Jestr Journal of Engineering Science and Technology Review 14 (4) (2021) 76 - 83

Research Article
JOURNAL OF
Engineering Science and
Technology Review

r
www.jestr.org

Discrete Element Simulation on the Key Parameters of Bucket Wheel Stacker-

Reclaimer Based on Virtual Prototyping Technology
Ruibin Han1, * and Yuren Guo2
1
Chn Energy Huanghua Port Affairs Co., Ltd, Cangzhou, 061113, China
2
School of Hotel and Tourism Management, Macau University of Science and Technology, Macau, 999078, China

Received 27 March 2020; Accepted 2 August 2021

___________________________________________________________________________________________

Abstract

The key to the simulation of key parameters of bucket wheel stacker-reclaimer depends on simulating its operation via
discrete element analysis software. However, neither the operating performance nor the economic benefit obtained by the
existing methods can reach the optimal effect. To acquire the optimal productivity parameter of bucket wheel stacker-
reclaimer, a discrete element simulation model was designed for the key parameters of bucket wheel stacker-reclaimer
based on virtual prototyping technology. Specifically, an LDQZ2500 bucket wheel stacker-reclaimer was chosen as the
study object, and the constraint relations between its components were defined. Multiple rigid bodies and discrete flexible
beam elements were used to establish a virtual prototype model for the bucket wheel stacker-reclaimer and input into
EDEM software. EDEM software was employed to realize the discrete element simulation of this virtual prototype
through the discrete element method, and its key parameters were determined through the simulation results. Results
show that the error between the simulation result of the virtual prototype model and the actual operation result of bucket
wheel stacker-reclaimer is extremely small. When the bucket capacity was 1.3 m³ and the rotational speed was 6 r/min,
the bucket wheel stacker-reclaimer exhibits the best operating performance and economic benefit. The key parameters
acquired in this study provide a reference for the integrated design and efficient operation of bucket wheel stacker-
reclaimer.

Keywords: virtual prototyping technology, bucket wheel stacker-reclaimer, key parameter, discrete element simulation, EDEM software,
constraint relation
___________________________________________________________________________________________

1. Introduction conveyor on the arm frame through the tripper car and then
thrown to the storage yard from the front end of the arm
A bucket wheel stacker-reclaimer is efficient handling frame. The material pile can form an orderly shape with
machinery (continuous transport) that can stack and reclaim trapezoidal cross-section through the operation of complete
materials in large-scale dry bulk storage yards. It is machine and the turning and pitching of arm frame. The
composed of an adhesive tape-like conveying arm capable of material reclaiming is continuously realized through the
pitching and horizontal swinging, front-end bucket wheel, turning of arm frame and rotation of bucket wheel. The
and rack and running gear, where the adhesive tape can materials are unloaded to the arm frame belt conveyor,
operate in two directions. The materials are sent by the which operates inversely through the stripper plate and
bucket wheel through the conveying arm in the reclaiming carried by the belt conveyor via the bucket beneath the
process, and the cargoes transported by the main conveyor machining center. The bucket wheel can take all materials in
are thrown to the storage yard via the conveying arm during the storage yard by means of the operation of complete
the stacking process. A bucket wheel stacker-reclaimer is machine and the turning and pitching of arm frame. In terms
rail-type handling machinery that reclaims the materials by of the bridging form, the bridge frame-type bucket wheel
using the bucket wheel and continuously stacks the materials stacker-reclaimer is divided into gate type and bridge type,
by using the on-vehicle belt conveyor. As special machinery and some reclaimers are called bucket-wheel because they
applied to bulk material (bulk cargo) storage yards, it only have the reclaiming function. The operation of bucket
evolves from the bucket wheel excavator and can form a wheel stacker-reclaimer, which is of extremely strong
transportation mechanization system of storage yard together regularity, can be easily automated. The control mode is
with car (ship) unloader, belt conveyor and car (ship) loader, divided into manual, semiautomatic, and automatic modes.
with the production capacity reaching over 10,000 tons per During the operation of bucket wheel stacker-reclaimer,
hour. In terms of the structure, the bucket wheel stacker- large batch of bulk materials are reclaimed by virtue of the
reclaimer is divided into arm frame type and bridge frame, digging action of bucket wheel [1]. The bucket wheel should
where the arm frame type has two operating modes: stacking cooperate with equipment, such as car dumper, and its
and reclaiming. For the stacking process, the bulk cargoes production efficiency is approximately twice of a single-
transported by the belt conveyor are unloaded to the belt bucket loading machine. The bucket wheel stacker-reclaimer,
which has a wide operating range [2], applies to various
______________ places. The development of bucket wheel stacker-reclaimer
*E-mail address: [email protected]
ISSN: 1791-2377 © 2021 School of Science, IHU. All rights reserved.
in China has experienced three phases: (1) small-scale
doi:10.25103/jestr.144.10
 Ruibin Han and Yuren Guo/Journal of Engineering Science and Technology Review 14 (4) (2021) 76 - 83

