Bionic tooth base wear-resistant and impact-resistant structure design and service life prediction method for coal mining machine

Abstract

The application discloses a shearer bionic tooth base wear-resistant and impact-resistant structure design and life prediction method, and relates to the technical field of tooth base life prediction; the method comprises the following steps: establishing a tooth base parameterized model to generate a structure instance, material partition and a dangerous section set, forming a working condition characteristic sequence and a working condition category sequence based on operation monitoring data, further establishing a load to structure response mapping, generating an initial equivalent impact load spectrum, an initial equivalent stress amplitude sequence and an initial grinding energy sequence, and combining material partition degradation, section profile updating and stress amplitude spectrum recursion to realize coupling damage evolution analysis, output a residual life distribution, a failure position and a maintenance threshold suggestion; the application realizes wear-resistant degradation and impact fatigue coupling prediction of a dangerous area of a tooth base, accurately identifies a failure position and outputs a residual life and a maintenance suggestion.

Description

Technical Field

[0001] This invention relates to the field of tooth seat life prediction technology, and more specifically, to the design of wear-resistant and impact-resistant biomimetic tooth seat structure for coal mining machines and its life prediction method. Background Technology

[0002] During coal and rock cutting, the cutting teeth of a coal mining machine are connected to the drum via tooth holders. The tooth holders not only transmit cutting resistance but also endure complex service conditions such as coal-rock contact friction, alternating loads, localized impacts, and vibration disturbances over extended periods. As mining conditions continuously change, localized areas such as the transition zone at the tooth holder root, the weld toe area, the vicinity of the cutting tooth mounting holes, and the joints between reinforcing ribs often become critical regions with concentrated stress transmission, localized geometric sensitivity, and significant wear evolution. Existing technologies for the wear-resistant and impact-resistant design and life assessment of coal mining machine tooth holders typically focus on structural reinforcement, wear-resistant layer design, localized geometric optimization, operational status monitoring, and fatigue life analysis. These technologies already encompass tooth holder structural modeling, material zoning design, hazardous location identification, and load response analysis.

[0003] However, in actual coal cutting operations, when random impact loads such as rock inclusions and strong vibrations are present, stress concentration easily occurs in the transition zone at the root of the tooth holder and the weld toe area, inducing early impact fatigue cracking. This leads to sudden fracture failure of the tooth holder before wear is significant. Current technologies generally lack a mechanism to establish a consistent mapping between field operation monitoring data and the load spectrum, stress amplitude, and wear input of the aforementioned critical areas. They also lack wear and impact fatigue coupled life prediction methods for dangerous sections. This makes it difficult to reliably determine the failure location, remaining life, and maintenance / replacement timing of critical areas based on material zoning degradation, cross-sectional profile changes, and local load-bearing capacity evolution. Consequently, life assessment results and maintenance decisions lack sufficient basis.

[0004] In view of this, the present invention proposes a biomimetic tooth seat wear-resistant and impact-resistant structural design and life prediction method for coal mining machines to solve the above problems. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art and achieve the above objectives, the present invention provides the following technical solution: a biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines, comprising:

[0006] S1. Establish a parametric model of the tooth base, generate tooth base structural instances and material partitions, and extract the set of critical sections;

[0007] S2. Collect running time, cutting motor current, traction speed, cutting depth, vibration acceleration, impact count characteristics and temperature, and perform time alignment and sliding window statistics to generate working condition feature sequence. Output working condition category sequence based on working condition judgment threshold.

[0008] S3. Based on the working condition characteristic sequence and working condition category sequence, and combined with the dangerous section set, corresponding area index information and material partition information, establish the load to structural response mapping, and generate the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence and initial wear energy sequence of the root transition zone and weld toe zone.

[0009] S4. Based on the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence, and initial wear energy sequence, combined with the set of critical sections and the material zoning table, recursively update the remaining thickness, section profile, and load-bearing geometry of each critical section, and correct the stress concentration factor of the root transition zone and weld toe region; convert the initial equivalent impact load spectrum into the critical section stress amplitude spectrum, and recursively calculate the impact fatigue damage and wear damage according to the zoning count; update the coupled damage and condition level, determine the remaining tolerable cycles and calculate the remaining life, and output the remaining life distribution, failure location, and maintenance threshold recommendations.

[0010] Furthermore, the method for recursively updating the remaining thickness of each critical section, the section profile, and the load-bearing geometry, and correcting the stress concentration factors in the root transition zone and weld toe region includes:

[0011] Establish a cross-sectional state table and a zoned wear front table; for each critical cross-section, establish thickness coordinates along the zone's action surface direction, and determine the initial values ​​of each zone's boundary position, front position position, and remaining thickness of the zone based on the material zoning table;

[0012] The total periodic wear energy is obtained by accumulating the initial wear energy sequence according to the recursive cycle, and then converted into the forward advance along the thickness coordinate direction. The remaining thickness of each partition is updated in the order of material partition from the outside to the inside.

[0013] Based on the partitioned wear front table, the corresponding contour segment in the initial value of the cross-sectional contour is offset to form the current value of the cross-sectional contour. Based on the current value of the cross-sectional contour, the current value of the effective cross-sectional area, the current value of the local bearing thickness and the current value of the minimum transition curvature radius are calculated.

[0014] Based on the stress concentration correction rule table and combined with the cross-section related region index, the current values ​​of the stress concentration factors in the root transition zone and weld toe zone are corrected.

[0015] Furthermore, the method for converting the initial equivalent impact load spectrum into the stress amplitude spectrum of the critical section, and recursively calculating impact fatigue damage and wear damage by segmentation, includes:

[0016] Establish a stress amplitude spectrum table and fatigue spectrum recursion table for critical sections; read the load segment number, lower limit of load segment, upper limit of load segment and segment count from the initial equivalent impact load spectrum table, and take the median value of the lower limit of load segment and the upper limit of load segment as the representative value of load segment for each load segment.

[0017] Traverse the set of dangerous sections by section number, read the corresponding stress conversion factor, current value of stress concentration factor, section associated region index and state level mark, multiply the load grade representative value by the stress conversion factor and the current value of stress concentration factor to obtain the stress amplitude representative value of the current dangerous section under the current load grade, and write it together with the grade count into the dangerous section stress amplitude spectrum table.

[0018] The stress amplitude spectrum table of the critical section is traversed in groups according to the critical section number. The allowable number of cycles corresponding to the stress amplitude range is found in the fatigue spectrum recursion table according to the state level mark. The increment of impact fatigue damage for each grade is obtained by dividing the cycle count by the allowable number of cycles, and the cumulative fatigue damage value for the current recursion cycle is obtained by summing them up.

[0019] The wear damage increment for the current recursive cycle is calculated based on the changes in the remaining thickness of the partition and the changes in the effective cross-sectional area, and then accumulated to obtain the cumulative wear damage value.

[0020] Furthermore, methods for updating coupled damage and state levels, determining the remaining tolerable cycles and calculating the remaining lifetime, and outputting the remaining lifetime distribution, failure location, and maintenance threshold recommendations include:

[0021] The state level label is updated based on the remaining thickness and cumulative fatigue damage value of each zone. The state level label includes surface wear state, transitional exposure state, matrix bearing state and critical crack state.

[0022] The cumulative value of coupled damage is updated based on the state level mark, the cumulative value of fatigue damage, and the cumulative value of wear damage. The failure location is determined when the current state level is marked as critical crack state and the cumulative value of coupled damage is greater than or equal to one.

[0023] For unfailed sections, read the cycle count from the stress amplitude spectrum table of the critical section and the allowable number of cycles from the fatigue spectrum recursion table, calculate the remaining tolerable number of cycles and convert it into the remaining life value, summarize the remaining life values ​​of all critical sections according to the section number and the index of the section-related area to form the remaining life distribution, and generate maintenance threshold suggestions based on the maintenance warning threshold and maintenance shutdown threshold.

[0024] Furthermore, the method for generating the initial equivalent impact load spectrum includes:

[0025] Establish a load response mapping parameter table, which includes current mapping coefficient, vibration mapping coefficient, velocity mapping coefficient, impact count mapping coefficient, depth mapping coefficient, load offset value, correction coefficient for each working condition, load grade boundary sequence and load grade number sequence.

[0026] Traverse the working condition characteristic sequence table according to the window number, read the current change amplitude of the cutting motor, the peak value of vibration acceleration, the average value of traction speed, the impact count value, the average cutting depth and the working condition category label, calculate the initial window equivalent impact load value and write it into the initial equivalent impact load sequence table;

[0027] Based on the load grading boundary sequence and load grading number sequence, the equivalent impact load values ​​of each initial window are graded and the grading count is statistically analyzed to generate an initial equivalent impact load spectrum table. The root transition zone index and weld toe region index are written into the associated region index field.

[0028] Furthermore, the method for generating the initial equivalent stress amplitude sequence and the initial wear energy sequence includes:

[0029] Establish a cross-section stress conversion factor table, which includes cross-section number, cross-section associated region index, stress conversion factor, calibration load value and calibration stress value, and calculate the stress conversion factor based on the calibration load value and calibration stress value;

[0030] Traverse the initial equivalent impact load sequence table by window number, traverse the set of critical sections by section number, calculate the initial equivalent stress amplitude based on the stress conversion coefficient and the initial window equivalent impact load value, and write it into the initial equivalent stress amplitude sequence table.

[0031] Establish an initial contact parameter table, read the average traction speed, window length, working condition category mark and the initial window equivalent impact load value, calculate the window sliding distance and select the corresponding energy correction coefficient, and then calculate the initial window wear energy value based on the initial window equivalent impact load value, window sliding distance, contact coefficient and energy correction coefficient and write it into the initial wear energy sequence table.

[0032] Furthermore, methods for obtaining the operating condition feature sequence and determining the operating condition category include:

[0033] Establish an operation monitoring data table, which includes operation time series, cutting motor current series, traction speed series, cutting depth series, vibration acceleration series, impact count characteristic series and temperature series, and write sampling time mark and channel mark according to preset sampling period;

[0034] Read the runtime time series to establish an alignment time axis, map the data of each channel to the alignment time axis, and perform linear interpolation or forward hold-and-hold completion on missing positions to obtain an alignment monitoring data table;

[0035] Establish a window parameter table, generate a window index sequence according to the window length and window step size, read the aligned monitoring data within the corresponding time range of each window, calculate the average cutting motor current, the amplitude of cutting motor current change, the average traction speed, the average cutting depth, the root mean square of vibration acceleration, the peak value of vibration acceleration, the characteristic count value of impact count, the average temperature and the rate of temperature change, and generate a working condition characteristic sequence.

[0036] Establish a working condition judgment threshold table. Based on the working condition characteristic sequence, perform threshold judgment on each window in the order of no-load impact, rock-clamping impact, and strong vibration impact. The remaining windows are judged as steady-state cutoff, and the working condition category is written into the working condition category sequence.

[0037] Furthermore, the operating condition categories include operating condition type, no-load impact, rock-clamping impact, and strong vibration impact.

[0038] Furthermore, the methods for establishing a parametric model of the gear seat and generating gear seat structural instances and material partitions include:

[0039] Generate model identifiers, establish structural parameter tables, assembly constraint tables, and region index tables, and write the following parameters into the structural parameter table: tooth base body length, tooth base body width, tooth base body height, cutting tooth mounting hole diameter and axis position, root transition fillet radius, weld toe transition fillet radius, number of bionic ribs, spacing of bionic ribs, surface texture pitch, wear-resistant zone thickness, and material gradient layer parameters.

[0040] Based on the set of geometric generation rules, the initial solid generation of the gear seat body, the removal of the cutting tooth mounting hole body, the generation of the root transition fillet, the generation of the weld toe transition morphology, the bionic rib forming and fusion, and the generation and fusion of the surface texture are performed in sequence. Then, the partitioning is performed along the normal direction of the specified wear-resistant surface to obtain the gear seat structure instance and the material partition table.

[0041] Furthermore, the method for obtaining the set of dangerous sections includes:

[0042] Based on the critical section extraction step, a set of candidate sections is generated along the length and height directions of the tooth base structure instance. Based on the region index table, candidate sections covering the root transition area, weld toe area, tooth mounting hole neighborhood and rib connection are filtered.

[0043] For each candidate section, extract the section contour line, calculate the fitted circle radius of the root transition zone contour segment and the weld toe area contour segment and take the smaller value as the minimum transition curvature feature, calculate the effective section area difference between the current section and the adjacent section and divide it by the dangerous section extraction step size as the thickness change feature, calculate the turning angle feature of the contour segment at the rib connection as the geometric discontinuity feature, and count the number of partition layers crossed by the section as the material partition change feature.

[0044] The minimum transition curvature characteristic, thickness variation characteristic, geometric discontinuity characteristic, and material partition variation characteristic are written into the hazard assessment table. Each candidate section is judged according to the preset hazard assessment rules, and the sections that meet the hazard section conditions are written into the hazard section set.

