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Studia Geotechnica et Mechanica, Vol. 38, No.

2, 2016
DOI: 10.1515/sgem-2016-0015

MODELING AND SIMULATION


OF LONGWALL SCRAPER CONVEYOR
CONSIDERING OPERATIONAL FAULTS

KRZYSZTOF CENACEWICZ, ANDRZEJ KATUNIN

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

1. INTRODUCTION the development of mathematical models that imitate


behavior of real scraper conveyors. This approach
allows for testing various scenarios of operation modes
Scraper conveyors are some of the most important of a conveyor, including the possibility of modeling
machines that belong to the so-called three-machine operational faults, and predicting the behavior of
mining systems (a shearer, a hydraulic support and a machine.
a scraper conveyor) [1] in the mechanized under- The development of such models has several far-
ground mines (see Fig. 1). The current tendency of reaching goals. Besides the possibility of simulating
development of new, more advanced and more power- various operation scenarios and faulty conditions such
ful scraper conveyors induces the necessity of evalu- a model can be successfully applied as a tool for de-
ating the behavior of the whole machine as well as its signing new operation processes as well as a tool for
particular subsystems in the operation conditions in the model-based diagnostics, where signals measured
order to prevent unwanted operation modes or ma- on a conveyor are compared to simulated signals in
chinery downtime. The most effective way of such order to generate residuals. Then, residuals can be
evaluation is to perform continuous monitoring of used for fault detection and isolation. As a further
operation parameters of a machine and, based on the effect, the model developed can be implemented as
collected data, develop appropriate models and diag- a part of control algorithms that can be used for auto-
nostic procedures. However, performing extended mation of diagnostic processes of conveyors of such
measurements is often limited due to extremely diffi- a type.
cult operation conditions in the underground coal The development of models of machinery and
mines as well as difficulties in accessibility to various other technical objects is a common practice in design
mechanisms and devices installed in a conveyor. Thus, of monitoring and diagnostic systems. One can men-
the measurement data is often incomplete and insuffi- tion several model-based simulators that were devel-
cient for proper evaluation of behavior of a machine oped as a supporting tool for development of diagnos-
and detection of possible faults occurring during op- tic methodology of systems and processes: simulator
eration. One of the ways to overcome this problem is of an electro-pneumatic automatic actuator used as

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16 K. CENACEWICZ, A. KATUNIN

tional conditions of an underground scraper conveyor.


The simulator, implemented based on the mathemati-
cal model developed, provides a possibility of model-
ing various operational faults and taking into consid-
eration a measurement noise generated by transducers.
The parameterization of a model was performed based
on the scraper conveyor of type JOY® BLS. The devel-
oped model and simulator will be ultimately applied
for development of diagnostic and control algorithms
dedicated to underground scraper conveyors.

2. MATHEMATICAL MODEL
OF A SCRAPER CONVEYOR

As a basis of mathematical model the scraper con-


veyor of type JOY® BLS with three engines was as-
sumed. The mathematical model of a scraper con-
veyor consists of the following submodels: model of
a doubled main drive, model of auxiliary drive, model
of mine breaker and contactor control, power supply
model, model of equations of motion, model of
Fig. 1. The scraper conveyor in one of Polish mines
(courtesy of A. Katunin)
masses, and model of motion resistance. These sub-
models are schematically presented in Fig. 2, and are
described in the subsections below.
a platform of diagnostic benchmarking within the
DAMADICS project [2], simulator of a three-tank
system used for fault detection and identification de-
veloped within the DiaSter system [3], simulator of a
wind turbine developed within the fault tolerant con-
trol system [4], etc. Several systems were developed
also for mining machinery, in particular for convey-
ors. One should pay attention to the models of con-
veyors developed by Dolipski and his team and de- Fig. 2. The scheme of the assumed model
scribed in numerous publications (see, e.g., [5], [6]). of a scraper conveyor
Besides these studies, the mathematical models of
mining conveyors were developed by several other
2.1. DRIVELINE MODEL
research teams, e.g., Mao et al. [7] developed a dy-
namic mathematical model of a scraper conveyor in
order to investigate the chain behavior under certain The driveline model in the case under investiga-
operation conditions; while Eshin [8] developed the tions consists of the models of main and auxiliary
mathematical model (with Matlab®/Simulink® imple- drives. The main drive is responsible for the trans-
mentation) of a scraper conveyor in order to test dy- portation of excavated material located on the upper
namic control algorithms. operating tendon. It consists of two explosion proof
The following study presents a mathematical asynchronous cage motors, fluid coupling, gear and
model of scraper conveyor and its implementation in driving sprocket. The auxiliary drive is responsible for
the Matlab®/Simulink® environment taking into con- reducing the loading in the chain located on the driv-
sideration mechanical, electrical, measurement and ing sprocket. This drive consists of an explosion proof
control actuating systems that are originally installed asynchronous cage motor, fluid coupling, gear and
on the scraper conveyors. The model generates three a turning sprocket.
types of operation signals and can be launched in The model of asynchronous cage motor can be de-
eight pre-defined scenarios typical of usual opera- scribed by the following relations [9]