bucket wheel stacker-reclaimer, where the typical machine parameters in the discrete element simulation of wet bucket-
models are 3025, 8030, (2) large-scale bucket wheel stacker- type abrasive particles by taking angle of repose as the
reclaimer, which is applied to the piling and transfer of bulk evaluation index. Cheng et al. [12] presented a new contact
materials, with the material force output of 2,000 t/h and detection method to determine the contact point and used a
turning radius of 40, and (3) turning radius-type bucket rolling resistance model to dissipate the rotational kinetic
wheel stacker-reclaimer. During the working process of energy and realize the mechanical balance. They verified the
bucket wheel stacker-reclaimer, the interaction between effectiveness of this method through a series of tests. On the
materials and bucket wheel and that between materials are basis of the DEM, Vyazmensky et al. [13] established a
relatively complicated. The traditional method, which has geological model for the layered excavation of a thin-layer
some uncertainties, deviates considerably from reality. A open slope. They explored and summarized its toppling
virtual prototype model design of bucket wheel stacker- deformation characteristics by combining indoor and
reclaimer provides valuable reference for determining the outdoor evaluations. Sun et al. [14] studied the weight loss
working parameters of bucket wheel stacker-reclaimer and optimization problem of the forearm of bucket wheel
stabilizing its operation. It is directly related to the stacker-reclaimer under various uncertain factors, such as
reclaiming effect of bucket wheel stacker-reclaimer. Thus, structural parameters, material properties, load, and
studying the bucket wheel stacker-reclaimer and bulk substitution model. Billah et al. [15] minimized the forearm
cargoes is extremely important. weight of bucket wheel stacker-reclaimer while ensuring its
Discrete element method (DEM) is an important strength, stiffness, and nonresonance. They proposed a point
simulation analysis method at present, and EDEM software cloud management and visualization method by installing
is commonly used discrete element analysis software. In this laser radars on a bucket-wheel stacker-reclaimer (BWR) and
study, a virtual prototype of bucket wheel stacker-reclaimer implemented accurate and real-time management and
was established, and the material digging, lifting, and visualization of point cloud by using a semiautomatic system
unloading process in the operation of bucket wheel stacker- of point cloud data. Kannan et al. [16] developed a CFD-
reclaimer was simulated through the discrete element DEM framework for gravity meter optimization, and found
analysis software [3-5]. Its reclaiming mechanism was that the separation quality is very sensitive to the change of
discussed on the basis of the simulation results, thereby operating conditions. Although the above methods have their
providing a theoretical basis for the optimization design of advantages, they have obvious limitations, such as failure to
bucket wheel stacker-reclaimer and the selection of optimal acquire the optimal working parameters of BWR, low
parameters. The DEM method provided an effective machine operating efficiency, failure to utilize the machine.
analytical means for studying the digging process of bucket Consequently, either the operating performance or the
wheel stacker-reclaimer. The motion behavior of particle economic benefit obtained through the simulation cannot
