Mine truck scale life calculation method based on simulation data

Abstract

The application discloses a kind of mining truck scale life calculation method based on simulation data, including the following calculation formula of truck scale life calculation: T remaining=(1-D current) / D Wherein D current is the cumulative damage of the service life of truck scale;D is the cumulative damage of truck scale each year;T remaining is the remaining service life of truck scale;The calculation formula of the D is as follows: D=Σ (ni / Ni) Wherein, load data collection and division record the load frequency of each interval ni, the fatigue life cycle number that can be borne by truck scale under median weight in load parameter matching calculation is Ni.It solves the problem that the error of the method for estimating the service life of mining truck scale in the prior art is relatively large.

Description

Technical Field

[0001] This invention relates to the field of mining equipment technology, and specifically to a method for calculating the lifespan of a mining truck scale based on simulation data. Background Technology

[0002] As a core piece of equipment in the mine transportation metering system, mine truck scales play a crucial role in the settlement of bulk material trade and the control of transportation flow. They operate for extended periods in complex and harsh industrial environments characterized by high loads, strong vibrations, high dust levels, and drastic temperature and humidity fluctuations. Under these special conditions, the scale body must continuously withstand repeated impacts and fatigue loads from heavy-duty trucks. This not only exposes the system to the cumulative evolution of fatigue damage to the steel structure, but also subjects the reliability of its core weighing sensors to the coupled constraints of multiple environmental factors such as temperature drift, humidity corrosion, and pressure fluctuations, directly impacting the long-term stability and operational safety of the metering system.

[0003] Accurately predicting the fatigue life of mining truck scales is of great engineering significance for ensuring the safe and continuous operation of mining transportation, avoiding production losses caused by unplanned downtime, rationally formulating maintenance and repair plans, and reducing the total life cycle operation and maintenance costs.

[0004] However, the mainstream methods for assessing the lifespan of mining truck scales currently used in the industry are as follows: One type is the assessment method based on physical accelerated aging experiments. This method requires the construction of a simulated working condition experimental platform and continuous long-term testing. Not only is the experimental cycle lengthy and the cost of manpower and materials high, but it is also limited by experimental conditions, making it difficult to fully reproduce the complex and variable impact loads and environmental couplings of the actual working conditions in the mine. This results in insufficient characterization of the experimental data for the true lifespan. The other type is the calculation method based on theoretical formulas. Its core defect is that it often uses simplified constant load assumptions, fails to fully combine the dynamic stress state of the equipment during actual service, and fails to effectively integrate the refined stress distribution data obtained by finite element simulation technology. This results in a lack of comprehensiveness in fatigue strength correction and a serious disconnect between the load spectrum construction and the actual stress conditions on site. Summary of the Invention

[0005] The purpose of this invention is to solve the problem of large errors in the existing methods for estimating the service life of mine truck scales, and to provide a method for calculating the service life of mine truck scales based on simulation data.

[0006] To address the shortcomings of the aforementioned technical problems, the present invention adopts the following technical solution: a method for calculating the lifespan of a mining truck scale based on simulation data, comprising the following calculation formula for calculating the lifespan of the truck scale: T_remaining = (1 - D_current) / D Where Dcurrent represents the cumulative damage over the years the truck scale has been in use; Dan represents the cumulative damage per year of the truck scale; and Tremaining represents the remaining service life of the truck scale. The formula for calculating D is as follows: D=Σ(ni / Ni) Among them, the number of load cycles collected and recorded for each interval is ni, and the number of fatigue life cycles that the truck scale can withstand under the median weight is calculated by matching load parameters.

[0007] As a further optimization of the life calculation method for mine truck scales based on simulation data in this invention: the load data collection and division is carried out by the mine metering system and the truck scheduling table to collect the actual load information of different weighbridges, including the number of times they pass through each day and the load weight each time; the data is divided according to the preset weight range.

