚筒截割时刮板输送机运载煤流过程
Figure 5. Coal flow process of carried by scraper conveyor during front drum cutting
图 6 刮板输送机煤流时空分布预测模型
Figure 6. Prediction model of spatiotemporal distribution of coal flow in scraper conveyor
图 9 不同装载方式的瞬时装载截面积
Figure 9. Instantaneous loading cross-sectional area of different loading modes
图 10 开采工艺周期内刮板输送机煤流时空分布
Figure 10. Spatiotemporal distribution of coal flow in scraper conveyor during mining process cycle
图 13 刮板输送机煤流时空分布仿真结果
Figure 13. Simulation result of spatiotemporal distribution of coal flow in scraper conveyor
图 14 过煤量预测与实际结果对比
Figure 14. Comparison between forecasted and actual coal throughput results
表 1 工作面端头割煤和推溜情况
Table 1. Coal cutting and pushing at the end of working face
运行状态 前滚筒 后滚筒 推移浮煤 a 底部三角煤 底煤 否 b 底部三角煤 顶部三角煤 是 c 底煤 顶部三角煤 是 d 弧形煤层 空采 否 e 底部三角煤 顶煤 否 f 底部三角煤 顶部三角煤 否 g 底煤 顶部三角煤 否 h 弧形煤层 空采 否 i 空采 顶煤 否 j 空采 空采 是 k 空采 空采 是 
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表 2 仿真参数
Table 2. Simulation parameters
参数 值 滚筒直径D/m 3 筒毂直径Dt/m 1.52 采煤机两滚筒中心点距离lsh/m 16.89 采煤机截割深度lj/m 0.865 刮板链移动速度va/（m·s−1） 0.9 刮板输送机长度la/m 300 中部槽高度ha/m 0.263 刮板输送机弯曲段长度lw/m 27 煤岩碎胀系数km 1.2 煤的自然安息角α/（°） 45 截割顶煤后剩余煤层高度hs/m 2
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表 3 工作面设备参数
Table 3. Equipment parameters of working face
参数 值 滚筒直径D/m 2.24 筒毂直径Dt/m 1.1 采煤机两滚筒中心点距离lsh/m 12.75 采煤机截割深度lj/m 0.80 刮板输送机与煤壁之间的距离lb/m 0.48 刮板输送机长度la/m 220 中部槽高度ha/m 0.345 煤岩碎胀系数km 1.2 煤的自然安息角α/（°） 45
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