[0045] Compared with existing technologies, the biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines proposed in this invention have the following technical effects and advantages:

[0046] This invention establishes a parameterized model of the gear base and unifies the organization of structural parameters, material partitions, assembly constraints, region indexes, and geometric generation rules under the same data object. This enables the integrated generation of the gear base body, cutting tooth mounting holes, root transition zone, weld toe area, biomimetic ribs, and surface textures. At the same time, by combining the material partition table and the set of dangerous sections, it realizes the pre-linkage from structural design to dangerous location identification, improving the data consistency and traceability between structural modeling, critical area positioning, and subsequent life analysis.

[0047] Furthermore, this invention addresses the core technical problem that coal mining machine tooth holders are prone to stress concentration and early impact fatigue cracking in the root transition zone and weld toe area under random working conditions such as rock impact and strong vibration, and may even suddenly fracture before wear is significant. First, it generates a working condition characteristic sequence and a working condition category sequence from operational monitoring data. Then, it establishes a load-to-structural response mapping to generate an initial equivalent impact load spectrum, an initial equivalent stress amplitude sequence, and an initial wear energy sequence. Subsequently, it combines material zoning degradation, cross-sectional profile updating, load-bearing geometry correction, and stress amplitude spectrum recursion of critical sections to achieve coupled evolution calculation of impact fatigue damage and wear damage. Finally, it outputs the remaining life distribution, failure location, and maintenance threshold recommendations.

[0048] In summary, this invention can not only characterize the impact of local geometric degradation of the gear seat on the load-bearing capacity, but also establish a unified mapping between field conditions, stress response in key areas and life prediction results, which significantly improves the pertinence, accuracy and engineering practicality of wear-resistant and impact-resistant structural design and life assessment. Attached Figure Description

[0049] Figure 1 This is a schematic diagram of the wear-resistant and impact-resistant structure design and life prediction method of the bionic tooth seat of the coal mining machine in Embodiment 1 of the present invention;

[0050] Figure 2 This is a flowchart of the method for obtaining the set of dangerous sections in Embodiment 1 of the present invention;

[0051] Figure 3 This is a flowchart of the method for obtaining a working condition feature sequence and determining the working condition category according to Embodiment 1 of the present invention;

[0052] Figure 4 This is a flowchart of the method for generating the initial equivalent impact load spectrum in Embodiment 1 of the present invention;

[0053] Figure 5 This is a flowchart illustrating the method for generating the initial equivalent stress amplitude sequence and the initial wear energy sequence in Embodiment 1 of the present invention. Detailed Implementation

[0054] The technical solutions of the embodiments of the present invention will be described in detail, clearly, and completely below with reference to the accompanying drawings. It should be particularly noted that the specific embodiments described below are only for better illustrating and explaining the technical solutions of the present invention, and are intended to enable those skilled in the art to better understand and implement the present invention, and should not be construed as limiting the scope of protection of the present invention. Without departing from the spirit and substance of the present invention, those skilled in the art can modify, adjust, or make equivalent substitutions based on the content disclosed in the present invention, and these should all be considered within the scope of protection of the present invention.

[0055] Example 1:

[0056] Please see Figure 1 As shown in the figure, this embodiment discloses a biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines. In order to facilitate those skilled in the art to understand and implement the present invention, the key implementation contents are described below in conjunction with the method flow of the present invention.

[0057] In the method flow, step S1 includes: establishing a parameterized model of the tooth seat, generating tooth seat structure instances and material partitions, and extracting a set of dangerous sections.

[0058] It should be noted that the flowchart for obtaining the set of hazardous sections is as follows: Figure 2 As shown.

[0059] Furthermore, a more specific implementation of step S1 is as follows:

[0060] A parameterized model of the gear seat is established. This model describes the adjustable parameters of the gear seat structure and materials, assembly constraints, key area identifiers, and the computational logic for generating gear seat structure instances from these parameters, all in a unified data object format. The parameterized model includes a set of structural parameters, a set of material parameters, a set of assembly constraints, a set of region indexes, and a set of geometric generation rules. The structural parameter set describes the parameter names, value ranges, and constraint relationships for the gear seat body shape, tooth mounting holes, root transition fillets, weld toe transition morphology, biomimetic rib arrangement, and surface texture scale. The material parameter set describes the number of wear-resistant zones, the thickness of each wear-resistant zone, the number of material gradient layers, the thickness of each material gradient layer, and the material parameters of each material gradient layer. The assembly constraint set defines the relative position of the gear seat shape boundary and the tooth mounting holes, and performs interference and boundary checks on the gear seat structure instances. The region index set establishes unique identifiers for the root transition area, weld toe area, tooth mounting hole neighborhood, and rib connection points, and provides boundary descriptions and positioning rules for each identifier, enabling consistent region-based extraction of subsequent critical sections. The set of geometric generation rules is used to specify the generation order, calling relationship and trimming correction rules for generating toothed structure instances from the set of structural parameters and the set of assembly constraints, and to specify the update method that triggers the update of the structural instance when any parameter is updated.

[0061] It should be noted that the structure and execution method of the geometry generation rule set are as follows. The geometry generation rule set consists of several rule entries. Each rule entry is recorded in the generation rule field of the structure parameter table with a rule number, and a corresponding relationship is established with the specific parameter field in the structure parameter table. The rule entry includes a precondition field, an input parameter field, an operation type field, an object field, an output object field, a verification condition field, and a correction action field. The precondition field records the generated object on which the rule execution depends, such as the initial entity of the tooth base body or the rib-reinforced tooth base entity. The input parameter field reads the corresponding parameters from the structure parameter table, such as the length of the tooth base body, the diameter of the cutting tooth mounting hole, the radius of the root transition fillet, the spacing of the bionic ribs, and the surface texture pitch. The operation type field limits the geometry operation type, which includes entity construction, hole removal, fillet transition generation, transition morphology generation, extrusion forming, array laying, entity fusion, and geometry trimming. The object field and the output object field specify the input geometry domain number and the output geometry domain number of the rule, respectively. The geometry domain number is written into the geometry domain positioning rule field of the region index table. The verification condition field is bound to the verification rule field of the assembly constraint table, including interference check conditions for the vicinity of the cutting tooth mounting hole and boundary crossing check conditions for the installation space boundary. The correction action field records the trimming correction rules when the verification fails. The trimming correction rules include texture coverage trimming, rib end shape trimming, and local transition fillet radius regression correction. The rule number, correction amount, and correction reason of the trimming correction are written into the correction record field of the structural parameter table.

[0062] Furthermore, the set of geometric generation rules is executed in a fixed generation order, which includes the following rules: initial entity generation rule for the gear base body, removal rule for the cutting tooth mounting hole, root transition fillet transition rule, weld toe transition morphology generation rule, biomimetic rib stretching and forming rule, biomimetic rib entity fusion rule, surface texture array laying rule, surface texture morphology generation rule, surface texture entity fusion rule, assembly constraint verification rule, and trimming correction rule. The calling relationship is such that the output object of the previous rule is used as the target of the subsequent rule. For example, the hole removal rule uses the initial entity of the gear base body as the target, the rib entity fusion rule uses the initial gear base body entity and the rib entity set as the target, and the texture entity fusion rule uses the initial rib-enhanced gear base entity and the surface texture entity set as the target. The trimming correction rule is executed after the assembly constraint verification rule, and the geometric domain number after trimming correction is synchronously written back to the geometric domain positioning rule field of the region index table.

[0063] Furthermore, the set of geometric generation rules specifies how parameter updates trigger structural instance updates. The parameter update triggering method is recorded in the generation rule field as a dependency relationship, including the binding relationship between parameter fields and object fields, as well as the sequential dependencies between object fields. When any parameter field in the structural parameter table or assembly constraint table is updated, the affected object field is first located based on the dependency relationship, marked as the object to be updated, and then only the rule entries related to the object to be updated are recalculated according to the generation order, replacing the corresponding output object. For example, updating the tooth base body length triggers the recalculation of the initial entity generation rule and all subsequent rules for the tooth base body; updating the cutting tooth mounting hole diameter triggers the recalculation of the hole removal rule and its subsequent rules; updating the root transition fillet radius triggers the root transition fillet transition rule and its subsequent rules; updating the biomimetic rib spacing triggers the recalculation of the rib centerline placement rule and the rib stretching and forming rule and its subsequent rules; updating the surface texture pitch triggers the recalculation of the texture centerline array laying rule and the texture morphology generation rule and its subsequent rules; and updating the installation space boundary in the assembly constraint table triggers the recalculation of the assembly constraint verification rule and the trimming correction rule. After the update is complete, the set of rule numbers involved in this update and the result version number will be written into the record item corresponding to the model version number.

[0064] Initialize model parameters and establish a data carrier. First, generate a model identifier, including the model number and model version number, to distinguish different iteration states of the same parametric model. Establish a structural parameter table, which carries the specific values ​​of the structural parameter set and material parameter set. The structural parameter table includes the length, width, and height of the tooth base body, the diameter of the cutting tooth mounting hole, the axis position of the cutting tooth mounting hole, the root transition fillet radius, the weld toe transition fillet radius, the critical section extraction step size, the number of bionic ribs, the height, thickness, spacing, and arrangement direction of the bionic ribs, the surface texture peak height, the surface texture pitch, the number of wear-resistant zones, the thickness of each wear-resistant zone, the number of material gradient layers, the thickness of each material gradient layer, and the material parameters of each material gradient layer. Set a generation rule field and a correction record field in the structural parameter table. The generation rule field records the rule number and calling order of the geometric generation rule set, and the correction record field records the rule number, correction amount, and correction reason for trimming corrections.

[0065] Next, an assembly constraint table is established. This table contains the specific content of the assembly constraint set, including the overall machine installation space boundary, gear mount surface position constraint, cutting tooth assembly interference constraint, and hole axis attitude constraint. A verification rule field is set to record the verification rule number and trigger condition for interference checks and boundary crossing checks. Then, a region index table is established. This table contains a set of region indices, pre-set root transition zone index, weld toe region index, cutting tooth mount hole neighborhood index, and rib connection index. Each index is pre-set with a region boundary description field and a geometric domain positioning rule field. Design inputs are written into the structural parameter table and assembly constraint table. If any parameter is missing, it is filled with a preset default value. A default value marker and a default value source marker are written into the structural parameter table. After completing the table establishment, parameter writing, and default handling, the model identifier is bound, encapsulated, and stored with the structural parameter table, assembly constraint table, and region index table. The bound and encapsulated data object is defined as the gear mount parameterized model. Subsequent gear mount structure instance generation, material partition establishment, and critical section extraction are all based on this gear mount parameterized model, calling the corresponding table entries and rule fields.

[0066] Instantiate and generate the tooth holder structure skeleton. Based on the set of geometric generation rules, read the tooth holder body length, width, and height from the structural parameter table to construct the initial tooth holder body entity. Based on the cutting tooth mounting hole diameter and axis position, generate the cutting tooth mounting hole entity on the initial tooth holder body entity, and perform a hole removal operation to obtain the tooth holder body entity containing the cutting tooth mounting hole. Then, perform fillet transition generation in the root transition region of the tooth holder body entity. The input for fillet transition generation is the root transition fillet radius and the root transition region boundary line, which is determined by the contour curve at the intersection of the tooth holder body entity and the mounting surface. Next, perform weld toe transition morphology generation in the weld toe region. The input for weld toe transition morphology generation is the weld toe transition fillet radius and the weld toe region boundary line, which is determined by the nominal line of the welded connection and the outer edge of the heat-affected zone. After completing the above transition morphology, the root transition zone index and weld toe zone index are written into the region index set respectively, and the corresponding boundary lines and geometric domain numbers are written into the region index table. The region index table is used to bind the subsequent dangerous sections and material partitions to the corresponding regions.

[0067] Generate biomimetic ribs and fuse them with the skeleton. Based on the number, height, thickness, spacing, and orientation of the biomimetic ribs in the structural parameter table, first determine the starting baseline of the ribs. The starting baseline is determined by the outer contour of the coal-facing side of the tooth base body entity. Then, place the rib centerlines sequentially along the orientation of the biomimetic ribs according to the spacing. Subsequently, using the rib centerlines as a reference, extrude the biomimetic ribs according to their height and thickness to obtain a set of rib entities. Merge the set of rib entities with the tooth base body entity to obtain a rib-reinforced tooth base entity. Write the geometric domain numbers of the rib connections into the region index table, making the rib connections one of the key regions in the region index set.

[0068] Surface textures are generated and fused with the rib-reinforced solid. Based on the surface texture peak height and pitch in the structural parameter table, the designated wear-resistant surface is first determined. This surface consists of the coal-facing side and the lateral scraping surface, and its number is registered in the region index table. Then, a texture centerline array is laid on the designated wear-resistant surface according to the surface texture pitch, and texture protrusions or grooves are generated according to the surface texture peak height, resulting in a surface texture solid set. This surface texture solid set is then fused with the rib-reinforced tooth base solid to obtain the biomimetic structure tooth base solid. After fusion, assembly constraint verification is performed, including interference checks in the vicinity of the tooth mounting hole and boundary crossing checks in the mounting space. If interference or boundary crossing is found, the texture coverage and rib end shape are trimmed and corrected according to the geometric generation rule set. The rule number, correction amount, and correction reason are written into the correction record field of the structural parameter table to ensure consistent results in subsequent repeated generation.