[0008] As a further optimization of the life calculation method for mining truck scales based on simulation data of the present invention: the load parameter matching uses the median value of each weight range as the representative load of the corresponding load range, and determines the corresponding speed multiple by combining the finite element simulation data of the mining truck scale through the fatigue sensitivity curve.

[0009] As a further optimization of the life calculation method for mining truck scales based on simulation data of the present invention: fatigue strength correction and fatigue limit estimation need to be performed before matching the load parameters: fatigue strength correction is based on the standard SN curve of the truck scale material, combined with loading type and reliability level factors, to complete the estimation and correction of fatigue strength during cycles; fatigue limit estimation is performed by multi-dimensional correction of bending fatigue limit through loading type correction coefficient, surface quality correction coefficient, size coefficient and reliability level coefficient, to accurately estimate fatigue limit Se.

[0010] As a further optimization of the life calculation method for mining truck scales based on simulation data in this invention: the fatigue limit Se is calculated using a multi-coefficient coupled correction formula: Se=Sbe・CL・CS・CD・CR, where Sbe is the basic bending fatigue limit of the material, taken from the standard SN curve; CL is the loading type correction coefficient, CS is the surface quality correction coefficient, CD is the size coefficient, and CR is the reliability correction coefficient.

[0011] As a further optimization of the life calculation method for mining truck scales based on simulation data in this invention, the value of the loading type correction coefficient CL is determined as follows: CL is 0.9 when subjected to pure axial loading, and CL is 0.7 when there is slight bending due to installation error.

[0012] As a further optimization of the method for calculating the life of a mining truck scale based on simulation data in this invention: the surface quality correction coefficient CS is related to the truck scale processing technology and surface roughness. When the surface roughness is 12.5um, CS is taken as 0.7.

[0013] As a further optimization of the method for calculating the life of a mining truck scale based on simulation data in this invention: the size factor CD is 1.0 for truck scale components that bear axial loads.

[0014] As a further optimization of the life calculation method for mining truck scales based on simulation data of the present invention: when the loading type is bending loading, the ultimate tensile strength is 90%; when the loading type is axial loading, the ultimate tensile strength is 75%; when the loading type is torsional loading, the ultimate shear strength is 90%.

[0015] As a further optimization of the method for calculating the life of a mining truck scale based on simulation data in this invention: the cycle range is 10³ and 10⁷, and the standard SN curve covers 10. 3 The next cycle until fatigue limit 10 7 The complete interval of the next cycle.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention integrates key data from finite element simulation with actual mine load information, and combines multi-coefficient correction of material fatigue performance with linear cumulative damage theory to achieve accurate prediction of the fatigue life of mining truck scales. It also forms a complete technical chain of simulation data extraction, material performance environment correction, actual load spectrum processing, and quantitative calculation of cumulative damage. This fully leverages the advantages of the precision of simulation data and the authenticity of actual working condition data, effectively releasing the synergistic effect of the two and making the truck scale life calculation method more accurate.

[0017] This invention eliminates the need for complex physical accelerated aging experiments. Calculations can be completed based on existing metrological data and simulation results, resulting in a short cycle time and low cost. It can directly provide data support for equipment operation and maintenance decisions. Furthermore, data processing and calculations can be performed using common tools such as Excel and MATLAB, eliminating the need for specialized fatigue analysis software, thus lowering the technical threshold and facilitating widespread application. Simultaneously, the design for the harsh working conditions and structural characteristics of mining truck scales allows for parameter adjustments based on the load characteristics of mining trucks of different tonnages and different weighbridges, adapting to the transportation and metering needs of various mines. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the steps and structure of the present invention; Figure 2 This is a standard SN curve diagram of the structural steel used in this invention; Figure 3 This is a graph showing the relationship between surface roughness and surface quality correction factor (CS). Detailed Implementation

[0019] To better understand the present invention, the following embodiments further illustrate the content of the present invention, but the content of the present invention is not limited to the following embodiments.

