Research on impact dynamic characteristics of scraper conveyor driven by permanent magnet limited torque reduction drive

As the main piece of equipment used in coal mining, the scraper conveyor is always evolving to have larger capacities, longer haulage distances, and higher power. The traditional scraper conveyor drive system mostly adopts the method of “asynchronous motor + soft start device + reducer” to realize the low-speed and high torque drive. However, due to increased intelligence and extremely harsh working conditions, there is a significant risk of failure, which has a negative impact on mining efficiency. The possibility of failure increases dramatically due to the extremely hard-working environment and the rise in intelligence, which has a major impact on mining efficiency. Therefore, a new type of permanent magnet torque-limiting reduction device was designed and developed, which was highly integrated by a permanent magnet synchronous motor, a two-stage planetary reducer, and a column surface friction torque limiter. Additionally, The dynamic simulation model of the scraper conveyor and planetary reducer, the rigid-flexible coupling model of key components of the column friction torque limiter, and the control model of the permanent magnet motor were established by using ADAMS and MATLAB/Simulink software, realizing the joint simulation of the electromechanical coupling system. Dynamic response of speed, torque, and three-phase current of permanent magnet synchronous motor and speed, tension, and torque of scraper chain drive system as well as speed, torque, and meshing force of planetary drive of a scraper conveyor driven by a new type of permanent magnet torque-limiting reducer device were simulated and analyzed under impact load condition. The results show that the inrush load current with and without torque limiter protection is 2.9 and 7.7 times higher than that in stable operation, and the motor output power is reduced by about 48% under the inrush fault. The effect of shock loads on the motor at the load side is well reduced by the column friction torque limiter. When subjected to excessive shock loads, the chain drive system components are subjected to large forces between them. In this case, the torque limiter slips immediately, the system is unloaded and the drive components are protected against overload. The shock between the gears of the reducer is also increased by excessive shock loads, which are quickly and accurately protected by the torque limiter. Conventional systems are subjected to about 78% less load impact, proving that the permanent magnet limited-pitch reduction device is well suited for low-speed, high-torque engineering applications. The research findings have the potential to enhance the scraper conveyor drive system’s dependability and boost the coal machine device’s intelligence.