Abstract: To investigate the mechanical properties of mining machine cables, a physical model of the MCP-0.66/1.14 3*95+1*25 cable was constructed, and a cable bending device was designed based on the cables actual movement conditions. Tensile tests provided the material parameters for the cable strands, which served as the initial conditions for numerical simulations. The simulations covered cables with different stranding pitch ratios, twisting directions, and control unit cross-sectional areas. The results show that the cable stress increases with the stranding pitch ratio. Considering manufacturing costs and mechanical properties, a pitch ratio of 6 is optimal for this cable type. For twisting directions, where R denotes right-hand and L denotes left-hand twists, the stress order is RLR>RRL>RLL>RRR. Three-layer parallel twisting tends to cause strand dispersion, making the RLL twisting method optimal for mechanical properties. The fatigue life of the control unit conductor increases with the cross-sectional area during linear movement but decreases with the cross-sectional area during bending. Bending tests conducted with a bending machine corroborated the simulation results, validating the accuracy of the numerical simulations. These findings offer new insights into the design and analysis of complex cable stranding structures and provide theoretical support for enhancing cable mechanical performance and lifespan.

Key words: mining machine cable, stranded structure, tensile test, explicit dynamics, experimental validation

摘要： 为研究采煤机电缆的机械特性，构建了MCP-0.66/1.14 3*95+1*25型电缆的实体模型并依据电缆实际运动状态设计了一种电缆弯曲装置。通过拉伸试验得到电缆股线的材料参数作为数值模拟的初始条件，并对不同成缆节径比、捻制方向及控制单元截面积的电缆进行数值模拟。结果表明：电缆受力随着成缆节径比的增大而增大，考虑制造成本与机械特性，该型电缆成缆节径比为6时更优；以R为右向、L为左向捻制进行捻制描述，不同捻制方向下电缆所受应力从大到小依次为RLR、RRL、RLL、RRR，而三层同向捻制工作时容易出现散股的情况，故RLL捻制时电缆的机械特性最佳；控制单元导体在直线移动阶段，疲劳寿命随着截面积的增大而增大；在弯曲阶段，疲劳寿命随着截面积的增大而减小。通过弯曲试验机对电缆进行弯曲试验，试验结果与仿真分析结果基本一致，验证了数值模拟的准确性。研究结果为电缆复杂的绞合结构设计与分析提供了新的思路，并为提高电缆机械性能和使用寿命提供了理论支撑。

关键词: 采煤机电缆, 绞合结构, 拉伸试验, 显式动力学, 试验验证