[0020] like Figure 1 As shown, a method for calculating the life of a mining truck scale based on simulation data includes the following steps: after fatigue strength correction and fatigue limit estimation, load data processing and life calculation are performed.

[0021] The fatigue strength correction includes the following steps: Based on the standard SN curve of the truck scale material, combined with key factors such as loading type and reliability level, the fatigue strength at 103 cycles is estimated and corrected to provide basic data for subsequent life calculation.

[0022] Obtain the standard stress-life (SN) curve of the material: Based on the "Mechanical Design Handbook" and the measured data of the structural steel of the truck scale, obtain the standard stress-life (SN) curve of the material. This curve covers the complete range from 103 cycles to the fatigue limit of 107 cycles, and clarifies the corresponding stress amplitude at different cycle numbers.

[0023] Basic fatigue strength determined: 10 3 The fatigue strength during the next cycle depends on the loading type and is determined according to the following rules: Under bending loading, S1000≈90%·Ultimate tensile strength (Su); Under axial loading, S1000≈75%·Ultimate tensile strength (Su); Under torsional loading, S1000≈90%·shear strength limit (Sus); Reliability Correction: Considering the statistical dispersion of fatigue data, a reliability correction coefficient CR is introduced based on the specified reliability level. The formula for calculating fatigue strength after correction is: S1000, R=S1000·CR, where CR is the recommended correction coefficient corresponding to different reliability levels. For example, when the reliability requirement is 0.99, refer to the "Mechanical Design Handbook" and take CR=0.814.

[0024] Fatigue limit estimation includes the following steps: Considering the asymptotic characteristics of the SN curve, the fatigue limit refers to the constant stress amplitude when the fatigue life tends to infinity or no fatigue failure occurs. The bending fatigue limit is accurately estimated by applying multi-dimensional corrections using load factors, surface quality factors, size factors, and reliability level factors to accurately estimate the fatigue limit Se.

[0025] Load type correction factor (CL) acquisition: Under axial loading conditions, the CL value ranges from 0.7 to 0.9 for parts without cuts; CL is 0.9 for pure axial loading (without bending), and CL is 0.7 for slight bending due to installation errors.

[0026] Surface quality correction factor (CS) is obtained: The surface correction factor is related to the processing technology and surface roughness, and is used to describe the influence of surface residual stress on fatigue strength; when the surface roughness of the truck scale is 12.5um, CS=0.7 is taken based on the measured data of the processing technology.

[0027] Obtaining the CD size factor: For truck scale components subjected to axial loads, the critical axial stress distribution on the cross section is uniform, and the size has little impact on fatigue strength. Therefore, it is recommended to take CD=1.0.

[0028] Fatigue limit calculation: The bending fatigue limit Sbe is corrected by a multi-coefficient coupling correction formula. The formula is: Se=Sbe·CL·CS·CD·CR, where Sbe is the material-based bending fatigue limit, taken from the standard SN curve.

[0029] Load data processing and life calculation include the following steps: collecting actual load data from the mine, dividing the data into intervals and matching parameters, and then calculating the fatigue life of the truck scale based on the Palmgren-Miner linear cumulative damage rule.

[0030] Load data collection and classification: Collect actual load information of different weighbridges through the mine metering system and truck dispatch table, including the number of times the truck passes through each day and the weight of each load; record the number of loads in each weight range as ni, such as 40-49t, 50-59t, etc.

[0031] Load parameter matching: The median value of each weight range is used as the representative load for that range. Combined with finite element simulation data of mining truck scales, such as the stress value corresponding to a 40t load, the corresponding speed multiplier is determined through the fatigue sensitivity curve. The fatigue life cycle number Ni that the equipment can withstand under the median weight is calculated. For example, the median value of the 40-49t range is 45t. The simulation of a 40t load corresponds to Ni = 960,000 cycles, and the fatigue sensitivity is 1.125 times. Therefore, under a 45t load, Ni = 960,000 / 1.125 ≈ 853,333 cycles.