materials was simulated by using the DEM method to avoid reach the best effect. The virtual prototype model of bucket
substantive tests and experiments. This method helps in wheel stacker-reclaimer remains to be further improved, the
reducing the cost, acquiring the needed data, clarifying the theoretical analysis is imperfect, and the virtual prototype
essence of motion between particles [6-7], realizing the model design of bucket wheel stacker-reclaimer is faced
optimization design of bucket wheel stacker-reclaimer, and with enormous challenges. Designing the optimal key
improving its production efficiency. The virtual prototype parameters of bucket wheel stacker-reclaimer is still an
simulation technology uses 3D software to establish a important research direction.
simulation object model and realize the performance A discrete element simulation model was established on
evaluation. the basis of virtual prototyping technology to acquire more
ideal key parameters of bucket wheel stacker-reclaimer. The
structural model of bucket wheel stacker-reclaimer was
2. State of the Art simplified, and a virtual prototype model was established.
The optimal parameters contributing to the good operation
In the existing literature, the bucket wheel stacker-reclaimer of bucket wheel stacker-reclaimer were determined through
and bulk materials have been deeply and extensively the DEM method on the basis of the virtual prototype
explored, certain research progress has been achieved. Many simulation results. EDEM software was used to simulate the
models related to bucket wheel stacker-reclaimer and bulk reclaiming process of bucket wheel stacker-reclaimer. The
materials have been proposed, and the related technologies angular variation is 24.95 in the material digging process,
have developed rapidly. Clements et al. [8] conducted a the pitching angular velocity is stabilized to 0.013 rad/s, and
simulation study of cloth material and sieving performance the maximum relative wheel-pressure error between the
of cloth sieving system composed of mobile adhesive tape- simulation result and the experimental result is lower than
wide adhesive tape roll screen by using a discrete element 1% through the experimental verification. The proposed
model. However, the cost of this study is high. Araujo et al. method can realize a good simulation of the reclaiming
[9] applied kinematics to the bucket wheel stacker-reclaimer process of bucket wheel stacker-reclaimer. The established
and determined the working space of the mechanical model can be used to realize the discrete element simulation
cantilever. However, poor operating performance is obtained. and effectively reduce the energy consumed in the operation
Liu et al. [10] determined the final boundary parameters for of bucket wheel stacker-reclaimer.
the established discrete element model of manure particles. The remainder of this study is organized as follows:
However, the simulation results deviate considerably from Section three expounds the experimental design and EDEM
the practical operation results. Cao et al. [11] determined the discrete element simulation of the key parameters of bucket
values of the related physical property parameters of wet wheel stacker-reclaimer. Section Four proposes a virtual
bucket-type polishing abrasive materials during the contact prototype model and presents the result analysis. Section
process. On the basis of EDEM discrete element simulation, five summarizes the whole paper and provides the related
they selected Hertz-Mindlin and JKR contact models from conclusions.
the system and calibrated the optimal combination of

