Vibration source analysis and structural optimization design of rotary table based on OTPA
Authors: Xie Miao , Wang He , Liu Zhixiang , Ma Suning , Wu Xia , Dong Yufeng 
Published: July 2024

Due to the influence of coal rock shape, hardness, working environment and other factors in the cutting process of cantilever roadheader, the cutting head will produce irregular and violent vibration. As the rotary table of key stress components, its operation process stability, dynamic reliability and life affect the cutting efficiency and cutting stability of cantilever roadheader. In order to study the vibration characteristics of the rotary table in the cutting process, firstly, based on the theory of spatial force analysis and calculation, the spatial mechanical model of the rotary table of the cantilever roadheader is established. By solving the balance equation of the rotary table force system, the variation law of the load at the hinge ear of the rotary table with the cutting pitch angle and the horizontal angle is obtained. Secondly, based on the path transfer analysis method of working condition, the vibration data of cutting head, cutting cantilever, cutting lifting and rotary hydraulic cylinder under stable cutting condition are taken as input signals. By constructing the transfer path analysis model of rotary table working condition, the synthetic vibration of rotary table in cutting process is simulated, and the main vibration source of rotary table is determined. Then, the vibration contribution and contribution degree of each vibration excitation point to the hinge ear of rotary table are studied. By building a cutting test bench, the vibration response of rotary table in cutting process is tested to verify the correctness of the theoretical model.Thirdly, based on the frequency domain analysis method of random vibration fatigue life, combined with the S-N curve of the rotary table, the PSD curve at the maximum stress of the rotary table is obtained by modal excitation method, and the load data is imported into ANSYS nCode software to obtain the life cloud diagram and damage cloud diagram of the rotary table, and then the fatigue life of the rotary table under symmetrical cyclic load is solved. Finally, based on the response surface optimization analysis method, the maximum stress and maximum deformation of the rotary table are taken as the optimization objectives, and the aperture of each hinge ear of the rotary table is taken as the optimization variable. Based on Design Expert, a second-order regression model is established to realize the multi-objective optimization design of the key stress parts of the rotary table in the cutting process. The simulation results show that under the same cutting conditions, the maximum stress of the optimized rotary table is reduced by 15.82% year-on-year, and the maximum deformation is reduced by 24.70% year-on-year. The optimized rotary table structure can better adapt to the cutting process, which is beneficial to improve the service life of the rotary table and enhance its operation stability. The research results are beneficial to enrich the relevant research theory in the field of rotary table vibration of cantilever roadheader, and are beneficial to improve the service life of the rotary table and the efficiency of tunneling and mining.