Assessment of the flight section strength of an armoured face conveyor
A.D. Lazarev, I.A. Zhukov
Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation
Russian Mining Industry №4S/ 2026 p. 113-119
Abstract: The article sets the task of assessing the strength of a flight section of an armoured face conveyor, which operational loading has a complex character, thereby forming a complex stress-strain state. In the existing engineering practice, the strength of the section is assessed by individual structural elements, which does not allow taking into account the combined effect of stresses and identifying critical areas at the design stage. It is established that direct application of the finite element method to a complete model of the section involves significant computational costs, and modeling welded joints as a solid body introduces an additional systematic error in the stress calculation. Application of the superelement method is proposed as a solution, based on decomposition of the structure into subsystems, which allows reducing the order of the final system of equations while maintaining the accuracy of the initial discretization. A minimally sufficient design scheme has been established and the structural element limiting the bearing capacity of the node has been identified using the guide rail subsystem as an example.
Keywords: coal mining, armoured face conveyor, conveyor flight section, strength assessment, finite element analysis, superelement method
For citation: Lazarev A.D., Zhukov I.A. Assessment of the flight section strength of an armoured face conveyor. Russian Mining Industry. 2026;(4S):113–119. (In Russ.) https://doi.org/10.30686/1609-9192-2026-4S-113-119
Article info
Received: 02.06.2026
Revised: 29.07.2026
Accepted: 10.08.2026
Information about the authors
Artur D. Lazarev – Postgraduate Student, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation
Ivan A. Zhukov – Dr. Sci. (Eng.), Head of the Department of Mechanical Engineering, Empress Catherine II Saint Petersburg Mining University, Saint Petersburg, Russian Federation; https://orcid.org/0000-0001-9068-3201; e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.
References
1. Litvinenko V.S., Petrov E.I., Vasilevskaya D.V., Yakovenko A.V., Naumov I.A., Ratnikov M.A. Assessment of the role of the state in the management of mineral resources. Journal of Mining Institute. 2023;259:95–111. https://doi.org/10.31897/PMI.2022.100
2. Kazanin O.I. Promising technology trends in underground coal mining in Russia. Gornyi Zhurnal. 2023;(9):4–11. (In Russ.) https://doi.org/10.17580/gzh.2023.09.01
3. Liu Q., Qiu Z., Li M., Shang J., Niu W. Evaluation and empirical research on green mine construction in coal industry based on the AHP-SPA model. Resources Policy. 2023;82:103503. https://doi.org/10.1016/j.resourpol.2023.103503
4. Maksarov V.V., Kufaev V.G. Magnetic Abrasive Finishing of Workpieces for Anti-friction Bronze Slide Bearing Shells. International Journal of Engineering, Transactions A: Basics. 2026;39(1):26–33. https://doi.org/10.5829/IJE.2026.39.01A.03
5. Zhang L., Ponomarenko T. Directions for sustainable development of China’s coal industry in the post-epidemic era. Sustainability. 2023;15(8):6518. https://doi.org/10.3390/su15086518
6. Kazanin O., Sidorenko A., Drebenstedt C. Intensive underground mining technologies: Challenges and prospects for the coal mines in Russia. Acta Montanistica Slovaca. 2020;26(1):60–69. https://doi.org/10.46544/AMS.v26i1.05
7. Kazakov Yu.A., Kozachkov G.S. Technological requirements for the processing of excavated organic raw material. Mining Informational and Analytical Bulletin. 2025;(12-3):85–99. (In Russ.) https://doi.org/10.25018/0236_1493_2025_123_0_85
8. Khamidov O.U., Shibanov D.A. Regulated maintenance and repair of quarry excavators considering real-world conditions and operating modes. Mining Informational and Analytical Bulletin. 2025;(12-3):152–167. (In Russ.) https://doi.org/10.25018/0236_1493_2025_123_0_152
9. Gabov V.V., Xuan N.V., Zadkov D.A., Tho T.D. Increasing the content of coarse fractions in the mined coal mass by a combine using paired cuts. Journal of Mining Institute. 2022;257:764–770. https://doi.org/10.31897/PMI.2022.66
10. Zubov V.P., Golubev D.D. Prospects for the use of modern technological solutions in the flat-lying coal seams development, taking into account the danger of the formation of the places of its spontaneous combustion. Journal of Mining Institute. 2021;250:534–541. https://doi.org/10.31897/PMI.2021.4.6
11. Zhukov I. A., Golikov N. S., Martyushev N. V. Design rationalization of the scraper conveyor section by means of an automated method of strength characteristics analysis. Sustainable Development of Mountain Territories. 2022;14(1):142–150. (In Russ.).