[0069] Establish material partitions and generate partition material definition outputs. A material partition table is created, which carries the specific mapping relationships of the material parameter set. The material partition table includes partition number, partition action surface number, partition thickness, partition material parameters, gradient layer number, gradient layer thickness, and gradient layer material parameters. Based on the number of wear-resistant partitions and the thickness of each wear-resistant partition, the biomimetic structure gear seat entity is divided into wear-resistant surface partitions, transition partitions, and matrix partitions along the normal direction of the specified wear-resistant action surface. The boundaries of each partition are determined by the cumulative partition thickness, and the corresponding geometric domain number and partition number are written into the material partition table. For transition partitions requiring gradient transitions, the transition partition is subdivided into several material gradient layers based on the number of material gradient layers and the thickness of each material gradient layer, and the corresponding material parameters are written for each material gradient layer. After completion, a binding relationship is established between the material partition table and the region index table, with the binding relationship indexed by the partition action surface number and geometric domain number, thus forming a partition material definition output that can be used for subsequent calculations and predictions.

[0070] It should be noted that during the partitioning process, the surface numbers of the specified wear-resistant surfaces are first read from the region index table, and the set of facets corresponding to these surface numbers is located in the biomimetic tooth base entity. This set of facets is then defined as the wear-resistant surface set. Subsequently, the area-weighted summation and normalization of the outward normal directions of each facet in the wear-resistant surface set are performed to obtain the average outward normal direction, which is then defined as the partition normal direction. Based on the partition normal direction, a partition measurement reference surface is established. This reference surface is perpendicular to the partition normal direction and tangent to the outer boundary of the wear-resistant surface set. The partition measurement reference surface is defined as the zero position for thickness calculation.

[0071] Then, the thicknesses of the wear-resistant surface layer and transition zone are read from the structural parameter table, and the thicknesses of the surface boundary and transition boundary are calculated. The surface boundary thickness is equal to the wear-resistant surface layer thickness, and the transition boundary thickness is equal to the sum of the wear-resistant surface layer thickness and the transition zone thickness. For any geometric point in the biomimetic gear seat entity, the directed distance from the geometric point to the zone measurement reference surface is calculated along the zone normal direction. Based on the comparison between the directed distance and the surface boundary thickness and transition boundary thickness, the zone to which the geometric point belongs is determined. Geometric points with a directed distance not greater than the surface boundary thickness are assigned to the wear-resistant surface layer zone; geometric points with a directed distance greater than the surface boundary thickness but not greater than the transition boundary thickness are assigned to the transition zone; and geometric points with a directed distance greater than the transition boundary thickness are assigned to the base zone.

[0072] Furthermore, to map the partitioning results to recordable geometric domain numbers, a partitioning operation is performed on the biomimetic gear seat entity along the partitioning normal direction. This partitioning operation includes generating a first partitioning interface and a second partitioning interface. The first partitioning interface is obtained by translating the surface boundary thickness along the partitioning normal direction from the partitioning measurement reference plane, and the second partitioning interface is obtained by translating the transition boundary thickness along the partitioning normal direction from the partitioning measurement reference plane. The first and second partitioning interfaces divide the biomimetic gear seat entity into a wear-resistant surface partition entity, a transition partition entity, and a matrix partition entity. Geometric domain numbers are generated for each of the three entities, and the partition number, geometric domain number, and partition thickness are written into the material partitioning table. The wear-resistant surface partition thickness is taken from the surface boundary thickness, the transition partition thickness is taken from the difference between the transition boundary thickness and the surface boundary thickness, and the matrix partition thickness is determined by the remaining thickness of the entity. If the specified wear-resistant surface set includes two types of surface patches, namely the coal-facing side and the lateral scraping surface, and the partitioning normal directions of the two types of surface patches are inconsistent, then the partitioning normal direction and partitioning measurement reference plane are calculated respectively based on the surface patch set corresponding to the coal-facing side and the surface patch set corresponding to the lateral scraping surface, and the splitting interface generation and material partitioning table writing operations are performed respectively.

[0073] Extract the set of hazardous sections and output traceable results. Establish a set of hazardous sections, representing the set of sections that meet the hazard threshold. For easy storage and retrieval, write the hazardous section set into a hazardous section set table, which includes section number, section location parameters, section normal direction, section associated region index, and section geometric contour data. Based on the hazardous section extraction step size, generate a candidate section set along the length and height directions of the tooth holder body entity. The candidate section set covers the root transition zone, weld toe area, tooth mounting hole neighborhood, and rib connection point. Coverage is determined using a region index table.

[0074] When performing a hazard assessment on each candidate section, the corresponding section plane is first selected in the tooth base structure instance, and the section contour line of the tooth base entity is extracted within the section plane. The section contour line includes the outer contour and the hole contour. Subsequently, four types of input feature quantities are calculated within the section plane. The minimum transition curvature feature quantity is calculated as follows: the contour segments corresponding to the root transition area and the weld toe area are located in the section contour line, and several sampling points are obtained on the contour segments at a preset sampling interval. Circle fitting is performed on the sampling points of each contour segment to obtain the radius of the fitted circle. The radius of the fitted circle of the root transition area contour segment is recorded as the root transition curvature radius, and the radius of the fitted circle of the weld toe area contour segment is recorded as the weld toe transition curvature radius. The smaller value between the root transition curvature radius and the weld toe transition curvature radius is taken as the minimum transition curvature feature quantity. The thickness variation characteristic is calculated as follows: The effective cross-sectional area of ​​the current candidate cross-section is calculated within the cross-sectional contour line. The effective cross-sectional area is the area enclosed by the outer contour minus the area enclosed by the hole contour. The adjacent effective cross-sectional areas are then calculated in the same way at adjacent candidate cross-sections. The difference between the two areas is taken and divided by the critical section extraction step size to obtain the thickness variation characteristic. The geometric discontinuity characteristic is calculated as follows: The contour segment corresponding to the rib connection point is located within the cross-sectional contour line. The turning angles of adjacent line segments are calculated sequentially on the contour segment. The maximum value of the turning angle or the number of times the turning angle exceeds a preset threshold is taken as the geometric discontinuity characteristic. The material partition variation characteristic is calculated as follows: The intersection areas of the candidate cross-section and each partition entity in the material partition table are calculated within the cross-sectional plane. The number of non-empty partitions in the intersection area is counted to obtain the number of partition layers traversed by the cross-section. The number of partition layers traversed by the cross-section or the difference between the number of partition layers traversed and that of adjacent candidate cross-sections is taken as the material partition variation characteristic.

[0075] It should be noted that, for example, the extraction step size for the hazardous section is 5 to 20 millimeters. Further, the extraction step size for the hazardous section along the length of the gear body can be 10 millimeters, and the extraction step size for the hazardous section along the height of the gear body can be 5 millimeters; when it is necessary to increase the section coverage density of the root transition zone and weld toe area, the extraction step size for the hazardous section can be 3 to 8 millimeters; when only rapid screening is performed, the extraction step size for the hazardous section can be 15 to 30 millimeters.

[0076] The minimum transition curvature feature, thickness variation feature, geometric discontinuity feature, and material zoning variation feature are converted into normalized risk feature values ​​ranging from zero to one. These normalized risk feature values ​​include those for transition curvature, thickness variation, geometric discontinuity, and material zoning variation. Each normalized risk feature value is calculated from its corresponding feature value based on preset lower and upper limits. Subsequently, the normalized risk feature values ​​are weighted and summed according to preset weighting coefficients to obtain a comprehensive hazard score. This comprehensive hazard score is then compared with a comprehensive threshold for hazardous sections to determine the hazardous sections among the candidate sections.

[0077] For example, the weighting coefficient for the normalized risk characteristic value of transition curvature is set to 0.35, the weighting coefficient for the normalized risk characteristic value of thickness variation is set to 0.25, the weighting coefficient for the normalized risk characteristic value of geometric discontinuity is set to 0.25, and the weighting coefficient for the normalized risk characteristic value of material zoning variation is set to 0.15, with the sum of all weighting coefficients being one. The above weighting coefficients are set based on the fact that the critical section determination of the root transition zone and weld toe area is more sensitive to the transition fillet, thus increasing the weight of the normalized risk characteristic value of transition curvature; the contributions of abrupt thickness changes and connection transitions to changes in cross-sectional load-bearing capacity are of the same order of magnitude, therefore the normalized risk characteristic value of thickness variation and the normalized risk characteristic value of geometric discontinuity are given the same weight; material zoning variation mainly reflects the structural non-uniformity caused by layer crossings, and is given a relatively low weight as a supplementary determination factor. Furthermore, the weighting coefficient is an adjustable parameter, allowing adjustment based on different gear seat structure schemes, different wear-resistant zone configurations, and different working condition categories. Adjustment methods include iteratively updating the weighting coefficient using historical hazardous section determination results and actual maintenance records as samples, or configuring different sets of weighting coefficients for different working condition categories according to preset working condition categories. The comprehensive threshold for hazardous sections is set to 0.60, and this comprehensive threshold is also an adjustable parameter updated synchronously with the weighting coefficient adjustment.

[0078] In the method flow, step S2 includes: collecting running time, cutting motor current, traction speed, cutting depth, vibration acceleration, impact counting features and temperature, and performing time alignment and sliding window statistics to generate a working condition feature sequence, and outputting a working condition category sequence based on the working condition judgment threshold.

[0079] It should be noted that the flowchart for obtaining the working condition feature sequence and determining the working condition category is as follows: Figure 3 As shown.

[0080] Furthermore, a more specific implementation of step S2 is as follows:

[0081] Establish an operation monitoring data table. First, create the operation monitoring data table in the storage medium. The table includes operation time series, cutting motor current series, traction speed series, cutting depth series, vibration acceleration series, impact count characteristic series, and temperature series. The acquisition end writes data into the operation monitoring data table according to a preset sampling period, and writes a sampling time marker and channel marker for each record. If a channel is missing, it is written according to the missing marker, and adjacent valid records are retained for subsequent completion.

[0082] Perform time alignment and generate an aligned time axis. Read the running time series from the operation monitoring data table, establish the aligned time axis, and take the minimum value of the sampling period of each channel or a preset uniform sampling period as the sampling period of the aligned time axis. Perform alignment processing on the cutting motor current sequence, traction speed sequence, cutting depth sequence, vibration acceleration sequence, impact count characteristic sequence, and temperature sequence respectively. The alignment processing includes mapping each channel data to the aligned time axis according to the sampling time marker, using linear interpolation to fill in positions on the aligned time axis without corresponding sampling points, and using forward hold-and-fill to fill in positions with continuous missing time exceeding a preset missing time and writing a fill mark. After alignment is completed, write the aligned channel sequences to the aligned monitoring data table, and link the aligned monitoring data table with the operation monitoring data table through the running time index.

[0083] Establish a window parameter table and calculate the operating condition characteristic sequence. The window parameter table includes window length, window step size, and number of windows covered. Generate a window index sequence along the aligned time axis according to the window length and window step size. For each window index, read the cutting motor current sequence, traction speed sequence, cutting depth sequence, vibration acceleration sequence, impact count characteristic sequence, and temperature sequence within the corresponding time range from the aligned monitoring data table. Calculate the window statistical characteristics and write them into the operating condition characteristic sequence table. The window statistical characteristics include the mean cutting motor current, the amplitude of the cutting motor current change, the mean traction speed, the mean cutting depth, the root mean square of vibration acceleration, the peak value of vibration acceleration, the impact count characteristic count value, the mean temperature, and the temperature change rate. Each record in the operating condition characteristic sequence table includes the window start time, the window end time, and the window number.

[0084] Establish a working condition judgment threshold table and output the working condition category sequence. The working condition judgment threshold table includes current change amplitude threshold, vibration peak threshold, vibration root mean square threshold, impact count threshold, no-load current threshold, and low traction speed threshold. Perform working condition category judgment window by window on the working condition feature sequence table. The working condition categories include steady-state cutting, rock-clamping impact, no-load impact, and strong vibration impact. The judgment logic is as follows: first, determine no-load impact. When the average current of the cutting motor is less than the no-load current threshold and the peak vibration acceleration is greater than the vibration peak threshold, mark the window category as no-load impact; then, determine rock-clamping impact. When the impact count feature value is greater than the impact count threshold and the current change amplitude of the cutting motor is greater than the current change amplitude threshold, mark the window category as rock-clamping impact; then, determine strong vibration impact. When the root mean square vibration acceleration is greater than the root mean square vibration threshold and the average traction speed is greater than the low traction speed threshold, mark the window category as strong vibration impact; the remaining window categories are marked as steady-state cutting. The determination result is written into the working condition category sequence table, which is associated with the working condition feature sequence table through window number.

[0085] It should be noted that, exemplarily, in the technical solution of this invention, the rotational speed of the coal mining machine drum is 40 revolutions per minute, and the traction speed fluctuates within the range of 10 to 30 meters per minute. The preset sampling period for the operation monitoring data is 0.05 seconds, the sampling period for the aligned time axis is 0.05 seconds, the window length for the sliding window statistics is 2 seconds, and the window step size is 1 second. The operation monitoring data table is formed by collecting running time, cutting motor current, traction speed, cutting depth, vibration acceleration, impact count characteristics, and temperature, and the sampling time marker and channel marker are recorded; each channel sequence is mapped to the aligned time axis to obtain the aligned monitoring data table. The operating condition judgment thresholds are exemplarily set as follows: no-load current threshold of 40 amperes, current change amplitude threshold of 50 amperes, vibration peak threshold of 15 meters per square second, vibration root mean square threshold of 8 meters per square second, impact count threshold of 5 times, and low traction speed threshold of 3 meters per minute.

