Beruflich Dokumente
Kultur Dokumente
2, 2016
DOI: 10.1515/sgem-2016-0015
Silesian University of Technology, Faculty of Mechanical Engineering, Institute of Fundamentals of Machinery Design,
e-mail: cenacewicz@o2.pl; andrzej.katunin@polsl.pl
Abstract: The paper provides a description of analytical model of a longwall scraper conveyor, including its electrical, mechani-
cal, measurement and control actuating systems, as well as presentation of its implementation in the form of computer simulator
in the Matlab®/Simulink® environment. Using this simulator eight scenarios typical of usual operational conditions of an under-
ground scraper conveyor can be generated. Moreover, the simulator provides a possibility of modeling various operational faults
and taking into consideration a measurement noise generated by transducers. The analysis of various combinations of scenarios
of operation and faults with description is presented. The simulator developed may find potential application in benchmarking of
diagnostic systems, testing of algorithms of operational control or can be used for supporting the modeling of real processes oc-
curring in similar systems.
Key words: mining machinery, diagnostics and control, scraper conveyor, fault simulation and diagnosis
2. MATHEMATICAL MODEL
OF A SCRAPER CONVEYOR
d s kb k c
U s Rs I s , (1) k . (12)
dt 3
d r Taking into consideration these relations and trans-
0 Rr I r jpb m r , (2)
dt forming the phase coordinates into the coordinates asso-
ciated with a stator the relations (1)–(8) take the form
s Ls I s LM I r , (3)
U s U s jU s , (13)
r Lr I r LM I s , (4)
I s I s jI s , (14)
Lr L
Is s M r , (5)
W W s s js , (15)
Ls L
I r r M s , (6) I r I r jI r , (16)
W W
where W Ls Lr L2M . r r jr , (17)
3 * d m 1 3
Me pb Im( s I s ) , (7) pb (s I s s I s ) M o . (18)
2 dt J 2
d m 1 The model of a fluid coupling can be described by
(M e M o ) , (8)
dt J the following relation [9]
where Me – electromagnetic torque, Mo – load torque, d s
J – moment of inertia, pb – number of pairs of mag- M s s s s3 s s ( s 3 s2 s ) ,
dt
netic poles, Ωm – angular velocity of the motor, (19)
Us – stator voltage space vector, Rs – stator winding
resistance, Rr – rotor winding resistance relegated to where Ms is the coupling torque, s – angle of rota-
the circuit of the stator, Is – stator current space vector, tion of the coupling, s, s – stiffness coeeficients
I r – the rotor current space vector relegated to the of participation of linear and non-linear compo-
nents, τs – delay constraint of a fluid coupling.
circuit of the stator, Ls – inductance of stator windings,
A gear can be defined by several equations related
Lr – rotor windings inductance relegated to the circuit to the particular components of a torque. Since the
of the stator, Lm – magnetizing inductance, Ψs – the torque on the motors is one of the signals analyzed on
stator flux space vector, r – space vector of the rotor the output of the model it is necessary to introduce the
flux brought to the circuit of the stator. relations which will allow the torque to be determined.
In the case of modeling the motor in the Clark- The gear ratio is described by the relation [9]
Stanley coordinate system it is necessary to introduce o n0
the transformation of phase coordinates a, b, c to the i , (20)
i ni
fixed coordinates associated with a stator α, β, 0. In
the case of absence of higher harmonics they can be where i is the gear ratio, ωi, ωo are the angular velocities
described as [9] on the input and otput of a gear, respectively. The torque
k k a , (9) losses which should be considered in the model can be
determined based on the following relationship [9]
kb k c
k , (10) Mb
3 M p (1 p ) , (21)
o p
where kα, kβ are α and β components, respectively, of
the vector k in a coordinate system associated with the where ΔMp – torque losses of a gear, Mb – torque of
stator, and ka, kb, kc are the phase components a,b,c of the drive drum, and ηp – gear efficiency. The engine
the vector k; while in the case of presence of higher torque relegated to the drive shaft of the driving
harmonics eqautions (9) and (10) take the form sprocket can be determined based on the following
relationship [10]
2 k kc
k ka b , (11)
3 2 M n [ M s M p ] n i , (22)
where n s p , Mn – drive torque of the engine where Ua, Ub, Uc – voltage of the phases, Um – maxi-
relegated to the drive shaft sprocket, and n, s – effi- mum value of the supply voltage, ω – supply voltage
ciency of the drive and coupling, respectively. The ripple, t – time. In the case of the mine power supply
torque on the driving spocket can be calculated as network, a network system with isolated neutral point
follows IT is used.
