Fatigue life prediction of hoist drum-rail contact pair based on digital twin

Abstract

Application of digital twin development technology allows to significantly improve safety and reduce operational costs of complex technical systems. The detailed description of the mine lifting complex elements digital twin development process is presented. In particular the geotechnical system “roller of the lifting vessel - mine conductor” digital twin is considered. The developed digital twin allows to determine the moving lifting vessel on mine conductors contact interaction forces in real time using data from the motion smoothness monitoring system. The obtained forces values allow us to calculate both the current conductors under the influence of the moving lifting vessel stress-strain state and the number of cycles “descent-lift” to conductors fatigue wear. A cycle of experimental studies on contact-mechanical fatigue of the system under consideration was performed. The contact load was increased stepwise according to the proposed loading scheme until significant values of plastic deformation, vibration and noise occurred. Modification of the mechanical-mathematical model of contact wear is performed. The variation of the normal load as a function of the loading cycle is taken into account. The developed mechanical-mathematical model of multi-cycle digital twin wear is verified by the experimental investigations and can be refined with a set of statistics of the considered physical object observations.The digital twin developed makes it possible to provide additional monitoring of the mine shaft steel structures under various operating conditions state, which makes it possible to rely not only on visual monitoring means. The proposed technology of mine shaft DT development allows to rapidly make important technical decisions on controlling the operation of critical elements of the geotechnical system considered (modes of operation, repair and replacement, etc.). This fact not only minimizes costs, but also ensures safe operation of the geotechnical system under consideration. The solutions developed were tested and implemented in the practice of one of the operating mining enterprises and showed their high efficiency.