Wang Yadong, Lin Guocong, Liu Xunan, Zhao Lijuan, Jia Baoxuan, Wang Yuan, He Jingqiang
School of Mechanical Engineering, Liaoning Technical University, Fuxin, 123000, China.
Liaoning Provincial Key Laboratory of Large-Scale Mining Equipment, Fuxin, 123000, China.
Sci Rep. 2024 Nov 3;14(1):26507. doi: 10.1038/s41598-024-77538-9.
To ensure that the discrete element model of the coal wall accurately reflects the actual cutting process of coal and rock during virtual prototype simulation of mining equipment, this study aims to expedite the development of intelligent mining machinery. Using coal samples from the 4602 working face of Yangcun Coal Mine, operated by Yanzhou Coal Mining Group, we conducted coal rock packing experiments and uniaxial compression tests to obtain the packing angle and compressive strength of the coal samples. Based on the experimental results, we designed Plackett-Burman experiments (PB experiments), steepest ascent experiments, and Box-Behnken experiments to study the influence of particle contact mechanics parameters and bonding mechanics parameters on the packing angle and compressive strength, using the packing angle and compressive strength as response variables. Our objective is to minimize the relative error between the simulated packing angle and the measured packing angle. We solved and optimized the parameter calibration model and conducted simulation calibration experiments based on the optimization results. A comparative analysis with the actual test results revealed that the maximum relative errors between the simulated and measured values for the packing angle and compressive strength were only 2.9% and 5.0%, respectively. Additionally, a discrete element model of a typical working face coal wall was established based on the parameters obtained from this calibration method. A bidirectional coupling model of the cutting process between the coal and rock was created using EDEM-RecurDyn to simulate the rigid-flexible coupling of the coal cutter. An experimental coal wall model was constructed based on similarity theory, and both simulation and physical experiments were conducted. The evaluation metrics for comparison were the time-domain and frequency-domain characteristics of the drum's vibration signals. The maximum relative error for the time-domain signal characteristics between the two experimental setups was only 4.19%, while the maximum relative error for the frequency-domain signal characteristics was 3.75%. This validates the feasibility of the proposed calibration method for the discrete element coal wall model and the accuracy of the calibration results. Furthermore, it demonstrates that the constructed discrete element coal wall accurately represents the actual coal and rock properties. The virtual simulation based on this model effectively replicates the interaction process between mining machinery and coal, providing a safe, efficient, and low-cost technological approach for performance analysis of mining equipment and intelligent control of supporting devices.
为确保在采矿设备虚拟样机仿真过程中，煤壁离散元模型能准确反映煤岩的实际切割过程，本研究旨在加快智能采矿机械的研发。利用兖州煤业股份有限公司杨村煤矿4602工作面的煤样，进行了煤岩充填实验和单轴压缩试验，以获取煤样的充填角度和抗压强度。基于实验结果，设计了Plackett-Burman实验（PB实验）、最速上升实验和Box-Behnken实验，以颗粒接触力学参数和粘结力学参数为自变量，以充填角度和抗压强度为响应变量，研究其对充填角度和抗压强度的影响。目标是使模拟充填角度与实测充填角度之间的相对误差最小。求解并优化了参数校准模型，并根据优化结果进行了模拟校准实验。与实际测试结果的对比分析表明，充填角度和抗压强度的模拟值与实测值之间的最大相对误差分别仅为2.9%和5.0%。此外，基于该校准方法获得的参数，建立了典型工作面煤壁的离散元模型。利用EDEM-RecurDyn创建了煤岩切割过程的双向耦合模型，以模拟采煤机的刚柔耦合。基于相似理论构建了实验煤壁模型，并进行了模拟和物理实验。比较的评价指标是滚筒振动信号的时域和频域特征。两种实验装置时域信号特征的最大相对误差仅为4.19%，频域信号特征的最大相对误差为3.75%。这验证了所提出的离散元煤壁模型校准方法的可行性和校准结果的准确性。此外，还表明所构建的离散元煤壁准确地代表了实际煤岩特性。基于该模型的虚拟仿真有效地再现了采矿机械与煤之间的相互作用过程，为采矿设备性能分析和支护装置智能控制提供了一种安全、高效、低成本的技术途径。