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3. Methodology
Where T and F denote the connection torque and
3.1 Virtual prototype of bucket wheel stacker-reclaimer connection acting force, respectively; d refers to the
An LDQZ2500 bucket wheel stacker-reclaimer was selected instantaneous deformation vector at monitoring points i and
as the study object to establish a virtual prototype model. j.
The axes x and y of the established bucket wheel stacker- The constraint relations between different components
reclaimer model are the horizontal line at the bottom of the should be defined when the virtual prototype of bucket
vehicle wheel of traveling mechanism and the centerline of wheel stacker-reclaimer is established. In this study, the
turning platform, including bucket wheel, driver’s cage, constraint relations between different components of bucket
pitching mechanism, and turning platform. The turning wheel stacker-reclaimer are listed in Table 1.
platform and arm frame of bucket wheel stacker-reclaimer
were connected by using a hydraulic cylinder to realize the 3.2 Key parameter design of bucket wheel stacker-
height adjustment of the upper mechanism and arm frame. reclaimer
The particle materials were stacked and reclaimed through The theoretical digging resistance of bucket wheel in the
the turning and movement of the established traveling stacker-reclaimer is expressed as:
mechanism in different directions.
The ground conveyer belt of bucket wheel stacker- Pl = f ´ L (2)
reclaimer was connected to the fixed-type tripper car
structure, thereby ensuring that the machine pitching and Where f and L represent the unit digging resistance and
turning motion characteristics were unaffected by the motion the total length of cutting edge of bucket wheel, respectively.
of complete machine. The structural model of bucket wheel In the simulation analysis, the unit digging resistance of
stacker-reclaimer was simplified, the tripper car structure materials was 180 N/cm.
was ignored, and a virtual prototype model was constructed. The total length of cutting edge at the bucket wheel part
in the material digging process of bucket wheel stacker-
Table 1. Constraint Relations between Components reclaimer is:
Constrained Constraint Constraint Degree of Setting
component part quantity freedom mode
Gate seat and Revolute 16 16 Axial L = 2m 2V0j / D / j (3)
vehicle wheel rotation
Upper structure and Revolute 1 1 Axial
turning platform rotation Where j and V0 represent the central angle of cutting
Upper structure and Revolute 1 1 Axial process and the bucket capacity obtained through the
skeleton rotation theoretical calculation, respectively. f = 0.26p rad and
Upper structure and Fixed 1 0 Fixed
clump weight V0=1.36m3 are set; m and D denote the acting bucket count
Upper structure and Revolute 1 1 Axial and diameter of bucket wheel, respectively, which are taken
cylinder barrel rotation as 2 and 10 m, respectively.
Ground and guide Fixed 2 0 Fixed The average productivity of bucket wheel mechanism is
rail
Turning bearing Revolute 1 1 Axial
theoretically calculated as:
and turning rotation
platform
Gate seat and Fixed 1 0 Fixed Vm
turning bearing Qm = rn f (4)
Cylinder barrel and Translationa 1 1 Sliding
f
piston rod l
Turning platform Revolute 1 1 Axial Where f and nf represent the loosening coefficient and
and piston cylinder rotation utilization factor, respectively, with value ranges of
Arm frame and belt Fixed 2 0 Fixed
conveyor
[1.35,1.70] and [0.65,0.93], respectively.
Arm frame and Fixed 2 0 Fixed During the simulation process, the loosening coefficient
bucket wheel and utilization factor were taken as 1.70 and 0.65,
respectively. Vm and ρ denote the volumetric productivity of
During the working process of bucket wheel stacker- bucket wheel mechanism and the material stacking density,
reclaimer, the turning platform, upper mechanism, and gate respectively, and Vm = 61zV0 n .
seat had small deformations [17], so that they can be βR represents the lifting height needed to unload the
modeled by using multiple rigid bodies. The pull rod of materials; h and R represent the transmission efficiency
bucket wheel stacker-reclaimer belonged to a discrete of bucket wheel drive device and the radius of bucket wheel
flexible beam element, the pull rod structure was of the same cut circle, respectively. The transmission efficiency of drive
shape as the beam cross-section, and the parts, such as device in the bucket wheel stacker-reclaimer through the
driver’s cage, belt conveyor, and bucket wheel were above parameter calculation is expressed as:
expressed by the properties of mass block. The established
member models should have identical physical properties in
the model operation [18]. The bushing flexible connection Pv Qm b Rg
was set between the vehicle wheel and guide rail to ensure W = l
+ (5)
1000h 3600h
that the bearing reaction force of vehicle wheel in the
established model was more realistic. The bushing
connection is expressed as where β and R are the lifting height coefficient and
gravitational acceleration, respectively. The transmission
efficiency and lifting height coefficient were set to 0.86 and
F j = - Fi , T j = -Ti - dFi (1)
1.2, respectively, and the radius of bucket wheel cut circle

