Coordinated Speed Control Strategy for Minimizing Energy Consumption of a Shearer in Fully Mechanized Mining †
Abstract
:1. Introduction
- (1)
- We propose an energy consumption model of the shearer in unidirectional mining based on the force and resistance analysis through its entire mining process. The model has a special focus on the relationship among the energy consumption and output of mining, traction speed and drum rotating speed, as well as the effective coal mining time.
- (2)
- On the basis of the proposed model, we establish an optimal control strategy for the drum rotational speed and traction speed, with the purpose of the minimal energy consumption of the shearer in one production cycle, constrained by the working process, working load and technical limits.
- (3)
- Detailed analysis of the impact of the drum rotational speed and traction speed on the final energy consumption is provided to give practical implications on how to possibly approach more energy-saving production if optimal speed coordination cannot be achieved during the real complex production.
2. Coal-Mining Process
2.1. Oblique Cutting and Feeding at the End of the Longwall
2.2. Linear Cutting from Tail to Head
2.3. Empty Cutting
3. Energy Consumption Analysis of Coal-Mining Processes
3.1. Force Analysis of Shearer
3.1.1. Instantaneous Total Average Cutting Resistance of the Drum
- : diameter of the spiral drum of the shearer [m].
- : the number of picks on the -th transversal line of the shearer.
- : instantaneous average cutting resistance of -th conical pick on the -th transversal line of the shearer.
- : coefficient of resistance to cutting coal.
- : increase in traction force when drum cutting, and .
- : unidirectional compressive strength of coal, , Mpa.
- : coefficient of coal rock firmness.
- : wear area of a conical pick.
- : volume coefficient of the stress state of coal.
- : average cutting resistance of the coal seam.
- : cutting edge width of a conical pick.
- : reflect the influence of edge cutting width.
- : brittleness coefficient of coal.
- : average distance between pick-tip and the center of cutting header [cm].
- .
- : coefficient of the free surface.
- : influence coefficient of cutting angle.
- : influence coefficient of the cutting surface shape of the conical pick.
- : coefficient of conical pick arrangement.
- : influence coefficient of ground pressure on coal mining face.
- : the deflection angle between the pick axis on the -th transversal line relative to the traction direction.
3.1.2. Traction Resistance of the Shearer
- : the inclination angle of coal mining face;
- is the sliding resistance caused by the weight of the shearer, take “+” when pulling upward.
- is the propulsive resistance of the front and rear drums, which is about 60~80% of the cutting resistance of the drums. In this paper, we use 0.8 in the following formula.
- : the rated power of a single cutting motor [kW].
- : transmission efficiency of cutting motor.
- : shearer design height [m].
- : working condition coefficient of the rear drum.
- : shearer weight [t].
3.2. Power Consumption Model of the Shearer
3.2.1. Traction Power Consumption of Drum Cutting
3.2.2. Power Consumption of Shearer Traction
3.2.3. Energy Consumption of the Shearer
4. Optimization of Energy Consumption Considering a Mining Cycle
4.1. Objective Function
4.2. Constraints
4.2.1. Range of Traction Speed , Drum Cutting Rotational Speed of Shearer in k-th Production Cycle
4.2.2. Mining Time
- (1)
- Total mining timeThe constraints (18)–(19) are set for the maximum allowable mining time.
- (2)
- Working time of coal miningThe constraints (22) are set for the requirement of mining time.
4.2.3. Production Requirement
5. Simulation, Results and Discussion
5.1. Simulation Parameters
5.2. Analysis of Simulation Result
5.2.1. Energy Consumption and Mining Output with Several Speed Coordination Cases
- (1)
- The maximum energy consumption of the shearer is 3,964,775 kJ [SC = (0.9, 1.05) (SC = [traction speed (p.u.), drum speed (p.u.)]) in case 5], and the minimum energy consumption of the shearer is 3,578,145 kJ [SC = (1.08, 0.96) in case4]. With the same production constraints, the energy consumption can be saved 9.75% by coordinating the traction speed and drum speed.
- (2)
- Combinations of case 1 and case 2 which with consistent speed variation are selected to analyze the influence of changing traction speed and drum speed on the shearer’s energy consumption.
5.2.2. Energy Consumption and Mining Output with Optimal and and Other Analyzed Speed Coordination Cases
6. Conclusions
Author Contributions
Funding
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
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: 260 m | : 45 m | : 6 |
: 0.8 m | : 3.3 m | : 1.42 t/m3 |
: 0.98 |
: 10 m | : 60 m | : 400 kW |
: 2 m | : 0.8 | : 0.8 |
: 0.8 |
Process | Pr1 | Pr2 | Pr3 | Pr4 |
---|---|---|---|---|
traction speed (m/s) | 0.025 | 0.0333 | 0.0367 | 0.0467 |
drum speed (r/min) | 25 | 25 | 30 | 25 |
Case | Speed | Speed Value [p.u.] | ||||
---|---|---|---|---|---|---|
Case 5 | traction speed | 0.9 | 0.9 | 0.95 | 1 | 1.05 |
Drum speed | 0.95 | 1.05 | 1.1 | 0.9 | 0.95 |
Process | Pr1 | Pr2 | Pr3 | Pr4 |
---|---|---|---|---|
traction speed | 1.168 | 1.0511 | 1.0654 | 1.1156 |
drum speed | 0.92 | 0.92 | 0.9333 | 0.8 |
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Zheng, Z.; Chen, D.; Huang, T.; Zhang, G. Coordinated Speed Control Strategy for Minimizing Energy Consumption of a Shearer in Fully Mechanized Mining. Energies 2021, 14, 1224. https://doi.org/10.3390/en14051224
Zheng Z, Chen D, Huang T, Zhang G. Coordinated Speed Control Strategy for Minimizing Energy Consumption of a Shearer in Fully Mechanized Mining. Energies. 2021; 14(5):1224. https://doi.org/10.3390/en14051224
Chicago/Turabian StyleZheng, Zheng, Dilei Chen, Tao Huang, and Guopeng Zhang. 2021. "Coordinated Speed Control Strategy for Minimizing Energy Consumption of a Shearer in Fully Mechanized Mining" Energies 14, no. 5: 1224. https://doi.org/10.3390/en14051224