M gn M n1 M n 2 . (23)
2.3. MODEL OF MINE BREAKER
In the case of auxiliary drive relation (23) takes the AND CONTACTOR CONTROL
form
M gp M np . (24) The control system and contactor switch con-
trolled by this system are the additional mathematical
The output torque can be described as [11] models that allow modeling of different operational
states (run-up, run-down, tripping, shutdown, emer-
d s
M wy M s J s , (25) gency shutdown) of a conveyor. In real systems, con-
dt trol is carried out in the following configurations:
where Mwy – the output torque of the drive drum, local and remote control. A control voltage signal is
Ms – elastic torque, Js – moment of inertia of the mo- described by the relation
tor, s – the angular velocity of the motor. The elastic 0 for ‘ off’ ,
torque is described by Us (33)
1 for ‘ on’.
d
M s c , (26) In the case of switch contactor the following de-
dt
vices are modeled most often: main contactor, trigger
d m circuit, short circuit protection, overloading protec-
M s M wy J m , (27)
dt tion, and asymmetric protection.
The model of main contactor is described by
where – damping coefficient, c – elasticity coef-
ficient, Jm – moment of inertia of the mechanism, 0 when U wya ,U wyb ,U wyc 0,
– angle of rotation, m – angular velocity of the U sg
mechanism. The instantaneous value of the angle of 1 when U wya ,U wyb ,U wyc U wea , U web ,U wec ,
rotation is described with relations (34)
s m , (28) where Uwex, Uwyx – input and output voltage of phase x,
and Usg – control voltage of main contactor.
d A short-circuit protection model is described by
s m , (29) the following relation
dt
where s – angle of the motor shaft, m – angle of the 0 for I wya I zn ,
mechanism shaft. 0 for I wyb I zn ,
U sg (35)
0 for I wyc I zn ,
2.2. POWER SUPPLY MODEL 1 for I wya , I wyb , I wyc I zn ,
2.4. EQUATIONS OF MOTION where Wxx(j) – motion resistance of the j-th segment of
the conveyor, axx(j), bxx(j), cxx(j), dxx(j) – coefficients of
In order to represent equations of motion of scraper approximation of external friction (in the case of linear
conveyor, a discretized model of particular subsystems approximation b, c, d equal 0), – slope of a segment L/j.
that describe motion of scrapers was assumed. The
following four subsystems were considered: lower ten- 2.6. MODEL OF MASSES AND LOADING
don (segment 1), turning sprocket with auxiliary drive OF EXCAVATED MATERIAL
(segment 2), upper (operating) tendon (segment 3), and
driving sprocket (segment 4). A scheme of the discre- The model of masses of an operating tendon is de-
tized model is presented in Fig. 3. The modelling proce- scribed by [5]
dure assumes two approaches: complex and simplified
one. The complex approach assumes replacement of m
parts of scraper chain by a system of differential equa- m xx ( j ) mk z cuxx ( j ) muxx ( j ) L , (40)
2 pz
tions. This approach is used by Dolipski and his team.
The equations of motion for a scraper conveyor using where mxx(j) – mass of the j-th segment of conveyor,
this approach can be found, e.g., in his book [5]. mk – unitary mass of chain, mz – mass of a scraper,
In the case of simplified approach, tendons of pz – pitch of bearing elements, cuxx(j) – mass coefficient
a conveyor are modelled as vibrating elements or vi- for chain vibration, muxx(j) – unitary mass of excavated
brating elements with damping. Usually three types of material; while in the case of non-operating tendon
models of tendons are used: elastic model, viscoelastic equation (40) takes the form
model, and standard (three-parameter) model. In this
study, the simplest elastic model was assumed. This m
m xx ( j ) mk z L . (41)
model is described by the following equations [13] 2 pz
V ( j ) m( j ) l ( j ) F ( j 1) F ( j ) P( j ) W ( j ) l ( j ) , In the case of sprockets the masses can be deter-
(37) mined using the following equations
Fig. 4. The main block of the simulator of scraper conveyor and a parameterization window
Table 4. Possible scenarios in the simulator [16] and experts’ knowledge. The fault U1 assumes
Scenario
a drop of the supply power by 19 V; while the fault
Description U2 assumes an increase of the friction coefficient a
nomenclature
S1 idle run-up by 0.5 with respect to its nominal value (see Table 2).