[0086] Within the window corresponding to the running time of 100 to 102 seconds, the window statistical characteristics of the aligned monitoring data table are as follows: average cutting motor current 230 amps, cutting motor current variation 70 amps, average traction speed 15 meters per minute, average cutting depth 0.7 yards, root mean square vibration acceleration 9 m / s², peak vibration acceleration 18 m / s², impact count 7, average temperature 58 degrees Celsius, and temperature change rate 0.15 degrees Celsius per second. According to the judgment logic, thresholds are compared sequentially. In this window, the impact count is greater than the impact count threshold and the cutting motor current variation is greater than the current variation threshold; therefore, the window condition category is marked as "intercalation impact". Taking another window corresponding to the running time of 200 to 202 seconds as a control example, the average cutting motor current is 25 amps, the peak vibration acceleration is 17 m / s², and the average traction speed is 12 meters per minute. This satisfies the condition that the average cutting motor current is less than the no-load current threshold and the peak vibration acceleration is greater than the peak vibration threshold; therefore, the window condition category is marked as "no-load impact".

[0087] Furthermore, when the root mean square of vibration acceleration in a certain window is greater than the root mean square threshold of vibration and the average traction speed is greater than the low traction speed threshold, but the no-load impact condition and the interlocking rock impact condition are not met, the working condition category of this window is marked as strong vibration impact; when a certain window does not meet the no-load impact condition, the interlocking rock impact condition, and the strong vibration impact condition simultaneously, the working condition category of this window is marked as steady-state truncation. Thus, step S2 can output the working condition feature sequence and the working condition category sequence under a unified window numbering system, and output the interlocking rock impact category as a judgment result among the working condition categories, so that subsequent steps can call it according to the window number.

[0088] It should be noted that step S2 in this invention is used to convert operational monitoring data into operating condition feature sequences and operating condition category sequences. Step S2 performs time alignment and sliding window statistics on the operational monitoring data to form window-level operating condition feature sequences, and performs operating condition category determination on each window according to the operating condition judgment threshold table, outputting the operating condition category sequences corresponding to steady-state cutting, rock-clamping impact, no-load impact, and strong vibration impact. The operating condition feature sequences and operating condition category sequences serve as inputs for subsequent steps to establish load-to-structural response mapping, enabling subsequent steps to read the cutting motor current change amplitude, peak vibration acceleration, average traction speed, impact count value, average cutting depth, and corresponding operating condition category markers according to the window number, and generate the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence, and initial wear energy sequence accordingly. Thus, a data connection relationship is formed between step S2 and subsequent steps, indexed by the window number.

[0089] In the method flow, step S3 includes: based on the working condition characteristic sequence and working condition category sequence, and combined with the dangerous section set and corresponding area index information and material partition information, establishing a load-to-structure response mapping, and generating the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence and initial wear energy sequence of the root transition zone and weld toe zone.

[0090] It should be noted that the flowchart for generating the initial equivalent impact load spectrum is as follows: Figure 4 As shown, the flowcharts for generating the initial equivalent stress amplitude sequence and the initial wear energy sequence are as follows: Figure 5 As shown.

[0091] Furthermore, a more specific implementation of step S3 is as follows:

[0092] First, establish and initialize the load response mapping parameter table. This table includes parameter version numbers, current mapping coefficients, vibration mapping coefficients, velocity mapping coefficients, impact count mapping coefficients, depth mapping coefficients, load offset values, rock inclusion impact correction coefficients, steady-state truncation correction coefficients, no-load impact correction coefficients, strong vibration impact correction coefficients, load grading boundary sequences, and load grading number sequences. The parameter version number identifies the parameter version being called in the current execution process, while the load grading boundary sequence and load grading number sequence are used to subsequently construct the initial equivalent impact load spectrum. The load response mapping parameter table and the operating condition characteristic sequence table are then linked through window numbers.

[0093] Generate an initial equivalent impact load sequence. Let the currently called parameter version number in the load response mapping parameter table be the initial parameter version number. The current mapping coefficient, vibration mapping coefficient, velocity mapping coefficient, impact count mapping coefficient, depth mapping coefficient, load offset value, and correction coefficients for each working condition corresponding to the initial parameter version number together constitute the initial load response mapping parameter set. Establish an initial equivalent impact load sequence table, which includes a window number and the initial window's equivalent impact load value. Traverse the working condition feature sequence table in window number order, reading the cutting motor current variation amplitude, peak vibration acceleration, average traction speed, impact count value, and average cutting depth for each window, and also reading the working condition category label. Calculate the initial base load value based on the initial load response mapping parameter set. The initial base load value equals the current mapping coefficient multiplied by the cutting motor current variation amplitude, plus the vibration mapping coefficient multiplied by the peak vibration acceleration, plus the velocity mapping coefficient multiplied by the average traction speed, plus the impact count mapping coefficient multiplied by the impact count value, plus the depth mapping coefficient multiplied by the average cutting depth, and finally the load offset value.

[0094] The working condition correction factor is determined based on the working condition category label. When the working condition category label is "intercalated rock impact," the intercalated rock impact correction factor is selected; when the working condition category label is "steady-state cutting," the steady-state cutting correction factor is selected; when the working condition category label is "no-load impact," the no-load impact correction factor is selected; when the working condition category label is "strong vibration impact," the strong vibration impact correction factor is selected; if the working condition category label is missing, the steady-state cutting correction factor is selected and an anomaly label is added. The initial foundation load value is multiplied by the selected working condition correction factor to obtain the initial window equivalent impact load value. The window number and the initial window equivalent impact load value are written into the initial equivalent impact load sequence table. The initial equivalent impact load sequence table is then used to form the initial equivalent impact load sequence according to the window number order.

[0095] It should be noted that the initial load response mapping parameters used in the current execution process are used to map the cutting motor current variation amplitude, peak vibration acceleration, average traction speed, impact count value, and average cutting depth in the working condition characteristic sequence to initial base load values, thereby forming the initial window equivalent impact load value. The initial load response mapping parameters include current mapping coefficient, vibration mapping coefficient, velocity mapping coefficient, impact count mapping coefficient, depth mapping coefficient, load offset value, and working condition correction coefficient, wherein the working condition correction coefficient includes the rock-clamping impact correction coefficient, steady-state cutting correction coefficient, no-load impact correction coefficient, and strong vibration impact correction coefficient.

[0096] The current mapping coefficient is used to characterize the contribution weight of the cutting motor current variation amplitude to the impact load; the vibration mapping coefficient is used to characterize the contribution weight of the peak vibration acceleration to the impact load; the velocity mapping coefficient is used to characterize the contribution weight of the average traction speed to the impact load; the impact count mapping coefficient is used to characterize the contribution weight of the impact event density to the impact load; the depth mapping coefficient is used to characterize the contribution weight of the average cutting depth to the impact load; and the load offset value is used to provide a zero-point shift term for the initial base load value, so that the base load in the low-disturbance window can still be included in the load grading statistics. The working condition correction coefficient is used to introduce working condition category differences on top of the initial base load value. When the working condition category is marked as "intercalated rock impact," the intercalated rock impact correction coefficient is selected; when the working condition category is marked as "steady-state cutting," the steady-state cutting correction coefficient is selected; when the working condition category is marked as "no-load impact," the no-load impact correction coefficient is selected; and when the working condition category is marked as "strong vibration impact," the strong vibration impact correction coefficient is selected.

[0097] The above parameters can be written into the load response mapping parameter table as preset data, and the initial parameter version number corresponding to the current execution process is marked by the parameter version number. The source of the initial parameter version number can be historical operating data fitting, bench calibration, or engineering experience initialization. The scope of historical operating data fitting is to select window samples marked with known working condition categories, so that the change trend of the initial window equivalent impact load value is consistent with the change trend of indicators such as peak vibration acceleration and impact count value, and the mapping coefficient is determined by minimizing the error. The scope of bench calibration is to apply impacts of different intensities to the test bench and record the combination characteristics of the cutting motor current change amplitude, peak vibration acceleration, impact count value, and average cutting depth, so that the mapping results can be distinguished and counted in different intensity levels. The scope of engineering experience initialization is to set the coefficient size according to the relative sensitivity of each variable to the impact load contribution, and update the parameter version number in the subsequent online calibration process.

[0098] For example, the current mapping coefficient is set to 0.35, the vibration mapping coefficient to 2.2, the velocity mapping coefficient to 1.2, the impact count mapping coefficient to 5, the depth mapping coefficient to 40, and the load offset value to 10; the rock-clamping impact correction coefficient is set to 1.3, the steady-state cutting correction coefficient to 1, the no-load impact correction coefficient to 1.1, and the strong vibration impact correction coefficient to 1.2. For a certain window, the current variation of the cutting motor is set to 70 amperes, the peak vibration acceleration is set to 18 m / s², the average traction speed is set to 15 m / min, the impact count value is set to 7, and the average cutting depth is set to 0.7 yards. The initial foundation load value is calculated as the current mapping coefficient multiplied by the current variation of the cutting motor, plus the vibration mapping coefficient multiplied by the peak vibration acceleration, plus the velocity mapping coefficient multiplied by the average traction speed, plus the impact count mapping coefficient multiplied by the impact count value, plus the depth mapping coefficient multiplied by the average cutting depth, plus the load offset value. Substituting these values, the initial foundation load value is approximately 157.5. If the operating condition category of this window is marked as "intercalation impact," then the initial window equivalent impact load value is equal to the initial base load value multiplied by the intercalation impact correction factor, with an example result of approximately 204.8. If the operating condition category of this window is marked as "steady-state cutting," then the initial window equivalent impact load value is equal to the initial base load value multiplied by the steady-state cutting correction factor, with an example result of approximately 157.5. The above examples are only used to illustrate the meaning of parameters and calculation methods. Actual values ​​can be configured in the load response mapping parameter table according to the gear geometry, material partitioning, monitoring channel range, and calibration conditions, and updated through parameter version numbers.

[0099] Furthermore, the calculation of the initial window equivalent impact load value adopts a method of linearly combining and superimposing the multi-source working condition characteristics and working condition corrections. This is because the present invention needs to convert the operational monitoring data into a load scalar that can be used for calculating the response of the dangerous section at the window scale, so as to form a consistent data interface with the dangerous section set, the section stress conversion coefficient, and the subsequent spectrum classification and counting recursion. The amplitude of the cutting motor current change reflects the transient fluctuation of the cutting resistance, the peak vibration acceleration reflects the impact excitation intensity, the average traction speed reflects the motion state of the contact process, the impact count value reflects the impact event density, and the average cutting depth reflects the instantaneous cutting load level. Therefore, by converting and superimposing the above characteristics through mapping coefficients to obtain the initial basic load value, different windows can be compared and classified statistically significant in terms of load intensity. On this basis, the corresponding working condition correction coefficient is selected according to the working condition category label, and differentiated corrections are applied to different windows such as rock-clamping impact, strong vibration impact, no-load impact, and steady-state cutting, so that the load expression can reflect the difference in the degree of impact dominance under different working condition categories, thereby forming the initial window equivalent impact load value.

[0100] The connection between the initial window equivalent impact load value and the technical problem solved by this invention lies in the fact that the failure mode targeted by this invention is the stress concentration and early initiation of impact fatigue cracks in the root transition zone and weld toe region under random impact loads such as rock inclusion impact and strong vibration, leading to the risk of sudden fracture before wear is significant. The initial window equivalent impact load value uniformly expresses the impact intensity and impact event density on a window scale and serves as the basis for constructing the initial equivalent impact load spectrum, enabling step S4 to recursively extrapolate impact fatigue damage based on load spectrum grading and counting. Simultaneously, the initial window equivalent impact load value is multiplied by the section stress conversion coefficient corresponding to the set of critical sections to obtain the initial equivalent stress amplitude sequence, ensuring that the key sections of the root transition zone and weld toe region obtain inputs that can be directly used for impact fatigue calculations under the same window numbering system. Through the above correlation, this invention establishes a unified mapping between the load spectrum, stress amplitude sequence, and wear energy sequence of the operating conditions and key areas, providing an input benchmark for subsequent wear degradation and impact fatigue coupling extrapolation and life prediction.

[0101] Construct an initial equivalent impact load spectrum and define the root transition zone and weld toe region. Establish an initial equivalent impact load spectrum table, including load class number, lower bound, upper bound, class count, and associated region index fields. Read the load class boundary sequence and load class number sequence from the load response mapping parameter table, and set the initial class count to zero for each load class. Traverse the initial equivalent impact load sequence table, performing class determination for each initial window equivalent impact load value. The class determination rule is to compare the initial window equivalent impact load value with the lower and upper bounds of the load class, incrementing the class count for values ​​falling into the corresponding interval. After completing the traversal, the initial equivalent impact load spectrum table is obtained. Read the root transition zone index and weld toe region index from the region index table and write them into the associated region index field of the initial equivalent impact load spectrum table in list form, establishing a connection between the initial equivalent impact load spectrum table and the root transition zone and weld toe region.