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was set to 5 m. g denotes the gravitational acceleration.

The operating torque Maxis at the bucket wheel axle of max 1.6765e+2[MPa]
bucket wheel drive device is expressed as: min 2.4177e-5[MPa]

M axis = 9660W / n (6) Pressure

dimension value
[MPa]
where n is the rotational speed of bucket wheel. max 1.6765e+2
1.3186e+3
In the discrete element simulation of virtual prototyping 1.0258e+3

technology, the average productivity of bucket wheel 7.9836e+2

4.8538e+2

mechanism is expressed as: 1.6768e+2

min 2.4177e-5

60 znM
Qm' = (7)
1000

Where M represents the single-bucket average material

digging mass in the EDEM simulation, and z denotes the
bucket count.
The motor power of bucket wheel mechanism is
expressed in the simulation model as follows: Fig.1. Bucket Wheel Stacker-Reclaimer Model

PL¢ Pm¢ gh max 1.6644e-3[MPa]

min 8.1348e-5[MPa]
W¢ = + (8)
1000h 3600h

Pressure dimension
where PL¢ and h represent the material lifting height and value
max 1.6644e-3[MPa]

acting force borne by the bucket wheel body from the 1.3158e-3
1.1853e-3
1.0618e-3
materials in the discrete element simulation process. 1.0368e-3
9.1257e-4
7.8834e-4
6.6431e-4
5.4988e-4
3.3 EDEM discrete element simulation of the key 4.1565e-4
2.9886e-4

parameters of bucket wheel stacker-reclaimer 1.7728e-4

min 8.1348e-5
In accordance with the operating conditions of bucket wheel
stacker-reclaimer, iron ore materials were set as the
production materials, and their dimensions were set to
5m×2.5m×5m in the discrete element simulation. In the
operation process of bucket wheel stacker-reclaimer, only
the influence of gravity on the particle material was Fig.2. Pull Rod Simulation Resultsucket Wheel Stacker-Reclaimer
considered. When the materials were naturally stacked, a Model
slope angle was generated due to the gravity effect, which
was approximate to the actual material stockpile [19]. After The material reclaiming process of bucket wheel stacker-
the material stockpile was generated, it was imported into reclaimer was simulated by using the proposed model. The
the virtual prototype model of bucket wheel stacker- angular variation during this process is shown in Fig 3. The
reclaimer, and its material reclaiming process was simulated angular variation during the material reclaiming process was
via EDEM software. analyzed, as shown in Fig 3. A lifting angle of 128.87° was
found in the material reclaiming process simulated by the
proposed method, and the angular variation was 24.95 in the
4. Result Analysis and Discussion material digging. The simulation results in Fig 3 show that
the proposed method can simulate the material reclaiming
The virtual prototype model of bucket wheel stacker- process of bucket wheel stacker-reclaimer, indicating that
reclaimer was constructed on SIMSOLID software, as this method can establish a virtual prototype model and
shown in Fig 1. The pull rod solution results of this virtual realize the discrete element simulation through the
prototype model are displayed in Fig 2. The simulation established model.
results in Figs 1 and 2 show that the proposed method can be When the bucket wheel stacker-reclaimer was operating
used to effectively establish the virtual prototype model of under pitching conditions, the angular velocity curves of the
bucket wheel stacker-reclaimer. The pull rod of bucket upper structure within different ranges of pitch angle are
wheel stacker-reclaimer belongs to a discrete flexible beam shown in Fig 4. As shown in Fig 4, the initial pitch-up
element. The proposed method can establish the rigid model angular velocity and pitch-down angular velocity of the
and is effective for establishing the discrete flexible element upper structure in the bucket wheel stacker-reclaimer are
model. A realistic 3D model was constructed in accordance 0.028 rad/s, They gradually tended to be steady through the
with the actual operating state of bucket wheel stacker- angular velocity change for 20s, and the pitch angular
reclaimer. This model contributed to the accurate velocity can be stabilized to 0.013 rad/s. The pitch-up
determination of the optimal parameters of bucket wheel oscillation amplitude and frequency of bucket wheel stacker-
stacker-reclaimer. It can be used to effectively simulate the reclaimer are lower than those under the pitch-down
pressure values of bucket wheel stacker-reclaimer and pull condition by analyzing the angular velocity curves of the
rod and provide the maximum and minimum pressure upper structure. Hence, the bucket wheel stacker-reclaimer is
values. more flexible when it operated under the pitch-down