S2 idle run-up and run-down
The faults U1 and U2 can appear in every opera-
S3 idle run-up, loading, run-down
tional scenario. The fault U3 assumes increase of the
unitary mass of excavated material by ca. 100 kg/m
S4 idle run-up, loading, unloading, run-down
with respect to its nominal value (see Table 2) and
S5 run-up with excavated material
can appear only in scenarios that consider operation
run-up with excavated material, unloading,
S6
run-down
with excavated material (S3 –S8). For the rest of
S7 run-up with loading of excavated material
scenarios (S1, S2), despite choosing such a type of
fault, the simulation is performed similarly as for the
run-up with loading of excavated material,
S8
unloading, run-down healthy condition U0. The faults U4–U6 assume an
increase in measurement noise by 50 times with re-
spect to their nominal values. These types of faults
Table 5. Possible faults in the simulator can be simulated only when the modes of particular
transducer simulated signals are turned on.
Fault
Description
nomenclature
U1 drop of the supply power 4.2. SIMULATION
U2 dust pollution of the lower space of gutters AND COMPARATIVE STUDIES
U3 overloading by excavated material
U4 fault of the transducer for Mpg
The simulations were performed for all possible sce-
U5 fault of the transducer for Mgn
narios. The time of simulation was set to 40 s, which
U6 fault of the transducer for vn
allows all significant changes in simulated signals to be
observed. The resulting signals for selected scenarios for
It is assumed that during a given simulation only the healthy condition of a conveyor without taking into
one type of fault may occur. The faults were mod- consideration measurement noise are presented in Figs.
eled based on the technical documentation of 6–8. In the context of diagnostics all of the process sig-
the modeled conveyor, literature survey [5], [15], nals considered were normalized.
Fig. 6. Results of simulation following the scenario: idle run-up, loading, unloading, run-down (S4)
From the waveforms presented in Figs. 6–8, one tions performed. For example, one can observe that
can observe significant variability in operation con- run-up with excavated material requires much more
ditions which is connected directly with the opera- power and the velocity of conveyor in significantly
lower than in the case of idle run-up (cf. torque overload conveyor motors. One can also observe
waveforms in Figs. 6 and 7). Much more favorable dependences between simulated signals, e.g., the
conditions can be observed during performing run-up increase of torques causes a decrease in conveyor
with loading of excavated material, which does not velocity.
The influence of measurement noise for all simu- resulting signals for the faults U1–U3 are presented in
lated signals is shown in Fig. 9 based on scenario S8. Figs. 10–12, while the signals for the faults U4–U6
This scenario was also selected to present faulty con- are presented in a common set of waveforms in Fig. 13,
ditions with simulation of all modeled faults. The since in each case only one signal changes.
Analyzing the results obtained for simulations of In further studies it is planned to tune up the model
the faults, one can observe that the cases considered and simulator using real measurement data and ad-
differ from each other, which introduces a basis for vanced methods of artificial intelligence and soft
development of diagnostic tools for testing fault de- computing.
tection and isolation algorithms.
ACKNOWLEDGEMENTS
5. CONCLUSIONS
The research presented in the paper was financed by the Na-
tional Centre of Research and Development (Poland) within the
A mathematical model of scraper conveyor and framework of the project titled “An integrated shell decision
support system for systems of monitoring processes, equipment
a simulator based on this model was introduced and and hazards” carried out in the path B of Applied Research Pro-
presented in this paper. The model was developed and gramme – grant No. PBS2/B9/20/2013.
parameterized according to the technical documenta-
tion of the JOY® BSL scraper conveyor, literature
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