多永磁电机串联驱动刮板输送机机−电耦合建模与试验研究

Mechatronic coupling modeling and experimental study of the multi-permanent magnet motor series drive scraper conveyor

  • 摘要: 为顺应超长综采工作面的发展趋势,解决传统机头机尾异步驱动系统存在的传动效率低、功率集中、故障率高等缺点,提出了多永磁电机串联驱动刮板输送机新构型。利用离散单元法和Kelvin-Voigt模型构建了多永磁直驱式刮板输送机链传动系统的动力学方程,确定了多永磁直驱式刮板输送机关键技术参数,并计算离散化动力学模型参数,通过永磁同步电机转矩与负载的关系构建了多永磁直驱式刮板输送机机−电耦合模型,在MATLAB/Simulink中建立了多永磁电机串联驱动刮板输送机链传动系统的动力学仿真模型,仿真分析了多永磁电机直驱系统在空载启动、满载运行、冲击载荷等多种工况下永磁同步电机的输出转速、转矩以及刮板链的速度、加速度、张力等动态特性变化规律。随后搭建了小型多永磁电机串联直驱刮板输送机模拟实验台,同步开展了空载启动、带载启动、冲击载荷等多种工况试验,获取了永磁同步电机的动态特性曲线,验证了所建机−电耦合模型的正确性。仿真和试验结果表明:多永磁电机串联直驱系统对于各工况下负载变化具有较快的响应速度,中间驱动在链传动系统中参与动力传递的程度随工况变化;该系统可实现刮板输送机整机链条张力的分段控制,显著降低负载波动对整机链条的冲击影响,可在保证刮板输送机输送能力的前提下减小链条抗拉上限,降低链条自重,减少系统运行能耗,有助于推动矿山装备智能化与能效优化发展。

     

    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.

     

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