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condition, and the angular velocity change is more sensitive. changed, the resistance variations in the operation of bucket
wheel body in the stacker-reclaimer are displayed in Fig 6.
The average digging resistance, maximum digging
Lifting process:128.87° resistance, and minimum digging resistance of bucket wheel
Material unloading
stacker-reclaimer all increased with the bucket volume by
analyzing the simulation results in Fig 6. From the
simulation results in Fig 6, the digging resistance of bucket
wheel stacker-reclaimer was in direct proportion to the
bucket volume, and the digging resistance of bucket wheel
stacker-reclaimer was enhanced with the increase in the
bucket volume.

140

138
136 Simulation result

Material digging process: experimental result

134

wheel pressure/KN
24.95°
132
Fig. 3. Change of Angular Interval in the Material Reclaiming Process 130
128

126

0.20 124

0.18 pitch-up 122

0.16 pitch-down 120
0 15 30 45 60 75 90 105 110
0.14
Angular velocity/（rad/s）

turning angle/°
0.12
Fig. 5. Comparison Results of No.5 Wheel Pressure
0.10
0.08
Minimum digging resistance
0.06
60 Average digging resistance
0.04

0.02
52 Maximum digging resistance
48
0
0 10 20 30 40 50 60 70 80
Operation hours /s
42
Resistance/KN

Fig. 4. Angular Velocity Curves of the Upper Structure 36

30
When the bucket wheel stacker-reclaimer operated under 24
the turning condition, the pressure of No.8 vehicle wheel
was measured by using a static measurement system. The 18
load sensor in the static measurement system should be 12
calibrated before the measurement. The sensor was placed 6
on the jack, which was loaded at 600 mm away from the
0
No.8 vehicle wheel, and the No.8 wheel of bucket wheel 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
stacker-reclaimer broken away from the rail surface. The Bucket capacities/m3
comparison results of wheel pressure in the virtual prototype Fig. 6. Variation of Digging Resistance under Different Bucket
model obtained through the discrete element simulation capacities
analysis are shown in Fig 5. The simulation results in Fig 5
show that when the complete bucket wheel stacker-reclaimer Under the varying bucket capacity, the various results of
operated under turning conditions, the wheel pressure actual loading capacity and maximum material digging
obtained through the discrete element simulation is volume are displayed in Fig 7. As shown in Fig 7, the
extremely approximate to the experimental wheel pressure at material digging volume of machine was elevated with the
different turning angles. The maximum relative error increase in the bucket capacity. The increasing trend of
between the simulated wheel pressure and experimental actual loading capacity was highly similar to the maximum
result is lower than 1%, indicating the high effectiveness of material digging volume. When the bucket capacity was
the established virtual prototype model of bucket wheel increased to 1.6 m3, the maximum material digging volume
stacker-reclaimer. When applied to the established virtual was the maximum by analyzing the simulation results.
prototype model, the discrete element simulation can realize However, the materials cannot be completely emptied under
the good simulation of the operating state of bucket wheel a small bucket capacity, and residual materials were found in
stacker-reclaimer. the bucket when the gravity-type unloading mode was
The bucket count was 8, and the rotational speed of adopted by the bucket wheel stacker-reclaimer, thereby
bucket wheel was 9 r/min during the operation of bucket affecting the operating efficiency of bucket wheel stacker-
wheel stacker-reclaimer. The operating performance of reclaimer.
bucket wheel stacker-reclaimer under different bucket
volumes was calculated. When the bucket capacity was