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Modeling and simulation of longwall scraper conveyor considering operational faults 17

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  js , (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  jr , (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)

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18 K. CENACEWICZ, A. KATUNIN

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 ,

where Iwyx – output current of phase x, Izn – current of


The mathematical model of the power supply net-
a short-circuit protection.
work consists of equations describing voltage of each
The model of overloading protection is described
of the supplying phases [12]
by
U a  U m  (sin t ) , (30)
0 for I wya , I wyb , I wyc  I pn and t pn  t pnu ,
U sg  
 2 
U b  U m   sin t    , (31) 1 for I wya , I wyb , I wyc  I pn and t pn  t pnu ,
 3  (36)
 2  where Ipn – overcurrent (thermal) protection, tpn – re-
U c  U m   sin t    , (32)
 3  sponse time of protection, tpnu – overloading time.

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Modeling and simulation of longwall scraper conveyor considering operational faults 19

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,

Fig. 3. Discretized model of a scraper conveyor

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

F ( j  1)  l ( j )  A  E  [v( j  1)  v( j )] . (38)  m  J nnap ( j ) 


mgnnap ( j )    mk  z    L , (42)
 2 pz  l ( j )  r 2
( j ) 
 nnap 
2.5. MOTION RESISTANCE
 m 
mgnap ( j )    mk  z 
 2 pz 
The motion resistance, based on [5], can be de-
scribed as follows:
1  J b ( j )  i p2 (k )  p (k )  
 
Wxx ( j )  9.81  mxx ( j )  2  L ,
l ( j )  rb2  i p (k  1)  p ( k  1)  0,5  J p (k  1) 
 [( a xx ( j )  bxx ( j )  q1xx ( j )  c xx ( j )  q xx
2 3
( j )  d xx ( j )  q xx ( j ) ) , (43)
 sgn q xx ( j ) cos  xx ( j )  sin  xx ( j ) ], where mgnnap(j), mgnap(j) – equivalent masses of the
(39) j-th segment of turning and driving sprockets, re-

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20 K. CENACEWICZ, A. KATUNIN

spectively, rb – radius of a sprocket, ip – gear ratio, 3. SIMULATOR


Jb – moment of inertia of a sprocket, p – gear effi- OF A SCRAPER CONVEYOR
ciency. AND ITS PARAMETERIZATION
2.7. MODEL OF TRANSDUCER
Based on the mathematical model presented in
The measurement transducers were considered in Section 2, a simulator of scraper conveyor was devel-
order to simulate real measurement conditions with oped in the Matlab®/Simulink® environment. The
measurement noise, quantization and sampling. Their model assumes the ability to simulate different opera-
parameters can be defined by the following relation tional scenarios of a conveyor, and the ability to simulate
 e  10 exp(log  s  0.05SNR ) , (44) operational faults typical of scraper conveyors working
underground. Similarly, as in the theoretical model the
where e – variance of noise generator, s – the vari- simulator consists of several subsystems responsible for
ance of the output signal, SNR – signal-to-noise ratio. various actions. The main block with a parameterization
It is also necessary to define: pk = 2–N – quantization window, and internal modular structure of a simulator
level, N – number of bits of a transducer, tp = 1/fp are presented in Figs. 4 and 5, respectively.
– sampling time of a transducer, fp – sampling fre- The parameterization of simulator was performed
quency of a transducer. based on technical documentation of the modelled

Fig. 4. The main block of the simulator of scraper conveyor and a parameterization window

