The high-precision 3D simulation model for geomechanics of a complex coal seam is the necessary premise for the research on intelligent shearer and unmanned mining. However, at present, a simulation model for geomechanics of a complex coal seam generally has the problems of simplifying complex geological structures and low accuracy for structures. In order to meet the needs of a coal seam simulation model in the mining process of an intelligent shearer, it is necessary to optimize the simplified model of a coal seam. Therefore, based on a 3D simplified simulation model constructed with discrete element technology, the complex coal seam application plug-in was compiled with the help of an Application Program Interface. Moreover, according to the geological characteristics, new attributes were added to the structures to complete the construction of the model of a complex coal seam. Finally, the model was verified with laboratory experiments. The results showed that the high-precision 3D simulation model for geomechanics of a complex coal seam effectively improved the accuracy of the modeling. The real-time transmission and the real-time sharing of multi-source data were realized by considering the 3D simulation model for geomechanics of a complex coal seam as the core. Additionally, the purpose of the real-time sensing of the coal cutting state was achieved in order to lay the foundation for the realization of unmanned mining.

Drum of Shearer undertakes the main function of coal falling and loading, and its performance directly affects the working efficiency of the shearer. Therefore, in order to realize the analysis of the performance of the shearer drum, the MG2 × 55/250-BW shearer drum was the engineered object. Combining the physical and mechanical properties experiment results of coal samples, the coupling model of the drum cutting in complex coal seam was established using discrete element method. The falling-coal characteristics of the spiral drum were studied under different working conditions, and the falling-coal trajectories of the coal and rock particles were fitted. Based on a virtual prototype, the variations of the coal loading rate and lump coal rate with different design parameters were determined by studying the falling-coal effect and loading performance of the drum. Considering the drum performance, multi-objective optimization theory was used to determine the optimal operating and structural parameters. The results indicate that, in the process of drum cutting, the cutting depth has the most significant effect on the coal loading rate, while, the blade spiral angle has the least significant. Moreover, with the increase of the cutting depth of drum and the traction speed, the lump coal rate increases. While, with the increase of the drum rotation speed and the blade spiral angle, the lump coal rate decreases. It is found that when the cutting depth of the drum is 597 mm, the traction speed is 5.4 m/min, the drum rotation speed is 104.8 r/min, and the blade spiral angle is 12° the performance of the drum is optimal. Compared with the falling-coal trajectories before optimization, the displacements of the coal and rock particles ejected along the optimal falling-coal trajectories increase in the coal loading direction. The loading rate and lump coal rate of the drum increase by 6.05% and 12.27%, respectively. The load fluctuation of the drum decreases, and the productivity increases.