Abstract:
To adapt to the trend of ultra-long fully mechanized coal mining faces and address the limitations of traditional asynchronous head-tail drive systems—such as low transmission efficiency, centralized power, and high failure rates—a novel series-driven scraper conveyor powered by multiple permanent-magnet synchronous motors (PMSM) was proposed. Using the discrete element method combined with the Kelvin–Voigt model, the dynamic equations of the chain transmission system were established, and the key technical parameters were determined. The discretized dynamic model parameters were calculated, and a machine–electrical coupled model was constructed based on the relationship between the PMSM torque and load. A dynamic simulation model of the chain transmission system was developed in MATLAB/Simulink. Simulations analyzed the PMSM output speed, torque, and the scraper chain’s velocity, acceleration, and tension under various operating conditions, including no-load start-up, full-load operation, and impact loads. A small-scale experimental testbed of the series-driven multi-permanent-magnet direct-drive scraper conveyor was then constructed. Experiments under no-load start-up, loaded start-up, and impact conditions were conducted to obtain the PMSMs’ dynamic characteristic curves, validating the accuracy of the machine–electrical coupled model. Simulation and experimental results demonstrate that the series-driven multi-permanent-magnet direct-drive system responds rapidly to load variations under different working conditions. The participation of intermediate drives in power transmission varies with operating conditions. The system enables segmented control of the scraper chain tension, significantly reducing the impact of load fluctuations. It also allows for a lower chain tensile upper limit while maintaining conveying capacity, reduces chain weight, decreases system energy consumption, and promotes the development of intelligent and energy-efficient mining equipment.