[0102] It should be noted that the initial equivalent impact load spectrum is not a single load value, nor is it a time series arranged by window number. Instead, it is a spectral table data formed after load grading statistics based on the initial equivalent impact load sequence. The initial equivalent impact load sequence is composed of the initial window equivalent impact load values ​​corresponding to each window in order of window number. After obtaining the initial equivalent impact load sequence, the load grading boundary sequence and load grading number sequence in the load response mapping parameter table corresponding to the initial parameter version number are read. The amplitude range of each load grading is defined by adjacent load grading boundaries, and an initial grading count is set for each load grading. The initial window equivalent impact load values ​​in the initial equivalent impact load sequence table are traversed, and each initial window equivalent impact load value is compared with the lower and upper bounds of each load grading to determine the load grading interval it falls into, and the grading count of the corresponding load grading is incremented by one. After traversing all windows, an initial equivalent impact load spectrum is obtained, including the load class number, lower bound of the load class, upper bound of the load class, class count, and associated region index field. The associated region index field contains the root transition zone index and the weld toe region index to characterize the key region range corresponding to the initial equivalent impact load spectrum.

[0103] Furthermore, the gradation count in the initial equivalent impact load spectrum table is used to characterize the frequency of occurrence of the initial window equivalent impact load value within different load amplitude ranges, thereby converting the window-level load result into a statistical result in spectral distribution form. Since the subsequent steps of this invention use a spectral gradation count recursive method to calculate the impact fatigue damage of the critical section, the initial equivalent impact load spectrum, as the gradation statistical result of the initial equivalent impact load sequence, can be directly used as input data for subsequently constructing the stress amplitude spectrum of the critical section and performing fatigue damage recursion. For example, when the load gradation boundary sequence is set to zero, fifty, one hundred, one hundred and fifty, two hundred, and three hundred, if the initial window equivalent impact load values ​​of some windows in the initial equivalent impact load sequence are thirty, seventy, ninety, one hundred and twenty, one hundred and eighty, and two hundred and ten, respectively, then the corresponding gradation counts are one, two, one, one, and one, respectively. Based on this, an initial equivalent impact load spectrum table is formed, and the root transition zone index and weld toe region index are written into the associated region index field.

[0104] Establish a cross-sectional stress transfer coefficient table and generate an initial equivalent stress amplitude sequence. Read the set of critical cross-sections and the table of critical cross-sections, and establish a cross-sectional stress transfer coefficient table, which includes the cross-section number, the index of the cross-section's associated region, the stress transfer coefficient, the calibration load value, and the calibration stress value. Initialize the stress transfer coefficient for each cross-section number, and calculate the stress transfer coefficient based on the calibration load value and the calibration stress value. The calculation rule is that the stress transfer coefficient equals the calibration stress value divided by the calibration load value. Establish an initial equivalent stress amplitude sequence table, which includes a window number, a cross-section number, an initial equivalent stress amplitude, and a key region marker field. Traverse the initial equivalent impact load sequence table by window number, reading the initial window equivalent impact load value for each window; then traverse the set of critical cross-sections by cross-section number, reading the corresponding stress transfer coefficient, and calculating the initial equivalent stress amplitude for that window and cross-section. The initial equivalent stress amplitude equals the stress transfer coefficient multiplied by the initial window equivalent impact load value. Write the window number, cross-section number, and initial equivalent stress amplitude into the initial equivalent stress amplitude sequence table. Furthermore, based on the cross-section associated region index field in the dangerous cross-section set table, the root transition zone index associated cross-section and the weld toe region index associated cross-section are filtered, and the filtering results are written into the key region marker field of the initial equivalent stress amplitude sequence table.

[0105] It should be noted that the stress transfer coefficient is used to characterize the proportional relationship between the initial window equivalent impact load value and the initial equivalent stress amplitude at the critical section. The stress transfer coefficient corresponds one-to-one with the section number and is written into the section stress transfer coefficient table. In step S3, when calculating the initial equivalent stress amplitude sequence according to the window number, the initial window equivalent impact load value of the corresponding window number is read, and the stress transfer coefficient of the corresponding section number is read. The initial window equivalent impact load value is multiplied by the stress transfer coefficient to obtain the initial equivalent stress amplitude of the section of that window, thus enabling the mapping process from load to structural response to have a reproducible parametric expression.

[0106] The calibrated load value serves as the load reference for the stress conversion coefficient, and the calibrated stress value serves as the stress reference for the stress conversion coefficient. For each section number, the geometric profile data and normal direction of the section corresponding to that section number are first determined. Then, a preset standard load is applied to the toothed structure instance, and the amplitude of the preset standard load is written into the calibrated load value field. Under the applied load condition, the equivalent stress is extracted at the corresponding section position and written into the calibrated stress value field. The stress conversion coefficient is calculated based on the calibrated stress value and the calibrated load value. The calculation rule is that the stress conversion coefficient equals the calibrated stress value divided by the calibrated load value. By establishing calibrated load values ​​and calibrated stress values ​​for different section numbers, the stress conversion coefficients of key areas such as the root transition zone and the weld toe area can reflect their respective geometric morphology and local load-bearing differences.

[0107] The data sources for calibration load values ​​and calibration stress values ​​can be either experimental calibration data or numerical calibration data. Experimental calibration data is obtained by applying a known amplitude impact load or quasi-static load to the gear-mounted structure instance on a test bench as the calibration load value, arranging strain measurement points at the corresponding locations on the cross-section, and converting the strain measurement results into the corresponding calibration stress value. Numerical calibration data is obtained by establishing a structural calculation model based on the gear-mounted structure instance, applying a preset standard load to the structural calculation model as the calibration load value, and solving for the equivalent stress at the cross-section location corresponding to the cross-section number as the calibration stress value. Both types of data can be written into the cross-section stress conversion factor table, and different calibration batches can be distinguished by parameter version numbers, allowing the current execution process to call the stress conversion factors under the corresponding parameter version number.

[0108] For example, for section number one associated with the root transition zone index, a calibration load value of 100 is taken, and a calibration stress value of 90 is extracted, resulting in a stress conversion factor of 0.9; for section number two associated with the weld toe area index, a calibration load value of 100 is taken, and a calibration stress value of 110 is extracted, resulting in a stress conversion factor of 1.1; for section number three associated with the neighboring area index of the cutting tooth mounting hole, a calibration load value of 100 is taken, and a calibration stress value of 100 is extracted, resulting in a stress conversion factor of 1. The above examples illustrate the setting and calculation methods for the stress conversion factor, calibration load value, and calibration stress value. Actual values ​​can be configured and updated based on the geometric dimensions, material partitions, and calibration conditions of the tooth holder structure example.

[0109] Furthermore, for a set of gear seat structure examples, the length of the gear seat body in the structural parameter table is 480 mm, the width of the gear seat body is 220 mm, the height of the gear seat body is 180 mm, the diameter of the cutting tooth mounting hole is 60 mm, the root transition fillet radius is 12 mm, and the weld toe transition fillet radius is 8 mm. In the material zoning table, the thickness of the wear-resistant surface layer is 6 mm, the thickness of the transition layer is 10 mm, the thickness of the base layer is determined by the remaining thickness, the number of material gradient layers is three, and the thickness of each material gradient layer is 3 mm, 3 mm, and 4 mm, respectively. Using this structural example as the calibration object, the amplitude of the preset standard load is set to one hundred and written into the calibration load value field. Under the applied load condition, the calibration stress value of each section number is extracted and written into the calibration stress value field. Among them, the calibration stress value of section number one associated with the root transition zone index is ninety-five, the calibration stress value of section number two associated with the weld toe area index is one hundred and fifteen, and the calibration stress value of section number three associated with the cutting tooth mounting hole neighborhood index is one hundred and five. Based on this, the stress conversion coefficients are calculated to be 0.95, 1.15 and 1.05 respectively.

[0110] For another example, when the root transition fillet radius in the structural parameter table is adjusted to 16 mm, and the wear-resistant surface layer thickness and transition zone thickness in the material partition table are adjusted to 8 mm and 8 mm respectively, while other parameters remain unchanged, the preset standard load amplitude of 100 is still taken as the calibration load value. Under the same extraction caliber, the extracted calibration stress value for section number one is 87, for section number two it is 108, and for section number three it is 102. Based on this, the stress conversion coefficients are calculated to be 0.87, 1.08, and 1.02 respectively. The above example illustrates the calibration process and value caliber where the stress conversion coefficient can be updated according to changes in geometric dimension parameters and material partition thickness parameters. The parameter version number can be used to record parameter configurations for different structural instances or under different calibration conditions.

[0111] An initial contact parameter table is established, and an initial wear energy sequence is generated. The initial contact parameter table includes correction factors for slippage, contact, rock-clamping impact energy, steady-state cutting energy, no-load impact energy, and strong vibration impact energy. The slippage correction factor is used to convert the average traction speed into a window slippage distance, and the contact coefficient is used to convert the initial window equivalent impact load value and window slippage distance into the window contact wear base energy. Each energy correction factor characterizes the wear input differences under different operating conditions. An initial wear energy sequence table is established, including a window number, initial wear energy value, and operating condition category marker fields.

[0112] Traverse the working condition characteristic sequence table by window number, read the average traction speed for each window, and read the corresponding window length from the window parameter table. Calculate the window slip distance, which is equal to the average traction speed multiplied by the window length and then multiplied by the slip correction factor. Read the initial equivalent impact load value of the corresponding window number from the initial equivalent impact load sequence table, and determine the energy correction factor according to the working condition category label. Select the rock-intercalated impact energy correction factor when the working condition category label is rock-intercalated impact; select the steady-state cutting energy correction factor when the working condition category label is steady-state cutting; select the no-load impact energy correction factor when the working condition category label is no-load impact; select the strong vibration impact energy correction factor when the working condition category label is strong vibration impact; select the steady-state cutting energy correction factor and write it into the anomaly label when the working condition category label is missing.

[0113] Calculate the initial window wear energy value, which is equal to the initial window equivalent impact load value multiplied by the window sliding distance, then multiplied by the contact coefficient, and finally multiplied by the selected energy correction factor. Write the window number, initial window wear energy value, and operating condition category label into the initial wear energy sequence table. The initial wear energy sequence table is then used to form the initial wear energy sequence in order of window number.

[0114] It should be noted that the slip correction coefficient is used to characterize the conversion relationship between the average traction speed and the actual slip distance at the critical section. Because the contact state between the mining machine's teeth and the coal / rock changes, local slippage occurs, and the traction motion and local contact motion are not entirely consistent during the actual cutting process, the displacement obtained by directly multiplying the average traction speed by the window length cannot fully characterize the actual slip process at the critical section. By setting the slip correction coefficient, the traction displacement at the window scale can be converted into a window slip distance that is closer to the actual contact conditions, thus ensuring that the calculated initial window wear energy value is consistent with the actual wear input.

[0115] The contact coefficient characterizes the contact wear conversion relationship under the combined effect of the initial window equivalent impact load value and the window sliding distance. The initial window equivalent impact load value reflects the impact intensity level within the window, the window sliding distance reflects the relative motion within the window, and the contact coefficient is used to convert the load-displacement product of the two into wear energy input. By setting the contact coefficient, wear inputs with different geometries, contact materials, and surface conditions can be unified into the same calculation scope, allowing the initial wear energy sequence to serve as a unified input for subsequent recursive updates of partition thickness.

[0116] The energy correction coefficients for intercalation impact, steady-state cutting, no-load impact, and strong vibration impact are used to characterize the differences in wear input under different operating conditions. When the operating condition is labeled as intercalation impact, the local contact pressure and impact event density are high, therefore the corresponding energy correction coefficient is higher than that for steady-state cutting. When the operating condition is labeled as strong vibration impact, although typical intercalation impact may not occur, the increased vibration disturbance leads to greater contact instability, thus the corresponding energy correction coefficient is higher than that for steady-state cutting. When the operating condition is labeled as no-load impact, the overall cutting resistance is low, but local collisions may still occur, therefore the corresponding energy correction coefficient can be higher than or close to that for steady-state cutting. By setting different energy correction coefficients for different operating conditions, the initial window wear energy value can reflect the differences in wear input under different operating states.

[0117] The above parameters can be written into the initial contact parameter table as preset data and identified by the parameter version number. Test calibration data is obtained by applying different traction speeds, load levels, and operating conditions on the test bench, recording the window slip distance, wear amount, or wear-equivalent input, and then backfitting to obtain the slip correction coefficient and contact coefficient. Historical operating data is obtained by reading maintenance records, wear records, and operational monitoring data of the actual equipment under different operating conditions, and adjusting the energy correction coefficients to ensure that the calculated initial wear energy sequence matches the actual wear change trend. Engineering experience initialization is achieved by pre-sorting the correction coefficients according to the relative influence of different operating conditions on the wear input, and updating the parameter version number during subsequent online calibration.

