Life cycle analysis and damage prediction of a longwall powered support using 3D numerical modelling techniques
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Powered shield support consists of structural members like hydraulic legs, canopy, base, goaf shield, lemniscate links and several pins connecting these members. All these members experience cyclic loading as the shearer cuts coal and the longwall face advances. During the operational life of a shield support, members may be damaged since loading conditions vary widely depending on the type of roof and floor strata. This study focuses on the analysis of responses of various members of a powered support in terms of stresses, minimum number of operational loading cycles for a given safety factor and the damage under cyclic loading conditions. Three-dimensional finite element models of a longwall panel are firstly analysed having powered support, rock strata, coal seam and goaf to determine the typical loading patterns those may occur on top of the canopy. Then these loading patterns are applied on a digital twin shield structure as cyclic loads for estimation of fatigue responses of various members. The study reveals that the most effected zone of the entire shield structure lies in goaf shield between the connectors of two lemniscate links. The links are the major load-bearing members and hence, their connection with the base and pins are severely also affected due to cyclic loading.
KeywordsPowered support Cyclic load Fatigue failure Operational life Safety factor and damage
The authors would like to thank the management of the Singareni Collieries Company Limited (SCCL) of Telangana state, India, for allowing to visit the mine and to collect the relevant data for this study.
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