12. Nedashkovskaya E.S., Sheshukova E.I., Korogodin A.S., Myakotnykh A.A., Shibanov D.A., Ivanov S.L. Structure of the system of maintenance and repair of mining machines. Transport, Mining and Construction Engineering: Science and Production. 2024;(25):155–162. (In Russ.) https://doi.org/10.26160/2658-3305-2024-25-155-162
13. Zhang P., Li B., Ma H., Xia R., Dong Y., Wang X. Fatigue life analysis of scraper conveyor chain ring under different chain speeds and loads. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering. 2026;240(1):509–521. https://doi.org/10.1177/09544089241253057
14. Jiang S., Ren W., Mao Q., Zeng Q., Yu P., Gao K., Wang L. Dynamic analysis of the scraper conveyor under abnormal operating conditions based on the vibration and speed characteristics. Shock and Vibration. 2021;2021:8887744. https://doi.org/10.1155/2021/8887744
15. Tian Z., Jing S., Zhao L., Liu W., Gao S. Numerical simulation on coal loading process of shearer drum based on discrete element method. Energy Exploration & Exploitation. 2021;39(6):1919–1938. https://doi.org/10.1177/01445987211013536
16. Yang L., Zhang H., Song Y., Chen W., Chen Y. Study on multibody contact load distribution characteristics of scraper conveying system of continuous miner. Transactions of the Canadian Society for Mechanical Engineering. 2023;47(4):575–587. https://doi.org/10.1139/tcsme-2023-0017
17. Velikanov V.S., Grishin I.A., Akmanova Z.S., Lukashuk O.A., Lukashuk A.D. Contemporary aspects of designing mining transport machines in the context of digital transformation of mining operations. Russian Mining Industry. 2024;(5S):28–32. (In Russ.) https://doi.org/10.30686/1609-9192-2024-5S-28-32
18. Linh N.K., Gabov V.V., Lykov Y.V., Urazbakhtin R.Y. Evaluating the efficiency of coal loading process by simulating the process of loading onto the face conveyor with a shearer with an additional share. International Journal of Engineering, Transactions A: Basics. 2021;34(7):1804–1809. https://doi.org/10.5829/IJE.2021.34.07A.25
19. Sheshukova E.I., Shibanov D.A., Ivanov S.L., Nedashkovskaya E.S. Assessment of loads acting on the working attachment of a mine shovel (Part 1). Russian Mining Industry. 2024;(3):143–148. (In Russ.) https://doi.org/10.30686/1609-9192-2024-3-143-148
20. Li S., Zhu Z., Lu H., Xue Y. Tension characteristics analysis of scraper chain of heavy-duty scraper conveyor with timevarying loads. Shock and Vibration. 2024;2024:5589346. https://doi.org/10.1155/2024/5589346
21. Hao J., Song Y., Liu H., Zhang P., Chen L., Zhang N. et al. The optimal design model for a new type of scraper and research on its material properties. Lubricants. 2023;11(4):171. https://doi.org/10.3390/lubricants11040171
22. Ma D., Wan L., Zhang X., Zeng Q., Gao K. Meshing characteristics and failure analysis of shearer walking wheel considering torsional deformation. Alexandria Engineering Journal. 2022;61(7):5771–5782. https://doi.org/10.1016/j.aej.2021.09.035
23. Lazarev A.D., Zhukov I.A. Methodological approaches to the determination and assessment of the strength of the grating block of a downhole scraper conveyor. Transport, Mining and Construction Engineering: Science and Production. 2025;(31):125–132. (In Russ.) https://doi.org/10.26160/2658-3305-2025-31-125-132
24. Ma H., Wang X., Li B., Liu Z., Bi W., Wei X. Study on the mechanical effect and wear behaviour of middle trough of a scraper conveyor based on DEM–MBD. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology. 2022;236(7):1363–1374. https://doi.org/10.1177/13506501211059259
25. Bärnkopf E, Kövesdi B, Dunai L. Investigation of stress concentration zones in FEM-based design of welded plated structures. Buildings. 2023;13(4):1057. https://doi.org/10.3390/buildings13041057
26. Arandjelovic M., Djordjevic B., Sedmak S., Radu D., Petrovic A., Dikic S., Sedmak A. Failure analysis of welded joint with multiple defects by extended Finite Element Method and Engineering Critical Analysis. Engineering Failure Analysis. 2024;160:108176. https://doi.org/10.1016/j.engfailanal.2024.108176
27. Yan R., Xin H., Yang F., El Bamby H., Veljkovic M., Mela K. A method for determining the constitutive model of the heat-affected zone using digital image correlation. Construction and Building Materials. 2022;342:127981. https://doi.org/10.1016/j.conbuildmat.2022.127981
28. Molski K.L., Tarasiuk P., Glinka G. Stress concentration at cruciform welded joints under axial and bending loading modes. Welding in the World. 2020;64(11):1867–1876. https://doi.org/10.1007/s40194-020-00966-4
29. Ghimire A., Wald F., Vild M., Kabeláč J. Numerical design calculation of the high-strength steel welds. Engineering Structures. 2024;300:117201. https://doi.org/10.1016/j.engstruct.2023.117201
30. Voronenok E.Ya., Palii O.M., Sochinskii S.V. Method of reduced elements for structural analysis. Leningrad: Sudostroenie; 1990. 220 p. (In Russ.)
31. Lee D., Chang S., Lee J. Generalized polynomial chaos expansion by reanalysis using static condensation based on substructuring. Applied Mathematics and Mechanics. 2024;45(5):819–836. https://doi.org/10.1007/s10483-024-3108-8
32. Feng Y., Zhang M., Li G., Meng G. Finite element analysis and structure optimization of the middle groove of scraper conveyor. IOP Conference Series: Materials Science and Engineering. 2019;616:012022. https://doi.org/10.1088/1757-899X/616/1/012022
33. Sun Y., Lu Y., Song Z. Review on the theories and applications of dynamic condensation and component mode synthesis methods in solving FEM-based structural dynamics. Acta Mechanica Solida Sinica. 2023;36(3):361–389. https://doi.org/10.1007/s10338-023-00383-2
34. Ge C., Liu Z., Miao T., Huo Y., Wu J., Cui M., Han J. Strength analysis and optimization of three-bridge rigid frame for mining dump truck using finite element stress linearization method. Journal of Physics: Conference Series. 2022;2343:012025. https://doi.org/10.1088/1742-6596/2343/1/012025
35. Zhang Q., Zhang R.X., Tian Y. Scraper conveyor structure improvement and performance comparative analysis. Strength of Materials. 2020;52(4):683–690. https://doi.org/10.1007/s11223-020-00218-2



