面向数字孪生的采煤机滚筒实时截割载荷模型研究

doi:10.3901/JME.260099

机械工程学报 ›› 2026, Vol. 62 ›› Issue (3): 479-491.doi: 10.3901/JME.260099

• 数字化设计与制造 • 上一篇

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面向数字孪生的采煤机滚筒实时截割载荷模型研究

王世博^1,2,3, 葛世荣⁴, 管增伦¹, 周士林¹, 王丽杰^3,5, 李雪峰⁶, 王赟⁷, 袁晓明⁷, 马广军⁸

1. 中国矿业大学机电工程学院徐州 221116;
2. 矿山智能采掘装备省部共建协同创新中心徐州 221116;
3. 智能采矿装备技术全国重点实验室徐州 221116;
4. 中国矿业大学(北京)机电与信息工程学院北京 100083;
5. 太重煤机有限公司太原 030032;
6. 南京工业职业技术大学机械工程学院南京 210023;
7. 中国煤炭科工集团太原研究院有限公司太原 030006;
8. 山西中阳华润联盛南山煤业有限公司吕梁 033400

修回日期:2025-03-07 接受日期:2025-08-18 发布日期:2026-03-25
作者简介:王世博,男,1979年出生,博士,教授,博士研究生导师。主要研究方向为智能采掘装备。E-mail:wangshb@cumt.edu.cn

Research on Real-time Cutting Load of Longwall Shearer Drum for Digital Twins

WANG Shibo^1,2,3, GE Shirong⁴, GUAN Zenglun¹, ZHOU Shilin¹, WANG Lijie^3,5, LI Xuefeng⁶, WANG Yun⁷, YUAN Xiaoming⁷, MA Guangjun⁸

1. School of Mechatronic Engineering, China University of Mining and Technology, Xuzhou 221116;
2. Jiangsu Province and Education Ministry Co-sponsored Collaborative Innovation Center of Intelligent Mining Equipment, Xuzhou 221116;
3. State Key Laboratory of Intelligent Mining Equipment Technology, Xuzhou 221116;
4. School of Mechanical and Electrical and Information Engineering, China University of Mining and Technology, Beijing 100083;
5. TZ Coal Machinery Co., Ltd., Taiyuan 030032;
6. School of Mechanical Engineering, Nanjing Vocational University of Industry Technology, Nanjing 210023;
7. China Coal Science and Engineering Group Taiyuan Research Institute Co., Ltd., Taiyuan 030006;
8. Shanxi Zhongyang Huarun Liansheng Nanshan Coal Ming Co, Ltd., Lvliang 033400

Revised:2025-03-07 Accepted:2025-08-18 Published:2026-03-25
Supported by:
国家自然科学基金(52474182)、工信部产业基础再造和制造业高质量发展专项(TC220A04W-1、167)和山西省揭榜挂帅科技(202301010101002)资助项目。

摘要/Abstract

摘要： 数字孪生是实现以采煤机为核心装备的综采工作面智能化运行的关键技术。采煤机滚筒截割是采煤机与煤岩环境动态耦合过程的首要环节，建立准确的滚筒截割载荷模型是构建采煤机高保真数字孪生模型的关键。综合考虑采煤机牵引运动、摇臂调高运动和滚筒转动，建立了采煤机滚筒齿尖运动轨迹方程，分析获得了截齿截割厚度、滚筒截割煤岩区域角等单齿截割载荷计算的必要参数。利用单齿截割力计算方程建立了滚筒截割负载模型，实现了滚筒转速、采煤机牵引速度、滚筒与煤岩界面相对位置等采煤机不同动态工况参数下的截割载荷实时计算。利用截割载荷模型初步构建了采煤机数字孪生系统，仿真分析了不同工况下的滚筒截割负载。研究结果表明：滚筒截割扭矩和截割力F_x受工况参数影响较大，而截割力F_y受工况参数影响较小。利用18201工作面历史运行数据，对采煤机滚筒截割负载模型进行了验证测试，发现恒速和变速牵引工况下截割扭矩的仿真值与测量值的平均误差分别为6.85 kN·m和6.36 kN·m，截割扭矩的仿真值与测量值包括7个本征模态函数(Intrinsic mode function, IMF)分量和一个残余项，且各IMF的频率范围和幅值变化非常相似，表明所建立的截割负载模型在频域内能够较为准确地对采煤机截割负载进行仿真。

关键词: 采煤机滚筒, 截割载荷, 截齿, 数字孪生, 模型

Abstract: Digital twin is the key technology for enabling intelligent operations at longwall mining face, with the shearer serving as the central equipment. The cutting of a longwall shearer drum is the primary part during the dynamic coupling process between the longwall shearer and coal/rock environment. Building an accurate cutting load of longwall shearer drum is important for a high-filed digital twins model of longwall shearer. A kinematic trajectory equation of cutting pick is built which includes the traction motion of longwall shearer, adjusting of range arm, and rotation of drum. With this equation, the necessary parameters, including cutting depth and angle of coal/rock cut range, for calculating cutting load of one cutting pick are obtained. The cutting load model of longwall shearer drum is built based on cutting load of one cutting pick. It realized that real-time cutting load is calculated under different conditions including rotating speed of drum, traction speed of longwall shearer, relative location between drum and coal/rock interface. The digital twin system of longwall shearer is built with the proposed real-time cutting load model of longwall shearer drum. The cutting load is simulated and analyzed under different conditions. The results shows that the cutting torque and cutting force F_x are greatly affected by working condition parameters, while the cutting force F_y is little affected by working condition parameters. Based on the historical operating data of 18201l longwall face, the shearer drum cutting load model is verified and tested. It is found that the average error between the simulation value and the measured value of cutting torque under constant and variable traction conditions is 6.85 kN·m and 6.36 kN·m, respectively. Both the simulation value and measured value of cutting torque include 7 IMF components and one residual term. Moreover, the frequency range and amplitude changes of each IMF are very similar, indicating that the established cutting load model can simulate the cutting load of shearer more accurately in the frequency domain.

Key words: longwall shearer drum, cutting load, cutting pick, digital twin, model

中图分类号:

TG42

王世博, 葛世荣, 管增伦, 周士林, 王丽杰, 李雪峰, 王赟, 袁晓明, 马广军. 面向数字孪生的采煤机滚筒实时截割载荷模型研究[J]. 机械工程学报, 2026, 62(3): 479-491.

WANG Shibo, GE Shirong, GUAN Zenglun, ZHOU Shilin, WANG Lijie, LI Xuefeng, WANG Yun, YUAN Xiaoming, MA Guangjun. Research on Real-time Cutting Load of Longwall Shearer Drum for Digital Twins[J]. Journal of Mechanical Engineering, 2026, 62(3): 479-491.

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面向数字孪生的采煤机滚筒实时截割载荷模型研究

Research on Real-time Cutting Load of Longwall Shearer Drum for Digital Twins

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