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were slightly the same. Therefore, the rotational speed had a

minor effect on the material digging volume of bucket wheel
1100 mechanism. The rotational speed improved the production
Maximum material digging volume
1040
Actual loading capacity
efficiency of bucket wheel stacker-reclaimer. However, the
980 bucket wheel vibration was extremely large when the bucket
wheel stacker-reclaimer operated at a high rotational speed.
920
This condition exerted a more serious effect on the bucket
860
Weight/Kg

wheel wear and increased the operating energy consumption

800 of bucket wheel stacker-reclaimer. On this basis, selecting
740 the rotational speed parameter under the operation of bucket
680
wheel stacker-reclaimer is extremely important because the
production efficiency of bucket wheel stacker-reclaimer can
620
be improved only by selecting a proper rotational speed. The
560 higher the rotational speed does not indicate the better the
500 effect on improving the production efficiency.
0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6
Bucket capacities/m3
Fig. 7. Variation of Material Digging Volume under Different Bucket 5r/min
capacities 200 6r/min
8r/min
180
The influences of different bucket capacities on the 10r/min
14r/min
operating performance of bucket wheel stacker-reclaimer 160

were comprehensively analyzed, as shown in Fig 6 and 7.

Force borne by bucket/KN

140
The digging resistance and loading capacity of bucket wheel 120
stacker-reclaimer increased with the increase in the bucket
100
capacity. When the bucket capacity was 1.6 m3, residual
80
materials were found in the bucket, and the material loss rate
was high, thereby reducing the productivity. Under the 60
bucket capacity of 1.3 m3 and other parameters were 40
unchanged, the bucket wheel stacker-reclaimer exhibited the
20
highest productivity, and the operating performance was the
best by comprehensively considering the digging resistance 0
0 10 20 30 40 50 60 70 80
and loading capacity. Turning angle of bucket wheel/°
Under different rotational speeds of bucket wheel, the Fig. 8. Resultant Force Borne by the Bucket under Different Turning
statistical results of the variation of force borne by the Angles of Bucket Wheel
bucket under varying rotational angles of bucket wheel are
presented in Fig 8. Under the fixed rotational speed, the
resultant force borne by the bucket increased when the
turning angle was enlarged by analyzing the simulation 3500 5r/min
results in Fig 8. Under the same turning angle, the resultant 3150
6r/min
8r/min
force borne by the bucket increased somehow with the 2800 10r/min
increase in rotational speed. When the bucket of bucket 14r/min
2450
Material mass in the bucket/kg

wheel stacker-reclaimer was under a large resultant force,

the bucket wheel was subjected to a large impact vibration. 2100
Affected by the enormous resultant force, the wear of bucket 1750
wheel was serious, thereby increasing the operating energy 1400
consumption of bucket wheel stacker-reclaimer. From the
1050
simulation results in Fig 8, the rotational speed of bucket
wheel influenced the digging resistance of bucket wheel 700
stacker-reclaimer. Under a high rotational speed of bucket 350
wheel, the digging resistance increased, and the digging
0
resistance was greatly affected by the rotational speed of 0 10 20 30 40 50 60 70 80
bucket wheel. Turning angle of bucket wheel/°
The mass variations of materials in the bucket under Fig. 9. Material Mass Change under Different Turning Angles
different rotational speeds and turning angles of bucket
wheel are shown in Fig 9. As shown in Fig 9, the material
mass in the bucket was influenced by the slight change in Under the varying rotational speed of bucket wheel, the
turning angle at different rotational speeds. At the same quantitative description results of bucket wheel stacker-
rotational speed, the material mass increased at a high rate reclaimer under the material unloading conditions are listed
with the increase in turning angle. When the turning angle in Table 2.Affected by the rotational speed, the start angle
was 50°, the increase in material mass reached the limit. and end angle of bucket wheel stacker-reclaimer increased
With the continuous increase in the turning angle, the with the elevation of rotational speed by analyzing the
material mass reduced to some extent or remained unloading conditions in Table 2. The start angle was
unchanged at different rotational speeds. Under a fixed influenced slightly by the rotational speed, and the end angle
rotational speed, approximate material masses existed under was affected considerably by the rotational speed. When the
different rotational speeds, and the variation amplitudes of rotational speed was accelerated, the unloading interval
single-bucket material digging volume and rotational speed range enlarged and resulted in the unloading delay under an

