Talking about the design elements of shearer cable structure

With the continuous improvement of coal mining technology, modern coal mining engineering requires the ground control center to timely grasp the operation status of the underground shearer, that is, the shearer cable is required to timely and effectively feedback the working conditions of the coal mining equipment to the ground control center in the process of ensuring the normal operation of the coal mining equipment under harsh natural working conditions, so that the ground control center can make rapid judgment and decision-making
.
Therefore, in the coal industry standard MT818, it is required that the shearer cable is equipped with a control core to ensure the detection and transmission of signals and realize online real-time monitoring
.

At present, the disadvantages of shearer cables in the domestic market are mainly reflected in the poor transmission of cable operation signals or the inability to transmit signals, which affects the ground control center to monitor the working conditions of shearers, and the main reasons for this situation are as follows:

1.
The working environment of the shearer cable is relatively bad, and the working area gangue or large coal block falls and rushes the cable, causing the cable sheath to be smashed or even the internal wire core will be broken;

2.
A certain amount of gangue or coal blocks accumulate in the cable trough, so that the cable scrapes with it during moving, causing the cable sheath to be scraped or even squeezed off the internal core;

3
.
The shearer cable is frequently stretched and bent during on-site use, which is also very easy to cause the occurrence of core breakage.

The above three points are all shearer cables in the process of coal mining, subject to various external forces, resulting in cable failures caused by cables being easily smashed and broken, which greatly shortens the service life of shearer cables and cannot ensure their safety and reliability during use; The detection model and control signal on the intelligent shearer cannot be transmitted in time, and online real-time detection and monitoring
cannot be realized.

In order to improve the reliability of shearer cables, it is necessary to solve the problem that shearer cables are prone to core breakage during operation, under the premise of standard MT818-2009 requirements, according to my many years of experience in shearer cable technology, the following improvement measures are proposed, so as to effectively improve the reliability
of cables.

1.
The conductor monofilament of the shearer cable power core and the control core conductor should ensure uniform elongation, tensile strength and qualified resistance, and the tension must be ensured
during the conductor twisting process.
The purpose is to ensure that the cable in the work, will not be due to the uneven conductor elongation or uneven tension during the twist caused by uneven force of monofilament or strand, and then break the phenomenon, for monofilament, its production equipment is best to use Nikhof company production of multi-head wire drawing machine production, so as to ensure that the electrical performance of each monofilament is basically the same, but also its mechanical properties are consistent
.

2.
When the power core of the shearer cable and the control core are formed into cables, it is necessary to add unvulcanized rubber filling strips to ensure that the rubber strips are fully filled in the middle of the cable core when the sheath is extruded, so that the cables are frequently bent and stretched during work to minimize the sliding damage
between each other.
To protect the control core, the sheath
needs to be squeezed outside the control core.
When the power core and the control core are cabled, it can be designed as a four-core cable structure to ensure the stability of the overall structural performance of the cable;

3.
The working environment of the shearer cable is harsh, in order to avoid the cable being smashed or cut, the sheath needs to have good tear resistance and compression resistance, so that the inner and outer sheath can be used, and the high-strength impregnated fiber rope is used for weaving and strengthening
。 In the process of construction and laying, the following two aspects can be started: in order to prevent the coal gangue or large coal blocks from falling and rushing the cable, advanced protective measures can be taken, namely: advanced support for the coal gang and coal top of the mining face, and adopt the management of moving the frame and the arc top of the mutual help; The cable can be given a length margin of 1% during laying and installation to prevent the cable from being overtightened and stretched, thereby effectively improving the reliability
of cable use.

The shearer cable needs to be in accordance with the national coal industry standard, on this basis, a reasonable cable structure is designed to ensure the stable performance of the cable structure, avoid failures such as core breaking during the use of the cable, reasonably and efficiently ensure the normal operation of the cable, and ensure the effective service life
of the cable.
Through the continuous optimization of product structure, improve the economic efficiency of enterprises while establishing the reputation of brand cables, and achieve high-quality cable manufacturers
.