Multi-physics Simulation Modeling of Plateau Roadheaders Oriented towards Digital Twins

CHEN Bin; LIU Mingyu; HONG Cheng'an; QI Jin; HU Jie; QI Jian; LIU Yang; ZHOU Lide

doi:10.19554/j.cnki.1001-3563.2026.12.003

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Packaging Engineering ›› 2026, Vol. 47 ›› Issue (12) : 29-46. DOI: 10.19554/j.cnki.1001-3563.2026.12.003

Special Subject: Innovation of Intelligent Manufacturing Systems for High-end Vehicle Equipment

Multi-physics Simulation Modeling of Plateau Roadheaders Oriented towards Digital Twins

CHEN Bin^1a, LIU Mingyu^1a, HONG Cheng'an^1b,*, QI Jin^1b, HU Jie^1a, QI Jian², LIU Yang², ZHOU Lide²

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Abstract

To address the issues that extreme geological environments in plateau regions exacerbate the randomness and complexity of the excavation process, resulting in a surge in manual labor intensity and limited efficiency of experience-based construction, the work aims to construct a high-precision and highly robust equipment-environment interactive digital twin model, to achieve real-time condition monitoring, performance prediction, and intelligent operation and maintenance for automated plateau roadheaders. A modeling strategy based on multi-physics collaborative simulation was proposed, systematically integrating the discrete element method (DEM), multibody dynamics (MBD), finite element method (FEM), and fluid power transmission technology. With the EBZ200I boom-type roadheader as the research object, a mechanical-electrical-hydraulic-control co-simulation system was established. Through multi-physics coupling calculations, a multimodal simulation model was constructed to reflect the kinematic characteristics of the entire machine under complex plateau working conditions. Simulation verification demonstrated that the constructed digital twin model could accurately predict the dynamic load distribution under different rock conditions and the real-time variations of environmental parameters at the excavation face. Furthermore, it revealed the equipment-environment interaction mechanisms and load transfer characteristics of the excavation equipment under complex conditions. This work introduces plateau environmental factors and the concept of equipment-environment interaction simulation into the digital twin modeling of roadheaders, providing crucial technical support for the robust design and the formulation of intelligent operation and maintenance strategies for heavy equipment in plateau regions and holding significant engineering value for enhancing the intelligence level and safety of plateau tunnel excavation operations.

Key words

plateau excavation / digital twin / machine-environment interaction / multi-physics coupling / intelligent operation and maintenance

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CHEN Bin, LIU Mingyu, HONG Cheng'an, QI Jin, HU Jie, QI Jian, LIU Yang, ZHOU Lide. Multi-physics Simulation Modeling of Plateau Roadheaders Oriented towards Digital Twins[J]. Packaging Engineering. 2026, 47(12): 29-46 https://doi.org/10.19554/j.cnki.1001-3563.2026.12.003

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