[0118] For example, the slip correction factor is set to 0.95, the contact factor to 0.35, the rock-clamping impact energy correction factor to 1.2, the steady-state cutting energy correction factor to 1, the no-load impact energy correction factor to 1.05, and the strong vibration impact energy correction factor to 1.15. For a certain window, the average traction speed is set to 15 meters per minute, and the window length is set to 2 seconds. The average traction speed is first converted to 0.25 meters per second, and then the window slip distance is calculated by multiplying the average traction speed by the window length and then by the slip correction factor, resulting in a window slip distance of 0.475 meters. If the initial window equivalent impact load value corresponding to this window is 125.45, and the working condition is marked as rock-clamping impact, then the initial window wear energy value is equal to the initial window equivalent impact load value multiplied by the window slip distance, then multiplied by the contact factor, and then multiplied by the rock-clamping impact energy correction factor. The example calculation result is approximately 24.99, and this is written into the initial wear energy sequence table.

[0119] For another example, when the operating condition category for the same window is marked as steady-state truncation, under the condition that other parameters remain unchanged, the initial window wear energy value is equal to 125.45 multiplied by 0.475, then multiplied by 0.35, and finally multiplied by 1. The example calculation result is approximately 20.82. If the operating condition category is marked as strong vibration and impact, then under the condition that other parameters remain unchanged, the initial window wear energy value is equal to 125.45 multiplied by 0.475, then multiplied by 0.35, and finally multiplied by 1.15. The example calculation result is approximately 23.94. The above examples are used to illustrate how the slip correction factor, contact factor, and various energy correction factors are used in different operating condition categories and their calculation method for the initial wear energy value.

[0120] Record the initial load response mapping parameters used in the current execution process. Record the current mapping coefficient, vibration mapping coefficient, velocity mapping coefficient, impact count mapping coefficient, depth mapping coefficient, load offset value, correction coefficients for each working condition, stress conversion coefficients, slip correction coefficient, contact coefficient, and energy correction coefficient corresponding to the current parameter version number as the set of initial load response mapping parameters used in the current execution process. Establish a correspondence between this set of initial load response mapping parameters and the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence, and initial wear energy sequence through the parameter version number and window number. Therefore, the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence, and initial wear energy sequence output in step S3 all have corresponding parameter source records.

[0121] In the described method, step S4 includes: based on the initial equivalent impact load spectrum, the initial equivalent stress amplitude sequence, and the initial wear energy sequence, combined with the set of critical sections and the material partition table, recursively updating the remaining thickness, section profile, and load-bearing geometry of each critical section, and correcting the stress concentration factor of the root transition zone and weld toe region; converting the initial equivalent impact load spectrum into the critical section stress amplitude spectrum, and recursively calculating impact fatigue damage and wear damage according to the grade count; updating the coupled damage and state level, determining the remaining tolerable cycles and calculating the remaining life, and outputting the remaining life distribution, failure location, and maintenance threshold recommendations.

[0122] Furthermore, a more specific implementation of step S4 is as follows:

[0123] A cross-section state table is established. The cross-section state table includes the cross-section number, cross-section associated region index, initial value of partition thickness, current value of partition thickness, initial value of cross-section profile, current value of cross-section profile, initial value of effective cross-sectional area, current value of effective cross-sectional area, current value of minimum transition curvature radius, current value of local load-bearing thickness, current value of stress concentration factor, cumulative value of fatigue damage, cumulative value of wear damage, cumulative value of coupled damage, state level marker, and failure marker. The initial value of partition thickness is read from the material partition table; the initial values ​​of cross-section profile and effective cross-sectional area are read from the critical cross-section set table; and the current values ​​of minimum transition curvature radius and local load-bearing thickness are calculated from the current value of cross-section profile. The state level markers include surface wear state, transition exposure state, matrix load-bearing state, and critical crack state. The transition exposure state refers to the state where the remaining thickness of the wear-resistant surface partition is equal to zero and the remaining thickness of the transition partition is greater than zero, indicating that the transition partition is exposed and participates in load-bearing.

[0124] Establish a partitioned wear front table and update the partition thickness. For each critical section, establish thickness coordinates along the partition's action surface direction, and determine the outermost contact boundary corresponding to the critical section as the starting point of the thickness coordinates, and determine the direction from the outside to the inside as the thickness increasing direction. Read the partition sequence corresponding to the critical section, the initial thickness of each partition, and the direction of the partition's action surface from the material partition table. Determine the position of each partition boundary on the thickness coordinates according to the cumulative value of each partition thickness, and establish a partitioned wear front table accordingly. The partitioned wear front table includes section number, partition number, partition outer boundary position, partition inner boundary position, initial value of front line position, current value of front line position, front line advance amount, and remaining partition thickness. The initial value of the front line position is the current partition outer boundary position, the current value of the front line position is equal to the initial value of the front line position at the initial moment, and the remaining partition thickness is equal to the partition inner boundary position minus the current value of the front line position.

[0125] The initial wear energy sequence is traversed according to the recursive cycle. The initial wear energy value within each recursive cycle is accumulated according to the window number to obtain the total periodic wear energy. The set of dangerous sections is traversed according to the dangerous section number. The section-related region index of the dangerous section, the direction of the partition action surface in the material partition table and the partition order are read. According to the correspondence between the region where the dangerous section is located and the partition action surface, the total periodic wear energy is converted into the total advance distance along the thickness coordinate direction, and the total advance distance is determined as the front advancement amount corresponding to the current recursive cycle. If the front advancement amount is less than the remaining thickness of the current partition, the current value of the front advancement position is advanced by the front advancement amount along the thickness increasing direction, and the remaining thickness of the partition is recalculated. If the front advancement amount is greater than or equal to the remaining thickness of the current partition, the current value of the front advancement position is first advanced to the inner boundary position of the current partition and the remaining thickness of the current partition is reduced to zero. Then, the remaining advancement amount after deducting the remaining thickness of the current partition from the front advancement amount continues to act on the next partition until the remaining advancement amount is less than the remaining thickness of the current partition or the update of the innermost partition has been completed. After the above update is completed, the current value of the front position recorded in the partition wear front table represents the position of the wear front in each partition at the end of the current recursion cycle, and the partition remaining thickness represents the remaining thickness of each partition after the current recursion cycle.

[0126] It should be noted that a leading edge propulsion conversion table is established to convert the total periodic wear energy into the total propulsion distance along the thickness coordinate direction. The leading edge propulsion conversion table includes the section number, zone number, propulsion energy per unit length of zone, current value of zone exposure length, current unit propulsion energy, and leading edge propulsion amount. Zone unit length propulsion energy represents the energy consumed when the wear leading edge advances a unit distance along the thickness coordinate direction within the corresponding zone and reaches the corresponding unit exposure length. The current value of zone exposure length represents the length of the profile segment actually involved in contact wear within the current cross-sectional profile value for the corresponding zone under the current recursive cycle. The current unit propulsion energy is directly calculated from the current value of zone exposure length and the zone unit length propulsion energy. The calculation rule is: multiply the current value of zone exposure length by the zone unit length propulsion energy to obtain the current unit propulsion energy for the current zone. Therefore, the current unit propulsion energy represents the total energy consumed when the wear leading edge advances a unit distance along the thickness coordinate direction within the current zone.

[0127] For each critical section, first read the total cyclic wear energy of the current recursive cycle, then determine the currently participating section in wear according to the material partitions from the outside to the inside. If the currently participating section in wear is the wear-resistant surface section, read the current unit propulsion energy corresponding to the wear-resistant surface section, and divide the total cyclic wear energy by the current unit propulsion energy to obtain the candidate propulsion distance under this recursive cycle. When the candidate propulsion distance is less than the remaining thickness of the current section, the candidate propulsion distance is directly determined as the leading edge propulsion amount of the current section. When the candidate propulsion distance is greater than or equal to the remaining thickness of the current section, first determine the remaining thickness of the current section as the leading edge propulsion amount of the current section, then multiply the remaining thickness of the current section by the current unit propulsion energy to obtain the energy consumption value of the current section, and deduct the energy consumption value of the current section from the total cyclic wear energy. The remaining energy continues to act on the next section, and the above conversion process is repeated until the remaining energy is insufficient to penetrate the current section or the propulsion of the innermost section has been completed. Thus, the leading edge propulsion amount of each section is accumulated sequentially according to the material partitions from the outside to the inside to obtain the total propulsion distance along the thickness coordinate direction.

[0128] Furthermore, the propulsion energy per unit length of the partition can be obtained through calibration. The calibration method involves applying a standard wear input to the corresponding partition under known partition material parameters and contact conditions, recording the cumulative wear energy as the wear front advances a calibrated distance along the thickness coordinate direction, and simultaneously recording the exposed length of the partition involved in the wear. Then, the cumulative wear energy is divided by the calibrated propulsion distance, and then further divided by the exposed length of the partition to obtain the propulsion energy per unit length corresponding to that partition. For example, when the calibrated propulsion distance of a wear-resistant surface partition at a certain critical section is two, the cumulative wear energy is one hundred and twenty, and the exposed length of the partition is six, then the propulsion energy per unit length of the partition is one hundred and twenty divided by two and then by six, resulting in ten. After entering the recursive phase, if the current value of the exposed length of the partition under the current recursive cycle is still six, then the current unit propulsion energy is six multiplied by ten, which equals sixty; if the total cycle wear energy of this recursive cycle is one hundred and twenty, then the current recursive propulsion distance is one hundred and twenty divided by sixty, which equals two; if the remaining thickness of the current partition is one point and five, then one point and five is first determined as the leading edge propulsion of the current partition, then ninety is deducted from the energy consumed by the current partition, and the remaining energy of thirty is continued to be applied to the next partition.

[0129] The cross-sectional profile and load-bearing geometry are updated based on the partitioned wear front table. For each critical section number, the cross-sectional geometric profile data in the critical section set table is first read and determined as the initial value of the cross-sectional profile. The initial value of the cross-sectional profile is the closed section boundary line obtained after the intersection of the critical section plane and the tooth seat structure instance. Then, the current value of the front edge position and the front edge advance amount in the partitioned wear front table, as well as the partitioning order, partitioning action surface direction, and partitioning boundary position in the material partitioning table, are read to determine the profile segments in the initial value of the cross-sectional profile corresponding to the wear-resistant surface partition, transition partition, and matrix partition, respectively.

[0130] The cross-sectional profile is updated in the order of material partitions from the outside to the inside. The update rule is as follows: For the profile segment of the currently worn partition, a profile offset is performed along the normal direction pointing inwards from the cross-sectional plane. The offset distance is the corresponding front advance amount of the partition in the current recursive cycle. When the front advance amount of a partition is insufficient to penetrate the remaining thickness of the partition, only one offset update is performed on the corresponding profile segment of the partition. When the front advance amount of a partition is greater than or equal to the remaining thickness of the partition, the offset update of the corresponding profile segment of the partition is first completed according to the remaining thickness of the partition, and then the remaining advance amount is applied to the profile segment corresponding to the next partition. After the offset of each profile segment participating in the update is completed, the updated profile segment is re-stitched with the remaining profile segments that did not participate in this update according to the endpoint positions to form a new closed cross-sectional boundary line, and the new closed cross-sectional boundary line is determined as the current value of the cross-sectional profile.

[0131] The load-bearing geometry refers to the set of geometric parameters characterizing the current load-bearing capacity of a critical section. This load-bearing geometry includes the current value of the effective cross-sectional area, the current value of the local load-bearing thickness, and the current value of the minimum transition radius of curvature. The load-bearing geometry is recalculated based on the current cross-sectional profile values. The current effective cross-sectional area is calculated using the net area enclosed by the current cross-sectional profile values. The current local load-bearing thickness is obtained by measuring the minimum net thickness at the critical load-bearing location along the direction of the partitioning action surface recorded in the material partitioning table. The current minimum transition radius of curvature is obtained by extracting local profile points on the root transition zone and weld toe region profile segments, performing curvature fitting, and then taking the minimum fitted radius. The current effective cross-sectional area, the current local load-bearing thickness, and the current minimum transition radius of curvature are written into the cross-sectional state table as inputs for subsequent correction of the stress concentration factors in the root transition zone and weld toe region, and for constructing the stress amplitude spectrum of the critical section.

[0132] The stress concentration factors in the root transition zone and weld toe zone are corrected. A stress concentration correction rule table is established, which includes a region index, a minimum transition radius of curvature variation range, a local load-bearing thickness variation range, an effective cross-sectional area variation range, a correction level, and a correction increment. The minimum transition radius of curvature variation range characterizes the degree of decrease in the current value of the minimum transition radius of curvature relative to its initial value; the local load-bearing thickness variation range characterizes the degree of decrease in the current value of the local load-bearing thickness relative to its initial value; the effective cross-sectional area variation range characterizes the degree of decrease in the current value of the effective cross-sectional area relative to its initial value; and the correction increment characterizes the increase in the stress concentration factor under the corresponding interval combination.