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extremely high rotational speed. When the materials were turning conditions and pitching conditions of the established
unloaded at a low rotational speed, the material stacking virtual prototype. thereby providing a theoretical basis for
positions were more concentrated. When the rotational speed improving the stability of complete machine and protecting
was elevated to 6 r/min, the unloading interval was slightly it from being affected by the operation of bucket wheel
dispersed compared with that at 5 r/min. However, the stacker-reclaimer.
unloaded materials were all concentrated in the designed (2) The parameter changes in the material reclaiming and
unloading interval, and the maximum unloading volume was unloading processes of bucket wheel stacker-reclaimer are
acquired. When the rotational speed was accelerated to 8 and explored through the discrete element simulation, providing
10 r/min, the dispersity of material stacking was higher after an idea for determining the working parameters of bucket
the material unloading, and some materials were located wheel machine and optimizing its operation.
outside the set unloading interval. When the rotational speed (3) The discrete element simulation results of bucket
was elevated to 13 r/min, the material unloading failed, and wheel stacker-reclaimer show that the machine can realize
all materials were unloaded outside the unloading interval. the optimal productivity under the bucket wheel rotational
In accordance with the above simulation results, the optimal speed of 6 r/min and bucket capacity of 1.3 m³.
rotational speed of bucket wheel stacker-reclaimer was 6 4) The discrete element simulation model can effectively
r/min. avoid the waste of energy resources and reduce the energy in
the operation of bucket wheel stacker-reclaimer with the best
Table. 2. Unloading Conditions at Different Rotational operating efficiency when it is used to determine the optimal
Speeds parameters of bucket wheel stacker-reclaimer.
5 r/min 6 r/min 8 r/min 10 r/min 13 r/min Although this study realizes the operation process
Initial end/° 125.68 126.85 127.84 129.52 132.57 simulation of bucket wheel stacker reclaimer, it verifies that
End angle/° 159.85 162.85 173.52 181.48 the virtual prototype model of Bucket Wheel Stacker
Unloading 1.52 1.37 1.28 0.98
time/s
Reclaimer has high effectiveness. However, due to the
Unloading 34.85 38.64 41.85 43.85 limitations of level and time, the model is not verified by the
angle/° simulation results of the prototype with similar power to the
Unloading 1385.64 1795.54 2785.15 3584.64 bucket wheel stacker reclaimer in the discrete element
interval/mm simulation. Therefore, in future research, more advanced
discrete element three-dimensional simulation software can
be used for verification, to improve the operation efficiency
5. Conclusion of bucket wheel stacker reclaimer and realize a good
simulation of the operation state of bucket wheel stacker
A virtual prototype model of bucket wheel stacker-reclaimer reclaimer.
was established to determine its optimal parameters. The
established virtual prototype model was highly effective on This is an Open Access article distributed under the terms of the
the basis of the simulation results. The conclusions were Creative Commons Attribution License.
drawn as follows:
(1) The bucket wheel stacker-reclaimer can reach the
optimal parameters for its good operation by determining the

______________________________
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