[0032] Cumulative Damage and Life Calculation: Based on the Parental-Miner rule, it is assumed that fatigue damage accumulates linearly under different load cycles. When the cumulative damage D reaches 1, the equipment fails due to fatigue. The calculation formula is: D=Σ(ni / Ni), where ni is the actual number of annual cycles in a certain load range, i.e., the number of daily load cycles·365, and Ni is the fatigue life cycle number of the equipment in that range. Next, the current cumulative damage D_current is calculated in combination with the years the equipment has been used. The final remaining life calculation formula is: T_remaining = (1-D_current) / D, where D_years is the cumulative damage per year.

[0033] In a specific application, a 40t-class mining truck scale is used as the research object for the No. 1 weighbridge, the south gate weighbridge, and the main shaft weighbridge of a certain mine. The remaining service life of the mining truck scale is calculated by example. The material of the mining truck scale studied is structural steel. The ultimate tensile strength Su = 460MPa and the ultimate shear strength Sus = 270MPa of the structural steel used, and it has been used for 2 years.

[0034] First, fatigue strength correction is performed, i.e., obtaining... Figure 2 The standard SN curve shown: According to the "Mechanical Design Handbook", the key parameters of the standard SN curve for structural steel are as follows: 103 cycles correspond to a stress amplitude of 3.999e+09 Pa, and 107 cycles correspond to a stress amplitude of 1.069e+09 Pa. Basic fatigue strength calculation: The truck scale mainly bears bending load, therefore S1000 = 90%·Su = 0.9·4.6e8 Pa = 4.14e8 Pa. Reliability correction: The reliability requirement for mining equipment is 0.99. CR = 0.814 is found. After correction, the fatigue strength S1000, R = 4.14e8·0.814 ≈ 3.37e8 Pa.

[0035] Fatigue limit estimation was then performed, i.e., the correction factors were determined: due to slight bending caused by installation error, CL = 0.7 was taken; surface roughness was 12.5 μm, combined with... Figure 3 The relationship curve shown is set to CS=0.7; the axial load component is set to CD=1.0; and the reliability coefficient is CR=0.814.

[0036] Fatigue limit calculation: The bending fatigue limit of the structural steel foundation is Sbe = 1.069e8 Pa. Substituting into the formula, we get: Se = 1.069e8·0.7·0.7·1.0·0.814≈4.18e7 Pa.

[0037] Based on the above data, load data processing and lifetime calculation are performed. The specific load data collection and division are as follows: At all weighbridge locations, ranging from 100t to 130t, a total of 67 cycles were performed with a load of 115t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 2.875 times, which corresponds to 18,000 cycles; ranging from 70t to 100t, a total of 1,123 cycles were performed with a load of 85t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 2.125 times, which corresponds to 51,000 cycles; ranging from 40t to 70t, a total of 5,165 cycles were performed with a load of 55t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 1.375 times, which corresponds to 330,000 cycles.

[0038] Of these, there were 5114 cycles at the 01 pound position, and 5005 cycles in the range of 40t to 49t. The load was 45t, and the simulation setting was 40t, which corresponds to a fatigue sensitivity of 1.125 times. A fatigue sensitivity of 1.125 times corresponds to 960000.

[0039] The south gate weighbridge underwent 1650 tests, with 1641 tests in the range of 41.25t to 104.65t; 1114 tests in the range of 80t to 104.65t, with a load of 90t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 2.25 times, which corresponds to 48104 tests; 354 ​​tests in the range of 60t to 80t, with a load of 70t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 1.75 times, which corresponds to 111560 tests; and 173 tests in the range of 41.25t to 60t, with a load of 50t and a simulation setting of 40t, corresponding to a fatigue sensitivity of 1.25 times, which corresponds to 570000 tests.