[0133] Among them, the initial values ​​of minimum transition curvature radius, local load-bearing thickness, and effective cross-sectional area are all reference geometric quantities of the critical section before wear and regeneration, and are pre-written into the section state table. The initial value of minimum transition curvature radius is obtained by extracting local contour points from the root transition zone contour segment and weld toe region contour segment in the initial value of the cross-sectional profile, performing curvature fitting, and taking the minimum fitted radius; the initial value of local load-bearing thickness is obtained by measuring the minimum net thickness of the initial value of the cross-sectional profile at the critical load-bearing position along the direction of the partition action surface recorded in the material partition table; the initial value of effective cross-sectional area is calculated from the net area enclosed by the initial value of the cross-sectional profile.

[0134] For each critical section number, read the current values ​​of the minimum transition radius of curvature, local bearing thickness, and effective cross-sectional area from the section status table, and read the corresponding initial values ​​of the minimum transition radius of curvature, local bearing thickness, and effective cross-sectional area. Calculate the change in the minimum transition radius of curvature, the percentage change in local bearing thickness, and the percentage change in effective cross-sectional area, respectively. Specifically, the change in the minimum transition radius of curvature is equal to the initial value of the minimum transition radius of curvature minus the current value; the percentage change in local bearing thickness is equal to the initial value of local bearing thickness minus the current value, then divided by the initial value; and the percentage change in effective cross-sectional area is equal to the initial value of effective cross-sectional area minus the current value, then divided by the initial value.

[0135] The section-related region index in the dangerous section set table is read, and the region type of the current dangerous section is determined. The region types include root transition zone, weld toe zone, and other regions. Then, the rule record corresponding to the region type of the current dangerous section is searched in the stress concentration correction rule table. Each rule record includes a region index, minimum transition radius of curvature variation range, local load-bearing thickness variation range, effective cross-sectional area variation range, correction level, and correction increment. The minimum transition radius of curvature variation, local load-bearing thickness variation ratio, and effective cross-sectional area variation ratio of the current dangerous section are compared with the corresponding intervals in each rule record. Target rule records that simultaneously satisfy the following conditions are selected: consistent region index, minimum transition radius of curvature variation falling within the corresponding variation range, local load-bearing thickness variation ratio falling within the corresponding variation range, and effective cross-sectional area variation ratio falling within the corresponding variation range. If a target rule record is found, the correction increment corresponding to that target rule record is read; if multiple target rule records are found, the target rule record with the largest correction increment is read; if no target rule record is found, the correction increment is recorded as zero.

[0136] After obtaining the correction increment, the initial value of the stress concentration factor corresponding to the critical section is read, and the initial value of the stress concentration factor is added to the correction increment to obtain the current value of the stress concentration factor. The current value of the stress concentration factor is then written into the section state table. The current value of the stress concentration factor serves as the input parameter for subsequently converting the initial equivalent impact load spectrum into the stress amplitude spectrum of the critical section. Thus, the stress concentration factor update process in the root transition zone and weld toe region is based on the section profile update driven by the partitioned wear front table, and is constrained by the bearing geometry characterized by the current value of the minimum transition curvature radius, the current value of the local bearing thickness, and the current value of the effective cross-sectional area. Furthermore, the update result maintains a correspondence with the section-related region index of the critical section.

[0137] For example, when the initial value of the minimum transition radius of curvature associated with a critical section of a root transition zone is 12 mm, the current value of the minimum transition radius of curvature is 9 mm, the initial value of the local bearing thickness is 20 mm, the current value of the local bearing thickness is 16 mm, the initial value of the effective cross-sectional area is 1200 square millimeters, and the current value of the effective cross-sectional area is 1080 square millimeters, then the change in the minimum transition radius of curvature is 3 mm, the change ratio of the local bearing thickness is 0.2, and the change ratio of the effective cross-sectional area is 0.1. If the stress concentration correction rule table stipulates that when the change in the minimum transition radius of curvature of the root transition zone is between 2 mm and 4 mm, the change ratio of the local bearing thickness is between 0.15 and 0.25, and the change ratio of the effective cross-sectional area is between 0.05 and 0.15, the corresponding correction increment is 0.12, and the initial value of the stress concentration factor of the critical section is 1.05, then the current value of the stress concentration factor is 1.17.

[0138] For example, when the initial value of the minimum transition radius of curvature corresponding to the critical section associated with a certain weld toe area index is 8 mm, the current value of the minimum transition radius of curvature is 6.5 mm, the initial value of the local bearing thickness is 18 mm, the current value of the local bearing thickness is 15.3 mm, the initial value of the effective cross-sectional area is 1050 square millimeters, and the current value of the effective cross-sectional area is 945 square millimeters, then the change in the minimum transition radius of curvature is 1.5 mm, the change in the local bearing thickness is 0.15, and the change in the effective cross-sectional area is 0.1. If the stress concentration correction rule table specifies that the correction increment corresponding to the weld toe area under the above interval combination is 0.09, and the initial value of the stress concentration factor of the critical section is 1.1, then the current value of the stress concentration factor is 1.19.

[0139] Construct the stress amplitude spectrum of the critical section. Establish a critical section stress amplitude spectrum table, which includes section number, load class number, representative value of load class, representative value of stress amplitude, cycle count, section-related region index, and state level label. Read the load class number, lower bound, upper bound, and class count from the initial equivalent impact load spectrum table. For each load class, take the median of the lower and upper bounds as the representative value of the load class. Traverse the set of critical sections by section number. For each critical section, read the stress conversion coefficient from the section stress conversion coefficient table, the current value of the stress concentration factor from the section state table, the section-related region index, and the state level label. Traverse the initial equivalent impact load spectrum table by load class number. For each load class, multiply the representative value of the load class by the stress conversion coefficient, then multiply by the current value of the stress concentration factor to obtain the representative value of the stress amplitude of the current critical section under the current load class. Write the corresponding class count to the cycle count field. Then, the section number, load grade number, load grade representative value, stress amplitude representative value, cycle count, section-related region index, and state level mark are written into the critical section stress amplitude spectrum table. Thus, a stress amplitude spectrum record is formed for each critical section number and each load grade number, and the initial equivalent impact load spectrum is converted into a critical section stress amplitude spectrum for each critical section.

[0140] It should be noted that the stress amplitude spectrum of the critical section is used to establish an intermediate mapping relationship between the initial equivalent impact load spectrum and the fatigue recursion of the critical section. The initial equivalent impact load spectrum only represents the number of times the load occurs within different load amplitude ranges, while the stress amplitude spectrum of the critical section further combines the current values ​​of the stress conversion coefficient and stress concentration coefficient of the critical section to convert the representative values ​​of the load class into the representative values ​​of the stress amplitude corresponding to each critical section, and retains the cycle count corresponding to each load class, thereby forming a spectralized stress input for a specific critical section.

[0141] The role of the stress amplitude spectrum at the critical section in this invention is to unify the differences in local geometric state, material degradation state, and operating load distribution of the root transition zone, weld toe region, and other critical sections into a single spectral structure. This allows subsequent steps to directly call the representative stress amplitude value and cycle count according to the section number and load class number, and perform impact fatigue damage calculation based on the class-counted recursion. Thus, in subsequent recursion processes, it is no longer necessary to repeatedly perform load-to-stress conversion for each window; instead, the allowable number of cycles for the critical section, the accumulation of fatigue damage increments, and the updating of coupled damage can be directly completed based on the stress amplitude spectrum at the critical section.

[0142] Furthermore, the stress amplitude spectrum of the critical section is also used to reflect the impact of the update of the zonal wear front and the correction of the stress concentration factor on the local stress response of the critical section. As the remaining thickness of the zonal section, the current value of the cross-sectional profile, the current value of the minimum transition radius of curvature, and the current value of the local bearing thickness change, the representative value of the stress amplitude corresponding to the same load band in different recursion periods will also change accordingly. Therefore, the stress amplitude spectrum of the critical section can transmit the changes in the bearing geometry after wear degradation to the subsequent fatigue recursion process. Thus, this invention establishes a unified interface between the initial equivalent impact load spectrum, the local geometry of the critical section, and the impact fatigue recursion calculation through the stress amplitude spectrum of the critical section, providing basic data for the output of remaining life distribution, failure location, and maintenance threshold recommendations.

[0143] A fatigue spectrum recursive table is established, and impact fatigue damage is recursively calculated based on the number of stress amplitudes. The fatigue spectrum recursive table includes a state level label, stress amplitude range, and allowable cycle count fields. The stress amplitude spectrum table for each critical section is traversed in groups by critical section number. For each critical section number, for each stress amplitude range, the representative stress amplitude value, cycle count, and the current state level label in the section state table are read. Based on the current state level label, the stress amplitude range corresponding to the representative stress amplitude value is found in the fatigue spectrum recursive table, and the allowable cycle count corresponding to that stress amplitude range is read. The cycle count is then divided by the allowable cycle count to obtain the impact fatigue damage increment corresponding to that stress amplitude range. The impact fatigue damage increments corresponding to each stress amplitude range for the same critical section in the current recursive cycle are summed to obtain the cyclic fatigue damage increment for that critical section in the current recursive cycle. This cyclic fatigue damage increment is then added to the cumulative fatigue damage value recorded at the end of the previous recursive cycle to obtain the cumulative fatigue damage value at the end of the current recursive cycle, and this cumulative fatigue damage value is written into the section state table. Since the fatigue spectrum recursion table is set according to the state level mark, when a certain dangerous section switches from the surface wear state to the transitional exposure state, even if the representative value of the stress amplitude remains unchanged, the corresponding allowable number of cycles will change with the state level mark switch. Thus, the impact fatigue damage recursion result reflects the influence of the material zone exposure state change on the fatigue bearing capacity.

[0144] The wear damage is recursively analyzed and forms a state-transitional coupled damage. For each critical section number, the remaining thickness of the current section, the advancement amount of the front corresponding to the current recursive cycle, and the current and initial values ​​of the effective cross-sectional area in the section state table are read from the section wear front table. First, the wear damage increment for the current recursive cycle is calculated. The reduction ratio of the wear-resistant surface layer thickness is equal to the reduction amount of the wear-resistant surface layer thickness in the current recursive cycle divided by the initial value of the wear-resistant surface layer thickness. The reduction ratio of the transition section thickness is equal to the reduction amount of the transition section thickness in the current recursive cycle divided by the initial value of the transition section thickness. The reduction ratio of the effective cross-sectional area is equal to the initial value of the effective cross-sectional area minus the current value of the effective cross-sectional area, and then divided by the initial value of the effective cross-sectional area. The maximum value among the reduction ratio of the wear-resistant surface layer thickness, the reduction ratio of the transition section thickness, and the reduction ratio of the effective cross-sectional area is determined as the wear damage increment for the current recursive cycle. Then, this wear damage increment is added to the cumulative wear damage value recorded at the end of the previous recursive cycle to obtain the cumulative wear damage value at the end of the current recursive cycle, and written into the section state table.

[0145] The current critical section's condition level is determined based on the remaining thickness of each zone and the cumulative fatigue damage value. The condition transition rules are as follows: when the remaining thickness of the wear-resistant surface zone is greater than zero, the condition level remains at surface wear; when the remaining thickness of the wear-resistant surface zone is equal to zero and the remaining thickness of the transition zone is greater than zero, the condition level switches to transition exposure; when the remaining thickness of the transition zone is equal to zero and the matrix zone begins to participate in load bearing, the condition level switches to matrix bearing; when the condition level is already matrix bearing, and the cyclic fatigue damage increment in two consecutive recursive cycles is greater than the wear damage increment in the corresponding recursive cycle, the condition level switches to critical crack state. The condition level is then written into the section condition table.

[0146] After obtaining the state level label, the cumulative value of coupled damage is updated. The remaining lifetime distribution refers to the result set formed by summarizing the remaining lifetime values ​​calculated for all critical sections according to the section number and the index of the associated region of the section. If the current state level is surface wear state or transitional exposure state, the cumulative value of fatigue damage and the cumulative value of wear damage are compared, and the larger value is determined as the current cumulative value of coupled damage. If the current state level is matrix bearing state, the cumulative value of fatigue damage and the cumulative value of wear damage are added to obtain the current cumulative value of coupled damage. If the current state level is critical crack state, the current cumulative value of coupled damage is kept equal to the sum of the cumulative value of fatigue damage and the cumulative value of wear damage, and the critical section is marked as the pre-failure state. The updated cumulative value of coupled damage is written into the section state table. Thus, the coupled damage recursion is determined by the changes in the remaining thickness of the partition, the changes in the effective cross-sectional area, the state level switching, and the cumulative value of fatigue damage, without relying on an additional abstract coupling coefficient.

[0147] Output remaining life distribution, failure location, and maintenance threshold recommendations. For each critical section number, read the current state level marker, cumulative fatigue damage value, cumulative wear damage value, and cumulative coupled damage value from the section state table to determine whether the critical section has entered a failure state. The determination rule is as follows: when the current state level marker is critical crack state and the cumulative coupled damage value is greater than or equal to one, the critical section is identified as a failure section, and the corresponding section number is written into the failure location table, while the failure marker is written as failure; other critical sections are identified as non-failed sections. For non-failed sections, traverse the stress amplitude spectrum table of critical sections according to the section number, read the cycle count corresponding to each spectrum and the allowable cycle count in the fatigue spectrum recursion table, calculate the remaining allowable cycle count for each spectrum, where the remaining allowable cycle count for each spectrum is equal to the allowable cycle count minus the cumulative cycle count consumed before the current recursion cycle; then select the minimum value from the remaining allowable cycle counts of each spectrum as the remaining tolerable cycle count for the critical section. Based on the recursive cycle length and window step size, the remaining tolerable number of cycles is converted into the remaining running time, and the remaining running time is determined as the remaining life value of the dangerous section.

