Abstract:
Intelligent and highly efficient ultra-long fully-mechanized working faces have become a key development direction in modern coal mining. However, conventional dual-end driven scraper conveyors, which are widely deployed in such environments, still suffer from excessive chain tension and insufficient shock resistance, thereby limiting their operational stability and long-term reliability. To address these challenges, this study proposes a novel scraper conveyor configuration driven directly by multiple series-connected permanent magnet motors, aiming to achieve segmented load transmission, reduce localized chain tension, and enhance system stability. A dynamic model of the chain drive system is developed based on the Kelvin–Voigt viscoelastic theory and discrete force analysis, serving as the theoretical foundation for evaluating transmission response. A multi-body dynamic simulation model is then constructed in ADAMS, enabling comparative analysis of torque, chain tension, and rotational speed between the proposed multi-drive system and conventional dual-drive systems under various operating conditions. Furthermore, a physical experimental platform is established for the multi-drive scraper conveyor, and experimental results are used to validate the theoretical and simulation models. Results indicate that, compared with the dual-drive system, the proposed multi-drive configuration reduces the peak start-up torque of the head drive unit by 13.9% and 46.1% under no-load and head-loading conditions, respectively. Under tail-loading conditions, the peak impact torque of the intermediate drive unit is reduced by 45.2%. During loaded start-up, the average torque and chain tension in the head section decrease by 42.3% and 48.9%, respectively. The theoretical model predicts the average tension and torque of the intermediate sprocket under the loaded condition with only a 5.8% difference. These findings demonstrate that segmented load distribution via multiple direct-drive units not only alleviates chain tension but also significantly suppresses torque fluctuations, thereby improving shock resistance and enhancing overall system stability. This work provides theoretical guidance for the development of power distribution strategies in scraper conveyors operating under ultra-long working face conditions.