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

doi:10.3901/JME.260099

Abstract

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

CLC Number:

TG42

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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