[0148] The remaining lifetime values ​​of all hazardous sections are summarized by section number to obtain a remaining lifetime distribution table including section number, section-related area index, remaining lifetime value, and failure marker. Then, maintenance warning thresholds and maintenance shutdown thresholds are read, and the remaining lifetime value of each hazardous section is compared with these thresholds: when the remaining lifetime value is less than or equal to the maintenance shutdown threshold, a shutdown maintenance recommendation is output; when the remaining lifetime value is greater than the maintenance shutdown threshold but less than or equal to the maintenance warning threshold, a warning maintenance recommendation is output; when the remaining lifetime value is greater than the maintenance warning threshold, a normal operation recommendation is output. The section number, remaining lifetime value, failure marker, and corresponding maintenance recommendation are written into a maintenance threshold recommendation table, thus forming the output result of failure location, remaining lifetime distribution, and maintenance threshold recommendations.

[0149] It should be noted that the maintenance threshold recommendations can be generated based on the remaining lifespan of each hazardous section and a preset maintenance threshold. For example, the maintenance warning threshold is set to fifty hours, and the maintenance shutdown threshold is set to twenty hours. After calculating the remaining lifespan of each section in the hazardous section set, the remaining lifespan is compared with the maintenance warning threshold and the maintenance shutdown threshold: when the remaining lifespan is less than or equal to twenty hours, a shutdown maintenance recommendation is output; when the remaining lifespan is greater than twenty hours and less than or equal to fifty hours, a warning maintenance recommendation is output; when the remaining lifespan is greater than fifty hours, a normal operation recommendation is output. If the failure marker of a hazardous section has already been written as failed, an immediate replacement recommendation is directly output, and the hazardous section is added to the failure location table.

[0150] For example, if the remaining lifespan of section number one associated with the root transition zone index is 18 hours and the failure marker is "not failed," then the recommended maintenance threshold for this section is shutdown maintenance. If the remaining lifespan of section number two associated with the weld toe area index is 36 hours and the failure marker is "not failed," then the recommended maintenance threshold for this section is early warning maintenance. If the remaining lifespan of section number three associated with the cutting tooth mounting hole neighborhood index is 72 hours and the failure marker is "not failed," then the recommended maintenance threshold for this section is normal operation. Furthermore, if the cumulative value of coupling damage corresponding to section number four associated with the rib connection index has reached the failure judgment condition, and the failure marker is written as "failed," then the recommended maintenance threshold for this section is directly written as immediate replacement. Thus, the section number, remaining lifespan value, failure marker, and corresponding maintenance recommendation can be jointly written into the maintenance threshold recommendation table to form a graded maintenance output result for different hazardous sections.

[0151] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0152] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A biomimetic tooth seat wear-resistant and impact-resistant structural design and life prediction method for coal mining machines, characterized in that, include: S1. Establish a parametric model of the tooth base, generate tooth base structural instances and material partitions, and extract the set of critical sections; S2. Collect running time, cutting motor current, traction speed, cutting depth, vibration acceleration, impact count characteristics and temperature, and perform time alignment and sliding window statistics to generate working condition feature sequence. Output working condition category sequence based on working condition judgment threshold. S3. Based on the working condition characteristic sequence and working condition category sequence, and combined with the dangerous section set, corresponding area index information and material partition information, establish the load to structural response mapping, and generate the initial equivalent impact load spectrum, initial equivalent stress amplitude sequence and initial wear energy sequence of the root transition zone and weld toe zone. S4. Based on the initial equivalent impact load spectrum, the initial equivalent stress amplitude sequence, and the initial wear energy sequence, combined with the set of critical sections and the material partition table, the remaining thickness of each critical section, the section profile, and the bearing geometry are updated recursively, and the stress concentration factor of the root transition zone and the weld toe region is corrected; the initial equivalent impact load spectrum is converted into the critical section stress amplitude spectrum, and the impact fatigue damage and wear damage are recursively calculated according to the segment count. Update the coupling damage and state level, determine the remaining tolerable number of cycles and calculate the remaining lifetime, and output the remaining lifetime distribution, failure location and maintenance threshold recommendations.

2. The method for designing and predicting the lifespan of a biomimetic tooth seat for a coal mining machine according to claim 1, characterized in that, The method for recursively updating the remaining thickness, section profile, and load-bearing geometry of each critical section, and correcting the stress concentration factors in the root transition zone and weld toe zone includes: Establish a cross-sectional state table and a zoned wear front table; for each critical cross-section, establish thickness coordinates along the zone's action surface direction, and determine the initial values ​​of each zone's boundary position, front position position, and remaining thickness of the zone based on the material zoning table; The total periodic wear energy is obtained by accumulating the initial wear energy sequence according to the recursive cycle, and then converted into the forward advance along the thickness coordinate direction. The remaining thickness of each partition is updated in the order of material partition from the outside to the inside. Based on the partitioned wear front table, the corresponding contour segment in the initial value of the cross-sectional contour is offset to form the current value of the cross-sectional contour. Based on the current value of the cross-sectional contour, the current value of the effective cross-sectional area, the current value of the local bearing thickness and the current value of the minimum transition curvature radius are calculated. Based on the stress concentration correction rule table and combined with the cross-section related region index, the current values ​​of the stress concentration factors in the root transition zone and weld toe zone are corrected.

3. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 2, characterized in that, Methods for converting the initial equivalent impact load spectrum into the stress amplitude spectrum of the critical section, and recursively calculating impact fatigue damage and wear damage by classifying and counting, include: Establish a stress amplitude spectrum table and fatigue spectrum recursion table for critical sections; read the load segment number, lower limit of load segment, upper limit of load segment and segment count from the initial equivalent impact load spectrum table, and take the median value of the lower limit of load segment and the upper limit of load segment as the representative value of load segment for each load segment. Traverse the set of dangerous sections by section number, read the corresponding stress conversion factor, current value of stress concentration factor, section associated region index and state level mark, multiply the load grade representative value by the stress conversion factor and the current value of stress concentration factor to obtain the stress amplitude representative value of the current dangerous section under the current load grade, and write it together with the grade count into the dangerous section stress amplitude spectrum table. The stress amplitude spectrum table of the critical section is traversed in groups according to the critical section number. The allowable number of cycles corresponding to the stress amplitude range is found in the fatigue spectrum recursion table according to the state level mark. The increment of impact fatigue damage for each grade is obtained by dividing the cycle count by the allowable number of cycles, and the cumulative fatigue damage value for the current recursion cycle is obtained by summing them up. The wear damage increment for the current recursive cycle is calculated based on the changes in the remaining thickness of the partition and the changes in the effective cross-sectional area, and then accumulated to obtain the cumulative wear damage value.

4. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 3, characterized in that, Methods for updating coupled damage and state levels, determining the remaining tolerable number of cycles and calculating the remaining lifetime, and outputting the remaining lifetime distribution, failure location, and maintenance threshold recommendations include: The state level label is updated based on the remaining thickness and cumulative fatigue damage value of each zone. The state level label includes surface wear state, transitional exposure state, matrix bearing state and critical crack state. The cumulative value of coupled damage is updated based on the state level mark, the cumulative value of fatigue damage, and the cumulative value of wear damage. The failure location is determined when the current state level is marked as critical crack state and the cumulative value of coupled damage is greater than or equal to one. For unfailed sections, read the cycle count from the stress amplitude spectrum table of the critical section and the allowable number of cycles from the fatigue spectrum recursion table, calculate the remaining tolerable number of cycles and convert it into the remaining life value, summarize the remaining life values ​​of all critical sections according to the section number and the index of the section-related area to form the remaining life distribution, and generate maintenance threshold suggestions based on the maintenance warning threshold and maintenance shutdown threshold.

5. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 1, characterized in that, The method for generating the initial equivalent impact load spectrum includes: Establish a load response mapping parameter table, which includes current mapping coefficient, vibration mapping coefficient, velocity mapping coefficient, impact count mapping coefficient, depth mapping coefficient, load offset value, correction coefficient for each working condition, load grade boundary sequence and load grade number sequence. Traverse the working condition characteristic sequence table according to the window number, read the current change amplitude of the cutting motor, the peak value of vibration acceleration, the average value of traction speed, the impact count value, the average cutting depth and the working condition category label, calculate the initial window equivalent impact load value and write it into the initial equivalent impact load sequence table; Based on the load grading boundary sequence and load grading number sequence, the equivalent impact load values ​​of each initial window are graded and the grading count is statistically analyzed to generate an initial equivalent impact load spectrum table. The root transition zone index and weld toe region index are written into the associated region index field.

6. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 5, characterized in that, The methods for generating the initial equivalent stress amplitude sequence and the initial wear energy sequence include: Establish a cross-section stress conversion factor table, which includes cross-section number, cross-section associated region index, stress conversion factor, calibration load value and calibration stress value, and calculate the stress conversion factor based on the calibration load value and calibration stress value; Traverse the initial equivalent impact load sequence table by window number, traverse the set of critical sections by section number, calculate the initial equivalent stress amplitude based on the stress conversion coefficient and the initial window equivalent impact load value, and write it into the initial equivalent stress amplitude sequence table. Establish an initial contact parameter table, read the average traction speed, window length, working condition category mark and the initial window equivalent impact load value, calculate the window sliding distance and select the corresponding energy correction coefficient, and then calculate the initial window wear energy value based on the initial window equivalent impact load value, window sliding distance, contact coefficient and energy correction coefficient and write it into the initial wear energy sequence table.

7. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 1, characterized in that, Methods for obtaining operating condition feature sequences and determining operating condition categories include: Establish an operation monitoring data table, which includes operation time series, cutting motor current series, traction speed series, cutting depth series, vibration acceleration series, impact count characteristic series and temperature series, and write sampling time mark and channel mark according to preset sampling period; Read the runtime time series to establish an alignment time axis, map the data of each channel to the alignment time axis, and perform linear interpolation or forward hold-and-hold completion on missing positions to obtain an alignment monitoring data table; Establish a window parameter table, generate a window index sequence according to the window length and window step size, read the aligned monitoring data within the corresponding time range of each window, calculate the average cutting motor current, the amplitude of cutting motor current change, the average traction speed, the average cutting depth, the root mean square of vibration acceleration, the peak value of vibration acceleration, the characteristic count value of impact count, the average temperature and the rate of temperature change, and generate a working condition characteristic sequence. Establish a working condition judgment threshold table. Based on the working condition characteristic sequence, perform threshold judgment on each window in the order of no-load impact, rock-clamping impact, and strong vibration impact. The remaining windows are judged as steady-state cutoff, and the working condition category is written into the working condition category sequence.

8. The method for designing and predicting the lifespan of a biomimetic tooth seat for a coal mining machine according to claim 7, characterized in that, The operating conditions include operating conditions, no-load impact, rock-filled impact, and strong vibration impact.

9. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 1, characterized in that, Methods for establishing a parametric model of the gear seat and generating gear seat structural instances and material partitions include: Generate model identifiers, establish structural parameter tables, assembly constraint tables, and region index tables, and write the following parameters into the structural parameter table: tooth base body length, tooth base body width, tooth base body height, cutting tooth mounting hole diameter and axis position, root transition fillet radius, weld toe transition fillet radius, number of bionic ribs, spacing of bionic ribs, surface texture pitch, wear-resistant zone thickness, and material gradient layer parameters. Based on the set of geometric generation rules, the initial solid generation of the gear seat body, the removal of the cutting tooth mounting hole body, the generation of the root transition fillet, the generation of the weld toe transition morphology, the bionic rib forming and fusion, and the generation and fusion of the surface texture are performed in sequence. Then, the partitioning is performed along the normal direction of the specified wear-resistant surface to obtain the gear seat structure instance and the material partition table.

10. The biomimetic tooth seat wear-resistant and impact-resistant structure design and life prediction method for coal mining machines according to claim 9, characterized in that, The method for obtaining the set of dangerous sections includes: Based on the critical section extraction step, a set of candidate sections is generated along the length and height directions of the tooth base structure instance. Based on the region index table, candidate sections covering the root transition area, weld toe area, tooth mounting hole neighborhood and rib connection are filtered. For each candidate section, extract the section contour line, calculate the fitted circle radius of the root transition zone contour segment and the weld toe area contour segment and take the smaller value as the minimum transition curvature feature, calculate the effective section area difference between the current section and the adjacent section and divide it by the dangerous section extraction step size as the thickness change feature, calculate the turning angle feature of the contour segment at the rib connection as the geometric discontinuity feature, and count the number of partition layers crossed by the section as the material partition change feature. The minimum transition curvature characteristic, thickness variation characteristic, geometric discontinuity characteristic, and material partition variation characteristic are written into the hazard assessment table. Each candidate section is judged according to the preset hazard assessment rules, and the sections that meet the hazard section conditions are written into the hazard section set.

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