Research on parameterized modeling and mechanical characteristics of shearer cables

Shearer cables, subjected to large deformations and exposed to harsh working conditions during frequent back-and-forth movements, pose difficulties in achieving comprehensive mechanical performance and extended fatigue life. This study addresses parametric modeling challenges related to determining...

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Bibliographic Details
Published in:PloS one 2024-05, Vol.19 (5), p.e0304007
Main Authors: Zhao, Lijuan, Zhang, Haining, Gao, Feng, Yang, Shijie
Format: Article
Language:English
Subjects:
Analysis
Bending fatigue
Cables
Coal mining
Conductors
Diameters
Equipment Design
Fatigue
Fatigue life
Fatigue testing machines
Fatigue tests
Insulation
Investigations
Materials
Materials fatigue
Mechanical properties
Modelling
Models, Theoretical
Physical Sciences
Pitch (inclination)
Sheaths
Stranding
Stress distribution
Stress, Mechanical
Tensile Strength
Undersea cables
Working conditions
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Summary:Shearer cables, subjected to large deformations and exposed to harsh working conditions during frequent back-and-forth movements, pose difficulties in achieving comprehensive mechanical performance and extended fatigue life. This study addresses parametric modeling challenges related to determining tangency within and between layers, recursively generating spiral curves from the (n-1)-th level to the n-th level, and constructing irregular surfaces for insulation and sheath. Investigating tensile and bending properties, the research explores the impact of varying pitch diameter ratios at different stranding levels, stranding directions, and monofilaments on mechanical performance across scales. The results reveal a nonlinear increase in stress in power and control conductors with growing pitch diameter ratios. The optimal combination is determined as a pitch diameter ratio of 6 for cabling, 5 for the control conductor, and 14 for the power conductor. The predicted fatigue life of the improved cable by Ncode aligns with bending test results, demonstrating functionality up to 15.12e4 cycles. Stress distribution in parallel stranding is lower and more even, tending to scatter. Conversely, counter stranding experiences relatively higher stress, ensuring a more stable structure. While maintaining a constant effective conductor cross-sectional area, finer monofilaments result in higher cross-sectional filling ratios, enhancing tensile and bending performance.
ISSN:1932-6203
1932-6203
DOI:10.1371/journal.pone.0304007