Competitive Reliability Analysis of Spiral Rollers in Thin Coal Seam Mining Machines

Thin-seam shearers operating in complex coal seams work under adverse conditions with poor visibility, making sensor installation difficult and signal sensing and collection challenging. As a result, identifying the cutting state becomes difficult, which significantly impacts the intelligent control of the shearer’s cutting section. Additionally, the complex working conditions lead to low reliability and shorten the service life of the spiral drum. The spiral drum is a typical symmetrical structure, and its load exhibits both symmetry and nonlinearity. The load under different gangue-inclusion conditions is developed in MATLAB R2022a. The occurrence times and corresponding load-spectrum data of the spiral drum, both under natural wear and sudden impact conditions, are extracted. Analysis reveals that the maximum stress under natural wear conditions exceeds 300 MPa, while under sudden impact conditions it reaches over 600 MPa. Fatigue analysis is carried out with the help of the ANSYS Ncode 2022 R1 module to identify the weak positions of fatigue damage in the spiral drum structure. Reliability models for natural wear and sudden impact failures are established using the Gamma and Weibull distributions, respectively. Parameter estimation is performed, and competing failure reliability models are constructed under independent and correlated conditions of the two failure modes. This approach obtains the competing reliability curve of the spiral drum, providing data support and new ideas for its reliability design.