Fig. 5. Internal modular structure of a simulator of scraper conveyor

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Modeling and simulation of longwall scraper conveyor considering operational faults 21

conveyor, and data available in the literature [5], [14]. 1 2 3 5


The main parameters of the modelled conveyor are pre- Starting current Ir 1983 A
sented in Table 1. The operational parameters were de- Rated power coefficient cos φn 0.9 –
termined theoretically or selected based on the experts’ Total moment of inertia JC 3.46 kg·m2
knowledge. The parameters for mass model and drive Moment of inertia
JS 2.46 kg·m2
of the motor
model are presented in Tables 2 and 3, respectively.
Rated slip sn 0.01 –
Rated critical slip skn 0.037 –
Table 1. Parameters of the conveyor JOY® BLS Rated critical torque Mkn 2572 Nm
Rated ripple ωsn 155.43 rad/s
Parameter Symbol Value Unit
Stator resistance Rs 0.18 Ω
Productivity Qp 2160 t/h
Rotor resistance Rr 0.181 Ω
Chain type
– ϕ34 × 126 × 200 mm Stator leakage reactance XSσ 0.0001 H
(diam.×pitch×spacing)
Diameter of the driving Rotor leakage reactance X r 0.0001 H
Dgn 0.2 m
sprocket Magnetizing reactance Lm 0.0149 H
Diameter of the turning Rated speed nn 1485 min–1
Dgp 0.2 m
sprocket Gear efficiency ηp 94 %
Number of chains lc 2 – Coupling efficiency Ηs 98 %
Velocity of the conveyor vp 1.3 m/s Rigidity coefficient c 2100 –
Length of the conveyor lp 250 m Damping coefficient μ 0.1 –
Gear ratio i 13 – Moment of inertia of the
Jm, Js 0.8 kg·m2
Drive power Pn 3 × 250 kW mechanism and the motor
Supply voltage Un 500 V Moment of inertia
Jzl 81 kg·m2
Sectional area of the chain A 9.0792·10–6 m2 of scrapers and a chain
Young’s modulus
of the chain E 2.1·1011 Pa
(for steel)
4. SIMULATION OF
OPERATION SCENARIOS
Table 2. Parameters of mass model
AND FAULTS
Parameter Symbol Value Unit
Unitary mass of the chain mjt 22.7 kg/m
Unitary mass of excavated
material
mju 461.54 kg/m 4.1. SCENARIOS AND FAULTS
Mass of the scraper mz 35 kg
Mass coefficient for
cxx 1 – The simulator of a scraper conveyor provides a pos-
chain vibration
Friction coefficient for sibility of simulating eight operating scenarios, which
a 3 –
scrapers represent the characteristic considering the operations
Moment of inertia of the
Jg 2.5 kg·m2
performed during work. A list of possible scenarios in
sprocket the simulator is presented in Table 4. The loading of
excavated material is modelled as a linear increase of
Table 3. Parameters of drive model
the coefficient kz (when it equals 1 – a full rated load-
ing is obtained).
Parameter Symbol Value Unit At the output of the simulator three parameters,
1 2 3 4 which characterize the operation of a conveyor, are
Rated power Pn 250 kW generated: loading torque of motors Mpg, torque gen-
Rated voltage Un 500 kV erated by motors Mgn, and velocity of a conveyor vn.
Rated current In 268 A Depending on needs, the signals can be generated
Rated torque Mn 1286 Nm with and without taking into account interference
Rated efficiency ηn 95.7 % from transducers.
Overload capability pm 2 – The simulator provides a possibility of simulating
Rated frequency fn 50 Hz six types of faults and the healthy condition (U0) of
Number of poles pairs p 2 – a conveyor. The types of the faults are presented in
Starting torque Mr 2829 Nm Table 5.

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22 K. CENACEWICZ, A. KATUNIN

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)

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Modeling and simulation of longwall scraper conveyor considering operational faults 23

Fig. 7. Results of simulation following the scenario:


run-up with excavated material, unloading, run-down (S6)

Fig. 8. Results of simulation following the scenario:


run-up with loading of excavated material, unloading, run-down (S8)

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

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24 K. CENACEWICZ, A. KATUNIN

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.

Fig. 9. Results of simulation following scenario S8


considering measurement noise generated by transducers

Fig. 10. Comparison of results of simulation following scenario S8


for healthy and faulty (U1) conditions

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Modeling and simulation of longwall scraper conveyor considering operational faults 25

Fig. 11. Comparison of results of simulation following scenario S8


for healthy and faulty (U2) conditions

Fig. 12. Comparison of results of simulation following scenario S8


for healthy and faulty (U3) conditions

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.

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26 K. CENACEWICZ, A. KATUNIN

Fig. 13. Comparison of results of simulation following scenario S8


for healthy and faulty (U4–U6) conditions

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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Modeling and simulation of longwall scraper conveyor considering operational faults 27

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