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Creating virtual prototypes of mining machines

Teodor Winkler, Jarosław Tokarczyk Suggested method for creation of virtual prototypes was presented on the background of the stages of mining machine lifetime. The following basic stages of mining machine lifetime were distinguished:
  • designing and constructing,
  • manufacturing / assembly,
  • stand tests,
  • installation at the workplace,
  • exploitation,
  • withdrawal from operation.
Scenarios of virtual prototyping are created for each stage. They include the following basic components of suggested method:
  • assessment criteria,
  • criterial states,
  • criterial models,
  • detailed methods.
Virtual prototypes are evaluated in the light of technical and anthropotechnical assessment criteria.
There are the following technical assessment criteria:
  • strength criteria,
  • functional criteria.
There are the following anthropotechnical assessment criteria:
  • ergonomic criteria,
  • safety criteria,
  • manufacturing possibilities criteria.

Structure of criterial models for each criterial state of mining machine was presented. Study of cases for ten or so virtual prototypes was made. Method for automation of preparing computational tasks by the Finite Elements Method, which takes into account changeability of location of machine systems and shortens the time for preparation of a single computational task, was suggested in the stage of designing and constructing.

In the installation at the workplace and exploitation stages results obtained in virtual prototyping process can be used in an analysis of feasibility of assembly and disassembly operations.

Verification of virtual prototypes was conducted on the basis of obtained results from stand tests and in situ conditions within the following criteria:

  • strength criteria – comparison of effort of real object by traditional methods (resistance strain gauges and inductive displacement converters) as well as by the use of Reverse Engineering method (non-touch method on the basis of photos),
  • safety criteria – comparison of boundary values of angles of powered-roof-support loss of stability,
  • functional criteria – comparison of so-called lemniscate curve of powered-roof-support,
  • ergonomic criteria – comparison of standard requirements with real in situ conditions.