[0040] The main shaft weighbridge underwent 2155 cycles, ranging from 48.15 to 70 tons, totaling 1592 cycles. With a load of 60 tons and a simulation setting of 40 tons, the fatigue sensitivity was 1.5 times, corresponding to 194090 cycles. The weighbridge underwent 554 cycles, ranging from 70 tons to 90.55 tons, with a load of 80 tons and a simulation setting of 40 tons. The fatigue sensitivity was 2 times, corresponding to 72196 cycles.

[0041] Based on the Palmgren-Miner rule formula and the calculation formula T_remaining = (1-D_current) / D, the remaining service life of the truck scale is calculated to be 3.49 years.

[0042] Implementation verification Ultrasonic testing of the weld seams of the longitudinal beams of the main shaft weighbridge revealed a 0.5mm microcrack, with an estimated remaining service life of 3-4 years, largely consistent with the calculated 3.49 years, thus verifying the accuracy and reliability of the settlement results. Simultaneously, field tests were conducted in several large open-pit mines, with an average prediction error of less than 8.5%, an improvement of over 42% compared to traditional empirical methods. Furthermore, the system supports dynamic updates of load spectra and material parameters, continuously optimizing life assessment results as equipment service conditions change, significantly enhancing the timeliness and reliability of maintenance strategies.

[0043] The specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A method for calculating the lifespan of a mining truck scale based on simulation data, characterized in that: The following calculation formulas are included for calculating the lifespan of truck scales: T_remaining = (1 - D_current) / D Where Dcurrent represents the cumulative damage over the years the truck scale has been in use; Dan represents the cumulative damage per year of the truck scale; and Tremaining represents the remaining service life of the truck scale. The formula for calculating D is as follows: D=Σ(ni / Ni) Among them, the number of load cycles collected and recorded for each interval is ni, and the number of fatigue life cycles that the truck scale can withstand under the median weight is calculated by matching load parameters.

2. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 1, characterized in that: The load data collection and classification are achieved by using the mine metering system and truck scheduling table to collect actual load information of different weighbridges, including the number of times they pass through each day and the weight of each load; the data is then classified according to preset weight ranges.

3. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 1, characterized in that: The load parameter matching uses the median value of each weight range as the representative load of the corresponding load range, and combines the finite element simulation data of the mining truck scale to determine the corresponding speed multiple through the fatigue sensitivity curve.

4. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 3, characterized in that: Before matching the load parameters, fatigue strength correction and fatigue limit estimation are required: fatigue strength correction is based on the standard SN curve of the truck scale material, combined with loading type and reliability level factors, to complete the estimation and correction of fatigue strength during cycles; fatigue limit estimation is performed by multi-dimensional correction of bending fatigue limit through loading type correction coefficient, surface quality correction coefficient, size coefficient and reliability level coefficient, to accurately estimate fatigue limit Se.

5. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 4, characterized in that: The fatigue limit Se is calculated using a multi-coefficient coupled correction formula: Se = Sbe・CL・CS・CD・CR, where Sbe is the material-based bending fatigue limit, taken from the standard SN curve; CL is the loading type correction coefficient; CS is the surface quality correction coefficient; CD is the size coefficient; and CR is the reliability correction coefficient.

6. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 5, characterized in that: The loading type correction factor CL is determined according to the following rules: CL is 0.9 when there is pure axial loading, and CL is 0.7 when there is slight bending due to installation error.

7. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 5, characterized in that: The surface quality correction coefficient CS is related to the weighbridge processing technology and surface roughness. When the surface roughness is 12.5 μm, CS is 0.

7.

8. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 5, characterized in that: The size factor CD is 1.0 for truck scale components that bear axial loads.

9. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 5, characterized in that: When the loading type is bending loading, the ultimate tensile strength is 90%; when the loading type is axial loading, the ultimate tensile strength is 75%; when the loading type is torsional loading, the ultimate shear strength is 90%.

10. The method for calculating the lifespan of a mining truck scale based on simulation data as described in claim 5, characterized in that: The cycle range is 103 and 107, and the standard SN curve covers 10. 3 The next cycle until fatigue limit 10 7 The complete interval of the next cycle.

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